MODEL MO, 03602 — 40001 & UP MODEL NO. 03803 — 40001 & UP FORM NO, 3316250 OPERATOR’S MANUAL T understand this product, and Tor safety and optimum performance, read this manual before starting the engine. Pay special attention lo SAFETY INSTRUCTIONS highlighted by this symbol. & i means CAUTION, WARNING or DANGER -~ personal safety Instruction. Allure 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 Set-up [instructions Maintenance Before Operating 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 . LOOSE PARTS CHART SET-UP INSTRUCTIONS Install Front Wheels Install Rear Wheels 10 Install Steering Wheel and Horn Button install Seat ., Install Seat Belts (Model 03603 Only) 11 Install Root Bar (Model 03603 Only) . Connect Battery Install Cutting Units . BEFORE OPERATING . Check Engine Ol Check Cooling System Silt Fuel Tank Check Hydraulic Circuit Oif . Check Front Axis Qil Level .
A SAFETY INSTRUCTIONS The REEL MASTER 3500-D was tested and certified by TOR for compliance with the specifications of the American National Standards Institute. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern, and proper training of the personnel involved in the operation, transport, maintenance, and storage of the machine.
A SAFETY INSTRUCTIONS 16. Operator must be skilled and trained in how to drive on hillsides. Failure to use caution on slopes or hills may cause loss of control and vehicle to tip or roll possibly resulting in personal injury or death, 17. When operating 4 wheel drive machine, always use the seat belt and TOPS together and have seat pivot retaining pin installed. 18.
A SAFETY AND INSTRUCTION DECALS The following safety and instruction decals are affixed to the traction unit, If any decal becomes illegible or damaged, install a new decal. Part numbers are listed below and in your Parts Catalog. O™ ON RIGHT HAND CONSOLE ON RIGHT HAND CONSOLE {Part No. 76-8710) ( Part No.
SPECIFICATIONS Engine: Peugeot, four—cycle, four cylinder, 1.9 fighter (1900 cc) displacement, liquid cooled diesel engine., 23.5:1 compression ratio. Low idle — 1600 rpm, high die — 2500 rpm. Qil capacity is 5.3 gts. with filter. Cooling System: Capacity is 3.5 gal. of 50/50 mixture of Peugeot recommended antifreeze. Fuel System: Capacity is 14 gal. diesel fuel. Hydraulic System: Reservoir capacity is 6.5 gal. Replaceable spin—on filter element. Traction System: Ground speed: Low Range; 0-6.5 mp.h (0 ~ 5.
SPECIFICATIONS 7 Blade L. H. Cutting Unit, Model No, 03754 (1 per machine} 7 Blade R. H. Cutting Unit, Model No. 03756 {2 per machine} 11 Blade L. H. Curling Unit, Model No. 08741 {1 per machine) 11 Blade R. H. Cutting Unit, Model No. 03751 (2 per machine) L. H. Thatcher Reel, Model No.03730 {1 per machine) A. H. Thatcher Reel, Model No.03732 {2 per machine) Cutting Unit Floating Head Kit, Mode! No. 03640 {1 per machine) Cutting Unit Fixed Head Kit, Model 03642 {1 per machine) Front Toiler Kit, Model No.
SET-UP INSTRUCTIONS INSTALL FRONT WHEELS (Fig. 1) 1. Mount wheels and tongue nuts to 45-55 Bk, INSTALL REAR WHEELS (Fig. 2} Mote: Rear wheels are mounted with nuts on 2 wheel drive machines and bolts are used on 4 wheel drive machines. 1. Remove and referral nuts or bolls securing rear wheels o shipping brackets, Figure 2 Saar Whale! 2. Nuts shown 10 2.
SET-UP INSTRUCTIONS 1, Adjustable Suspension Unit 2. Casserole, Lock washer & Flat washer 3. R—clamp (2) 4. Manual Tube 5, Spacers &, dam news 2. Remove lynch pin from seat latch pin (Fig. Figure § 2. Sent Latch Pin 1. Lynch Pin 3. Mount seal suspension assembly to seat support and secure with lock washers and nuts. 4. Pivot seat down and push lynch pin through seat fate stud. 8.
SET-UP INSTRUCTIONS INSTALL ROLL BAR (Fig. 8-9) {Standard on Model 03803 only) Harte: Foll bar is available as an option for mode! 08602, but must be used with seal bell., 1. Remove lynch pin from seat lathe pin (Fig. 5) and pivot seat support forward. Hold up seat with prop rod {Fig. 8). A Figure & 1. Beat Prop Rod 2. Lower rot bar onto frame, aligning mounting holes as shown in fig, 9, 5. Recurs each side of roll bar to frame with a 1/2x13 ~ 3/4” lg. cap screw and lock washer.
SET-UP INSTRUCTIONS WARNING Connecting cables o the wrong post could resell In personal Injury and/or damage fo the electrical system. 4. Coat both battery connections with with either Grease 112X {skin over} grease, Toto Part No, 50547, petroleum jelly or it grease to prevent corrosion and slide rubber boot over positive terminal, INSTALL CUTTING UNITS 1. Remove curling units from cartons.
