Toro 03706, 03707, Reelmaster 4000–D Operator's Manual
Reelmaster 4000–D
Traction Unit
Model No. 03706—230000001 and Up
Model No. 03707—230000001 and Up
Form No. 3329–757
Operator ’s Manual
English (EN)
Warning
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents
are known to the State of California to cause
cancer, birth defects, and other reproductive harm.
Important The engine in this product is not equipped
with a spark arrester muffler. It is a violation of California
Public Resource Code Section 4442 to use or operate this
engine on any forest-covered, brush-covered, or
grass-covered land as defined in CPRC 4126. Other states
or federal areas may have similar laws.
Contents
Page
Introduction 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe Operating Practices 3. . . . . . . . . . . . . . . . . . . .
Toro Riding Mower Safety 5. . . . . . . . . . . . . . . . . .
Sound Pressure Level 6. . . . . . . . . . . . . . . . . . . . . .
Sound Power Level 6. . . . . . . . . . . . . . . . . . . . . . .
Vibration Level 6. . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals 7. . . . . . . . . . . . . . . .
Specifications 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 12. . . . . . . . . . . . . . . . . . . . .
Measurements 13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Equipment 13. . . . . . . . . . . . . . . . . . . . . . .
Before Operating 14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Engine Oil 14. . . . . . . . . . . . . . . . . . .
Check Cooling System 14. . . . . . . . . . . . . . . . . . . . .
Fill Fuel Tank 15. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Hydraulic Fluid 15. . . . . . . . . . . . . . .
Check Reel To Bedknife Contact 16. . . . . . . . . . . . .
Check Tire Pressure 16. . . . . . . . . . . . . . . . . . . . . . .
Rear Ballast 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
Operation 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controls 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting And Stopping 21. . . . . . . . . . . . . . . . . . . . .
Bleeding Fuel System 21. . . . . . . . . . . . . . . . . . . . . .
Checking Warning Indicator Lights 21. . . . . . . . . . .
Checking Interlock System. 22. . . . . . . . . . . . . . . . .
Pushing Or Towing Traction Unit 22. . . . . . . . . . . .
Operating Characteristics 23. . . . . . . . . . . . . . . . . . .
Maintenance 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Maintenance Schedule 26. . . . . . . . .
Daily Maintenance Checklist 27. . . . . . . . . . . . . . . .
Lubrication 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Air Cleaner Maintenance 29. . . . . . . . . . . .
Servicing Air Cleaner 29. . . . . . . . . . . . . . . . . . . . . .
Engine Oil And Filter 29. . . . . . . . . . . . . . . . . . . . . .
Fuel System 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Cooling System 31. . . . . . . . . . . . . . . . . . . .
Alternator Belt 32. . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting Hand Brake & Traction Switches 32. . . .
Adding Hydraulic Oil 33. . . . . . . . . . . . . . . . . . . . . .
Draining Water From Hydraulic Reservoir 33. . . . .
Changing Hydraulic Oil 34. . . . . . . . . . . . . . . . . . . .
Replacing Hydraulic Filter 34. . . . . . . . . . . . . . . . . .
Replacing Hydraulic System Breather 34. . . . . . . . .
Checking Hydraulic Lines And Hoses 35. . . . . . . . .
Hydraulic System Test Ports 35. . . . . . . . . . . . . . . . .
Rear Wheel Toe–in 35. . . . . . . . . . . . . . . . . . . . . . . .
Checking Planetary Gear Drive 36. . . . . . . . . . . . . .
Engine Valve Clearance 36. . . . . . . . . . . . . . . . . . . .
Hydraulic Schematic 37. . . . . . . . . . . . . . . . . . . . . .
Electrical Schematic 38. . . . . . . . . . . . . . . . . . . . . . .
Battery Care 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Toro General Commercial Products Warranty 40. .
2003 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
All Rights Reserved
Printed in the USA
2
Introduction
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.
Whenever you need service, genuine Toro parts, or
additional information, contact an Authorized Service
Dealer or Toro Customer Service and have the model and
serial numbers of your product ready. Figure 1 illustrates
the location of the model and serial numbers on the
product.
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.
Safety
This machine meets or exceeds CEN standard EN
836:1997 (when appropriate decals applied), and ANSI
B71.4-1990 specifications in effect at the time of
production when rear tires are filled with calcium
chloride and two rear wheel weight kits (Part No.
11–0440) are installed.
Improper use or maintenance by the operator or owner
can result in injury. To reduce the potential for injury,
comply with these safety instructions and always pay
attention to the safety alert symbol, which means
CAUTION, WARNING, or DANGER—“personal
safety instruction.” Failure to comply with the
instruction may result in personal injury or death.
1
Figure 1
1. Location of the model and serial numbers
Write the product model and serial numbers in the space
below:
Model No.
Serial No.
This manual identifies potential hazards and has special
safety messages that help you and others avoid personal
injury and even death. Danger, Warning, and Caution are
signal words used to identify the level of hazard. However,
regardless of the hazard, be extremely careful.
Danger signals an extreme hazard that will cause serious
injury or death if you do not follow the recommended
precautions.
Warning signals a hazard that may cause serious injury or
death if you do not follow the recommended precautions.
Caution signals a hazard that may cause minor or moderate
injury if you do not follow the recommended precautions.
Safe Operating Practices
The following instructions are from the CEN standard EN
836:1997, ISO standard 5395:1990, and ANSI B71.4-1999.
Training
• Read the operator’s manual and other training material
carefully. Be familiar with the controls, safety signs,
and the proper use of the equipment.
• Never allow children or people unfamiliar with these
instructions to use or service the mower. Local
regulations may restrict the age of the operator.
• Never mow while people, especially children, or pets
are nearby.
• Keep in mind that the operator or user is responsible for
accidents or hazards occurring to other people or their
property.
• Do not carry passengers.
• All drivers and mechanics should seek and obtain
professional and practical instruction. The owner is
responsible for training the users. Such instruction
should emphasize:
– the need for care and concentration when working
with ride-on machines;
– control of a ride-on machine sliding on a slope will
not be regained by the application of the brake. The
main reasons for loss of control are:
• insufficient wheel grip;
• being driven too fast;
3
• inadequate braking;
• Do not use on slopes of more than
• the type of machine is unsuitable for its task;
• lack of awareness of the effect of ground
conditions, especially slopes;
• incorrect hitching and load distribution.
• The owner/user can prevent and is responsible for
accidents or injuries occurring to himself or herself,
other people, or property.
Preparation
• While mowing, always wear substantial footwear, long
trousers, hard hat, safety glasses, and ear protection.
Long hair, loose clothing, or jewelry may get tangled in
moving parts. Do not operate the equipment when
barefoot or wearing open sandals.
• Thoroughly inspect the area where the equipment is to
be used and remove all objects which may be thrown by
the machine.
• Warning—Fuel is highly flammable. Take the
following precautions:
– Store fuel in containers specifically designed for this
purpose.
– Refuel outdoors only and do not smoke while
refuelling.
– Add fuel before starting the engine. Never remove
the cap of the fuel tank or add fuel while the engine
is running or when the engine is hot.
– If fuel is spilled, do not attempt to start the engine
but move the machine away from the area of
spillage and avoid creating any source of ignition
until fuel vapors have dissipated.
–5° when mowing on side hills;
–10° when mowing uphill;
–15° when mowing downhill.
• Remember there is no such thing as a safe slope. Travel
on grass slopes requires particular care. To guard
against overturning:
– do not stop or start suddenly when going up or
downhill;
– engage clutch slowly, always keep machine in gear,
especially when travelling downhill;
– machine speeds should be kept low on slopes and
during tight turns;
– stay alert for humps and hollows and other hidden
hazards;
– never mow across the face of the slope, unless the
mower is designed for this purpose.
• Stay alert for holes in the terrain and other hidden
hazards.
• Use care when pulling loads or using heavy equipment.
– Use only approved drawbar hitch points.
– Limit loads to those you can safely control.
– Do not turn sharply. Use care when reversing.
– Use counterweight(s) or wheel weights when
suggested in the operator’s manual.
• Watch out for traffic when crossing or near roadways.
• Stop the blades rotating before crossing surfaces other
than grass.
– Replace all fuel tanks and container caps securely.
• Replace faulty silencers/mufflers.
• Evaluate the terrain to determine what accessories and
attachments are needed to properly and safely perform
the job. Only use accessories and attachments approved
by the manufacturer.
• Check that operator’s presence controls, safety switches
and shields are attached and functioning properly. Do
not operate unless they are functioning properly.
Operation
• Do not operate the engine in a confined space where
dangerous carbon monoxide fumes can collect.
• Mow only in daylight or in good artificial light.
• Before attempting to start the engine, disengage all
blade attachment clutches, shift into neutral, and engage
the parking brake.
• When using any attachments, never direct discharge of
material toward bystanders nor allow anyone near the
machine while in operation.