BEFORE OPERATING Figure 13 4. Sargasso Tank 2, Mounting Tabs 3. Coolant is low, remove degassed tank cap and add a 50/50 diuretic of water and Peugeot recommended anti—freeze. DO NOT USE WATER ONLY OR ALCOHOL/METHANOL BASE COOLANTS. IMPORTANT: Do not remove black plastic cap on degassed tank. 4. Install degassed tank cap. &, Close hood and secure fats, FILL FUEL TANK (Fig. 14} 1. Park making on a level surface. Release hood fats and open hood. 2. Remove fuel tank cap. iguana 14 1. Fuel Tank Cap 3.
BEFORE OPERATING 2. Oil level is not visible in gauge, remove cap from check label of lubricant. If elev! is not within 1/2 inch hydraulic oil reservation and slowly fll reservoir with from the groove in the dipstick, add enough to raise Mobil DTE 26 or equivalent hydraulic off sturdily level feel to groove mark. DO NOT OVERFILL by more reaches middle {(maximum) of sight gauge. DO NOT than 1/2 inch above groove, OVERFILL. Figure 15 Figure 17 1. Sight Gauge 2. Hydraulic Reservoir Cap 1. Dipstick Cap 4.
BEFORE OPERATING CHECK TIRE PRESSURE The the are overinflated for shipping. Therefore, release some of the alr to reduce the pressure. Correct alr pressure iy the font and rear tires s 15-20 psi, IMPORTANT, Maintain even pressure in all tires to assure a good and proper machine performance. DO NOT UNDER INFLATE.
KNOW YOUR CONTROLS Sat (Fig, 20) Seat adjusting lover on left side of seat allows 4 inch fore and aft adjustment. Seat adjusting knob on front of seat, adjusts chest for operators weight. Figures 20 1. Sat Adjusting Lover 2. Seat Adjusting Knob Traction Pedal {(Fig. 21) -~ Controls forward and reverse operation. Depress top of pedal to move forward and bottom to move backward.
KNOW YOUR CONTROLS Transport Latches (Fig. 23) —Three latches secure curling unis in upright position for transport operation, Figure 23 . Transport Lat eh (3) Hom ~ In center of steering wheel. Operates only when key switch is in ON. OPERATING INSTRUCTIONS STARTING AND STOPPING 1. Synthesis seat, keep foot off inaction pedal. Assure parking brake is engaged, action pedal is in NEUTRAL and curling unit engagement switch is in the DISENGAGED position. 2. Tum ignition switch to ON position.
OPERATING INSTRUCTIONS Figure 25 1. Injection Pump Fitting CHECKING INTERLOCK SYSTEM. The purpose of the interlock system is fo prevent the engine from cranking or starting unless the fraction pedal is in NEUTRAL and the cutting unit engagement switch is DISENGAGED. In addition, the engine will stop when the culling unit engagement switch is engaged or ration pedal is depressed with operator off the seat. A CAUTION THE INTERLOCK SWITCHES ARE FOR THE OPERATOR’S PROTECTION, SO DO NOT DISCONNECT THEM.
OPERATING INSTRUCTIONS Transport — When mowing is complete, raise cutting units by pulling back on lift control levers, Hold levers back until cutting units are fully raised. Lock curling units in place with transport latches. Move axe shift lever forward to Hi position. When driving from one area to another, always shift axle to LO position before encountering a slops. Never shift from Hl 1o LO position while on & slope. Stop machine on a flat surface, engage brakes and shift before climbing the slope.
SERVICE INTERVAL CHART -2 Wheel Drive RM 3500-D 2WD QUICK REFERENCE AID Run {154 ACC |5A Relay |5A @ CHECK/SERVICE 1. ENGINE OIL LEVEL/FILL 7. GREASE POINTS (22) -emy » 2. HYDRAULIC OIL LEVEL/FILL 8. RADIATOR SCREEN 3. FRONT AXLE OIL LEVEL/FILL 9. AIR CLEANER A FAN BELT 10. WATER SEPARATOR/FUEL FILTER 5. COOLANT LEVEL/FILL 11. BATTERY 6. FUEL-DIESEL ONLY 12. TIRE PRESSURE (1-1.
SERVICE INTERVAL CHART—4 Wheel Drive 3% 0 3l5 e @ CHECK/SERVICE 1. ENGINE OIL LEVEL/FILL, 2. HYDRAULIC OIL LEVEL/FILL 3. FRONT AXLE OIL LEVEL/FILL 4, REAR AXLE OIL A FILL B. CHECK (2) 5. COOLANT LEVEL/FILL 6. FUEL-DIESEL ONLY 7. GREASE POINTS ézz) 8. RADIATOR SCREEN 9. AIR CLEANER 10. WATER SEPARATOR/FUEL FILTER 11. BATTERY 12. FAN BELT 13. TIRE PRESSURE (1-1.5 PSI) FLUID SPECIFICATIONS/CHANGE INTERVALS *See operator's manual | FLUID TYPE |CAPACITY | CHANGE INTERVAL | FILTER for initial changes.