• Never operate the machine with damaged guards,
shields, or without safety protective devices in place. Be
sure all interlocks are attached, adjusted properly, and
functioning properly.
• Do not change the engine governor settings or
overspeed the engine. Operating the engine at excessive
speed may increase the hazard of personal injury.
• Before leaving the operator’s position:
– stop on level ground;
– disengage the power take-off and lower the
attachments;
– change into neutral and set the parking brake;
– stop the engine and remove the key.
4
• Disengage drive to attachments when transporting or
not in use.
• Stop the engine and disengage drive to attachment
– before refuelling;
– before removing the grass catcher/catchers;
– before making height adjustment unless adjustment
can be made from the operator’s position.
– before clearing blockages;
• Be careful during adjustment of the machine to prevent
entrapment of the fingers between moving blades and
fixed parts of the machine.
• On multi-cylinder/multi-reel machines, take care as
rotating one cylinder/reel can cause other
cylinders/reels to rotate.
• Disengage drives, lower the cutting units, set parking
brake, stop engine and remove key and disconnect spark
plug wire. Wait for all movement to stop before
adjusting, cleaning or repairing.
– before checking, cleaning or working on the mower;
– after striking a foreign object or if an abnormal
vibration occurs. Inspect the mower for damage and
make repairs before restarting and operating the
equipment.
• Reduce the throttle setting during engine run-out and, if
the engine is provided with a shut-off valve, turn the
fuel off at the conclusion of mowing.
• Keep hands and feet away from the cutting units.
• Look behind and down before backing up to be sure of
a clear path.
• Slow down and use caution when making turns and
crossing roads and sidewalks. Stop cylinders/reels if not
mowing.
• Do not operate the mower under the influence of
alcohol or drugs
• Use care when loading or unloading the machine into a
trailer or truck
• Use care when approaching blind corners, shrubs, trees,
or other objects that may obscure vision.
• Clean grass and debris from cutting units, drives,
silencers/mufflers, and engine to help prevent fires.
Clean up oil or fuel spillage.
• Use jack stands to support components when required.
• Carefully release pressure from components with stored
energy.
• Disconnect battery and remove spark plug wire before
making any repairs. Disconnect the negative terminal
first and the positive last. Reconnect positive first and
negative last.
• Use care when checking the cylinders/reels. Wear
gloves and use caution when servicing them.
• Keep hands and feet away from moving parts. If
possible, do not make adjustments with the engine
running.
• Charge batteries in an open well ventilated area, away
from spark and flames. Unplug charger before
connecting or disconnecting from battery. Wear
protective clothing and use insulated tools.
Toro Riding Mower Safety
Maintenance and Storage
• Keep all nuts, bolts and screws tight to be sure the
equipment is in safe working condition.
• Never store the equipment with fuel in the tank inside a
building where fumes may reach an open flame or
spark.
• Allow the engine to cool before storing in any
enclosure.
• To reduce the fire hazard, keep the engine,
silencer/muffler, battery compartment and fuel storage
area free of grass, leaves, or excessive grease.
• Check the grass catcher frequently for wear or
deterioration.
• Keep all parts in good working condition and all
hardware and hydraulic fittings tightened. Replace all
worn or damaged parts and decals.
• If the fuel tank has to be drained, do this outdoors.
The following list contains safety information specific to
Toro products or other safety information that you must
know that is not included in the ANSI standard.
This product is capable of amputating hands and feet and
throwing objects. Always follow all safety instructions to
avoid serious injury or death.
Use of this product for purposes other than its intended use
could prove dangerous to user and bystanders.
Warning
Engine exhaust contains carbon monoxide, which
is an odorless, deadly poison that can kill you.
Do not run engine indoors or in an enclosed area.
• Know how to stop the engine quickly.
• Do not operate the machine while wearing tennis shoes
or sneakers.
5
• Wearing safety shoes and long pants is advisable and
required by some local ordinances and insurance
regulations.
sufficient force to penetrate the skin and cause serious
injury. Seek immediate medical attention if fluid is
injected into skin.
• Handle fuel carefully. Wipe up any spills.
• Check the safety interlock switches daily for proper
operation. If a switch should fail, replace the switch
before operating the machine. After every two years,
replace all four interlock switches in the safety system,
whether they are working properly or not.
• Before starting the engine, sit on the seat.
• Using the machine demands attention. To prevent loss
of control:
– Do not drive close to sand traps, ditches, creeks, or
other hazards.
– Reduce speed when making sharp turns. Avoid
sudden stops and starts.
– When near or crossing roads, always yield the
right-of-way.
– Apply the service brakes when going downhill to
keep forward speed slow and to maintain control of
the machine.
• The grass baskets must be in place during operation of
the cylinders/reels or thatchers for maximum safety.
Shut the engine off before emptying the baskets.
• Raise the cutting units when driving from one work
area to another.
• Before disconnecting or performing any work on the
hydraulic system, all pressure in the system must be
relieved by stopping the engine and lowering the cutting
units and attachments to the ground.
• Check all fuel lines for tightness and wear on a regular
basis. Tighten or repair them as needed.
• If the engine must be running to perform a maintenance
adjustment, keep hands, feet, clothing, and any parts of
the body away from the cutting units, attachments, and
any moving parts, especially the screen at the side of the
engine. Keep everyone away.
• To ensure safety and accuracy, have an Authorized Toro
Distributor check the maximum engine speed with a
tachometer. Maximum governed engine speed should be
2900 RPM.
• The optional TORO tow bar (Part No. 58–7020) is for
emergency towing only. Use only the special tow bar if
it becomes necessary to tow machine. Use trailer for
normal transport. Refer to page 21 for towing
procedure.
• If major repairs are ever needed or if assistance is
desired, contact an Authorized Toro Distributor.
• Use only Toro-approved attachments and replacement
parts. The warranty may be voided if used with
unapproved attachments.
• Do not touch the engine, silencer/muffler, or exhaust
pipe while the engine is running or soon after it has
stopped because these areas could be hot enough to
cause burns.
• Stay clear of the rotating screen at the side of the engine
to prevent direct contact with your body or clothing.
• If the engine stalls or loses headway and cannot make it
to the top of a slope, do not turn the machine around.
Always back slowly, straight down the slope.
• When a person or pet appears unexpectedly in or near
the mowing area, stop mowing. Careless operation,
combined with terrain angles, ricochets, or improperly
positioned guards can lead to thrown object injuries. Do
not resume mowing until the area is cleared.
Maintenance and Storage
• Make sure all hydraulic line connectors are tight and all
hydraulic hoses and lines are in good condition before
applying pressure to the system.
• 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
Sound Pressure Level
This unit has an equivalent continuous A–weighted sound
pressure level at the operator ear of 88 dBA, based on
measurements of identical machines per Directive
98/37/EC and amendments.
Sound Power Level
This unit has a guaranteed sound power level of
105 dBA/1 pW, based on measurements of identical
machines per Directive 2000/14/EC and amendments.
Vibration Level
Hand-Arm
This unit does not exceed a vibration level of 2.5 m/s2 at
the hands based on measurements of identical machines per
ISO 5349 procedures.
Whole Body
This unit does not exceed a vibration level of 0.5 m/s2 at
the posterior based on measurements of identical machines
per ISO 2631 procedures.
6
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.
59-8440
1. Warning—contents under pressure.
76-8760
1. Danger—reels can cut hands of feet.
93-6681
1. Cutting/dismemberment hazard, fan—stay away from moving
parts.
93-7331
1. Stored energy hazard—read the
Operator’s Manual.
88-6700
93-6680
93-9404
1. Engine coolant 2. Read the
Manual.
Operator’s
93-6686
1. Hydraulic oil 2. Read the
Manual.
Operator’s
100-6574
1. Hot surface/burn hazard—stay a safe distance from the hot
surface.
2. Cutting/dismemberment hazard, fan and entanglement hazard,
belt—stay away from moving parts
7
1. Warning—read the
93-9400
Operator’s Manual
; do not tow the machine.
93-9406
1. Hydraulic oil level 2. Read the
Manual.
93-9407
1. Read the
Manual.
2. Lower the reels.
Operator’s
3. Neutral
4. Raise the reels.
Operator’s
93-9402
1. Reel—mowing speeds,
slow to fast.
2. Fast
3. Continuous variable
setting
4. Fast
5. Reel—mowing
6. Disengage
7. Reel—backlapping
8. Pull and move the lever.
9. Set the parking brake, set
the controls to neutral,
and start the engine.
93-9405
1. Tire pressure—read the
13 psi (0.9 bar) and the rear tires to 15 psi (1.0 bar).
Operator’s Manual
; fill the front tires to
93-9425
1. Warning—read the
2. High pressure fluid hazard, injection into the body—stay away
from moving parts and receive medical attention.
Operator’s Manual.
93-9399
1. Horn—press the button.
2. Warning—wear hearing
protection.