LUBRICATE GREASING BEARINGS AND BUSHINGS (Fig. 28-38) The traction unit has grease fittings that must be lubricated regularly with No, 2 General Purposes Lithium Base Grease. If machine is operated under normal conditions, lubricate all bearings and bushings after every 28 hours of operation. 1. The traction unit bearings and bushings that must be fabricated are: Two and Four wheel drive machines ~ #1 Lift arm pivot {1}, #11itt cylinder (1), brake arm pivots (2) (Fig.
AIR CLEANER MAINTENANCE A\ caution Before servicing or making adjustments to the machine, stop engine and remove key from the switch. GENERAL MAINTENANCE PRACTICES Inspect air cleaner and hose periodically to maintain maximum engine protection and to ensure maximum service life, 1. Assure hose between air cleaner and carburetor is clamped securely in place. Replace the hose if iris cracked or punctured. 2. Hack air cleaner body for dents and other damage which could possibly cause an air leak.
AlR CLEANER MAINTENANCE C. Dry filter element using warm, flowing air{180°F } max), or allow element to air—dry. Do not use compressed air or a light bulb to dry the filter element because damage could result. Compressed Alr Meted IMPORTANT Do not remove plastic fin assembly because back-blowing with compressed aly removals dust from beneath fins. A, Blow compressed air rom inside to the outside of dry filter element. Do not exceed 100 psi io prevent damage fo the element, B.
ENGINE MAINTENANCE A DANGER Because dissed] fuel is highly flammable, use caution when storing or handing it. Do not snake while filling the fuel tank, Donor fill fuel tank wheels engine s running, hot, or when machine Is In an enclosed area, Always fill fuel tank outside and wipe up any spilled diesel fuse before starting the engine.
ENGINE MAINTENANCE 2. Maintaining Cooling System — Capacity of the systems 3.5 gal. Always protect cooling system with 50/50 solution of wale and Peugeot recommended anti—freeze. DO NOT USE WATER ONLY IN COOLING SYSTEM. A. After every 100 operating hours, tighten hose connections. Replace any deteriorated hoses. B. After Avery 2 years, drain and flush the cooling system, Add anti—freeze {refer to Check Cooling System, Page 13). ENGINE FAN BELT (Fig. 45} Check condition and lesion of fan bek (Fig.
HYDRAULIC MAINTENANCE £ caution Before servicing or making adjustments tithe machine, stop engine and remove key from the switch. CHANGING HYDRAULIC Ol (Fig. 48 & 47} Normally, change hydraulic oil after every 500 operating hours. If oil becomes contaminated, contact your local TOR distributor because the system must be flushed, Contaminated oil looks milky or black when compared to clean oil. 1. Turn engine off, release hood arch and raise hood. 2. Remove drain plugs (Fig.
HYDRAULIC MAINTENANCE 4, Steering Circulate has a normal relies! setting of approximately 1200 psi. 4, Assure filter mounting area is clan. Screw filter on until gasket contacts mounting plate. Then tighten filter one—half turn, 5. Start engine and let run for about two minutes to purge air from the shyster. Stop the engine and check off level. Alec check for any leaks.
Figure 52 1. Traction Forward Rouault ADJUSTING TRACTION DRIVE FOR NEUTRAL (Fig. 53) The machine must not creep when traction pedal is released. If it does creep, an adjustment is required. 1. Park machine on a level surface, shut engine off and move shift lever to "HI” position, Depress only the right brake pedal and engage the parking brake. 2. Jack up left side of machine until front tire is off the shop floor. Support machine with jack stands to prevent it from failing accidentally. 3.
AXLE MAINTENANCE 4. After gil is drained, reinstall drain plug lino axis. 5. Fill side with lubricant; refer to Check Front Axle il Level, page 15, CHANGING REAR ABLE LUBRICANT {Model 036023 only) {Fig. 55) After every 500 hours of operation the oll in the rear axle must be changed. 1. Position machine on a level surface, 2. Clean area around the {3} drain plugs, (1) on each end and (1) in the center. Figure 55 4. Dean Plugs (3) 3. Remove pigs allowing oil to drain into drain pans.
ELECTRICAL MAINTENANCE Ab cation Before servicing or making adjustments to the machine, stop engine and remove key from the switch. BATTERY CARE IMPORTANT: Before welding on the machine, disconnect ground cable from the battery fo prevent damage o the electrical system, Nos: Check battery condition weekly or after every 50 hours of operation. Keep terminals and entire battery case clean because a dirty fiery will Figure 56 discharge slowly. To clean the battery, wash the 1. ACE Fuse 3.
PREPARATION FOR SEASONAL STORAGE Traction Unit 1. Thoroughly clean the ration unit, cutting units and the engine. 2. Check the tire pressure. Inflate all tires to 1520 psi. 3. Check all fasteners for looseness; tighten as necessary. 4, Grease or ol all grease filings and pivot points. Wipe up any excess lubricant. 5. Lightly sand and use touch—up paint on painted areas that are scratched, chipped, or rusted. Repair any dents in the metal body. 6.
The Toto Promise A One Year Limited Warranty The Toto Company 'promises to repair your TOR product if defective in materials or workmanship.