3. Read the
Manual.
4. Failure/malfunction—
press the button.
Operator’s
8
1. Temperature level
2. Four wheel drive flow divider
3. On
4. Off
98-3830
5. Engine—stop
6. Engine—start
7. Engine—preheat
1. Read the
Manual—
machine.
2. Warning—read the
Operator’s Manual.
Operator’s
do not tow the
104-5203
3. Warning—keep bystanders
a safe distance from the
machine.
4. Cutting hazard of hand or
foot—stay away from
moving parts.
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.
9
7. Tipping hazard—lower the
cutting unit when driving
down slopes.
104-5204 for CE
1. Read the
Manual—
machine.
2. Warning—read the
Operator’s Manual.
Operator’s
do not tow the
3. Warning—keep bystanders
a safe distance from the
machine.
4. Cutting hazard of hand or
foot—stay away from
moving parts.
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. Tipping hazard—lower the
cutting unit when driving
down slopes. Do not drive
the machine across or down
a slope greater than 15
degrees.
93-9397
1. 7-blade reel 2. Height of cut 3. Reel—mowing speeds 4. Reel—transport speeds
10
1. Battery
2. Read the instructions
before servicing or
performing maintenance.
1. Explosion hazard—wear
eye protection.
2. Caustic liquid/chemical
burn hazard—to perform
first aid, flush with water.
58-6520
1. Grease
93-6668
3. Contains lead; do not
discard.
93-9409
1. To unlock the reels before lowering them, press the pedal.
93-7276
3. Fire hazard—no fire, open
flames, or smoking.
4. Poison hazard—keep
children a safe distance
from the battery.
11
Specifications
Note: Specifications and design subject to change without notice.
General Specifications
Kubota, four–cycle, four cylinder, 134 cu–in. displacement, water cooled diesel
Engine
Cooling System Capacity is 3.7 gal. (14 L) of 50/50 mixture of ethylene glycol anti–freeze.
Fuel System Capacity is 15 gal. (56.8 L) of #2 diesel fuel.
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.
Hydraulic System
Traction System Ground speed is 0–12.5 mph (0–20 km/h).
Cutting Unit Drive System
Seat
Diagnostic System
Steering System Automotive type, full power.
Brakes
Electrical System 12 volt, 66 amp hour (DIN) battery and 40 amp alternator. Negative ground.
Interlock System
Warning Systems
Reservoir capacity is 9.3 gal. (35.2 L) and total system capacity is 18.2 gal. (69 L).
Replaceable breather element. Replaceable spin–on filter element.
Adjustable reel speed to match clip to ground speed. Backlap reel speed is 385
rpm.
Adjusts 6 in. (15.2 cm) forward and backward. Adjustable backrest and
three–positions for operator weight. Integral seat switch at rear of bottom seat
cushion.
Test ports for traction system, cutting unit drive system, lift/counterbalance,
lift/relief, steering circuits and charge pressure are located near individual
components.
Hand brake automatically locks traction linkage in neutral. With traction motor
wheel locks engaged, twin disc brakes provide positive, emergency braking.
Designed to stop engine if operator gets off seat while cutting unit drive lever is
either in forward or reverse. Prevents engine from starting unless parking brake is
engaged, traction pedal is in neutral and cutting units are disengaged. Low
hydraulic oil level and high engine temperature protection systems stop engine
from running.
Water in fuel, hydraulic oil filter, engine coolant temperature, engine oil pressure,
voltage indicator, air cleaner clogged, hydraulic oil temperature and hydraulic oil
level.
Ground Clearance Approx. 7 in. (17.8 cm)
5 Blade Cutting Unit: 1 – 3 in. (25 – 76 mm)
Height of cut
Wheel Thread 53 in. (135 cm)
Wheel Base 57 in. (145 cm)
Operating Circle 60 in. (152 cm)
Reel Speed
Clip
7 Blade Cutting Unit: 3/8 – 1 3/4 in. (9.5 – 45 mm)
11 Blade Cutting Unit: 3/8 – 3/4 in. (9.5 – 19 mm)
800 – 1000 rpm
Note: 1200 rpm is attainable with a special coupler.
5 Blade Cutting Unit: .176 in. per mph (.352 in. at 2 mph – 1.32 in. at 7.5 mph)
7 Blade Cutting Unit: .126 in. per mph (.252 in. at 2 mph – .945 in. at 7.5 mph)
11 Blade Cutting Unit: .080 in. per mph (.16 in. at 2 mph – .600 in. at 7.5 mph)
12
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