FORM NO. 3321-328 Rev A MODEL NO. MODEL NO. MODEL NO. MODEL NO.
Table of Contents SAFETY INSTRUCTIONS 3 SYMBOL GLOSSARY 6 SPECIFICATIONS 9 BEFORE OPERATING 10 Check the Engine Oil 10 Check the Cooling System 10 Fill the Fuel Tank 11 Check the Hydraulic Fluid 11 Check the Planetary Gear Drive Oil 12 Check the Rear Axle Lubricant (Model 03801) 13 Check the Tire Pressure 14 Check Reel-To-Bedknife Contact 14 Check the Torque Of the Wheel Nuts 14 KNOW YOUR CONTROLS 15 OPERATING INSTRUCTIONS Starting And Stopping Priming Fuel System Automatic Clip Control Selecting Cl
Safety Training 1. 2. thrown by the machine. Read the instructions carefully. Be familiar with the controls and the proper use of the equipment. 3. Never allow children or people unfamiliar with these instructions to use the lawn mower. Local regulations may restrict the age of the operator. 3. Never mow while people, especially children, or pets are nearby. 4. Keep in mind that the operator or user is responsible for accidents or hazards occurring to other people or their property. 5.
• • engage the clutch slowly, and always keep the machine in gear, especially when travailing downhill; machine speeds should be kept low on slopes and during tight turns; • stay alert for bumps and hollows and other hidden hazards; • never mow across the face of the slope, unless the lawn mower is designed for this purpose. porting or not in use. 14. Stop the engine and disengage the drive to the attachment 6. Use care when pulling loads or using heavy equipment.
9. On multi-bladed machines, take care as rotating one blade can cause other blades to rotate. 10. When the machine is to be parked, stored or left unattended, lower the cutting means unless a positive mechanical lock is used. Sound & Vibration Levels Sound Levels This unit has an equivalent continuous A-weighted sound pressure at the operator ear of: 82 dB(A), based on measurements of identical machines per 84/538/EEC. Vibration Levels This unit has a vibration level of 2.
Symbol Glossary Caustic liquids, Poisonous Electrical shock, chemical burns to fumes or toxic electrocution fingers or hand gases, asphyxiation Crushing of whole body, applied from above Explosion Shut off engine & remove key before performing maintenance or repair work 6 High pressure High pressure Crushing of Crushing of spray, erosion of spray, erosion of fingers or hand, toes or foot, force flesh flesh force applied from applied from above above Crushing of Crushing of fingers Crushing of leg, Cr
Eye protection must be worn Head protection Hearing Caution, toxic must be worn protection must risk be worn First aid Fire, open light & smoking prohibited Hydraulic system Brake system Coolant (water) Intake air Exhaust gas Pressure Level indicator Liquid level Filter Temperature Failure/ Malfunction On/start Off/stop Engage Disengage Attachment lower Attachment raise Spacing distance Snow thrower, collector auger Plus/increase/ Minus/decrease/ positive polarity negative polarity Hor
Engine coolant pressure Engine coolant f Engine ilter lubricating oil pressure Engine failure/ malfunction Engine rotational Choke speed/frequency Engine intake/ Engine intake/ combustion air combustion air pressure Engine intake/ air filter Engine start Engine stop n/min Primer (start aid) Electrical preheat Transmission oil Transmission oil Transmission oil (low temperature pressure temperature start aid) NH L F RP Transmission Clutch failure/malfunction Neutral High Low Forward Reverse Par
Specifications Engine: Peugeot, 4-cylinder, 4-cycle, overhead cam, 116 cu. in (1.9 liter) displacement liquid-cooled diesel engine. 38 hp (28 kW); governed to 2500 rpm high idle; 23.5:1 compression ratio, 3.27" (83 mm) bore x 3.46" (88 mm) stroke. Automatic glow plug/starter interlock system. Heavy-duty, 2-stage, remote air cleaner. Main Frame: All-welded formed steel frame, includes tie-down loops. Cooling System: Rear-mounted, cross-flow agricultural type radiator; 7 fins per inch. 7.1 liter capacity.
Before Operating CAUTION Before servicing or making adjustments to the machine, stop the engine and remove the key from the switch. ➀ CHECK THE ENGINE OIL (Fig. 2 & 3) Crankcase capacity is 5 l with filter. 1. Park the machine on a level surface. Release the hood latch and open the hood. Figure 2 1. 2. Remove the dipstick from the tube cap, wipe clean and reinstall the dipstick into the tube cap.
2. Remove the degasser tank cap and check the coolant level. The level should be up to or above the tabs in the degasser tank, when the engine is cold. 3. If coolant is low, remove the degasser tank cap and add a 50/50 mixture of water and Peugeot-recommended anti-freeze (Toro Part No. 93-7213). DO NOT USE WATER ONLY OR ALCOHOL/METHANOL BASE COOLANTS. 4. Install the degasser tank cap. 5. Close the hood and secure the latch. ➀ Figure 5 1. Fuel tank cap FILL THE FUEL TANK (Fig.
ISO type 46/68 anti-wear hydraulic fluid ➀ Mobil Mobil Fluid 424 Amoco Amoco 1000 International Harvester Hy-Tran Texaco TDH Shell Donax TD Union OIl Hydraulic/Tractor Fluid Chevron Tractor Hydraulic Fluid BP Oil BP HYD TF Boron OIl Eldoran UTH Exxon Torque Fluid Conoco Power-Tran 3 Kendall Hyken 052 Phillips HG Fluid Note: The fluids within this group are interchangeable.
3. Remove the dipstick from the filler neck and wipe it with a clean cloth. Insert the dipstick into the filler neck; then remove it and check the level of fluid. Fluid level should be within 0.6 cm of the mark on the dipstick. 4. If the level is low, add fluid to raise the level to the full mark. 5. Install the dipstick and cap onto the filler neck. ➀ CHECK THE PLANETARY GEAR DRIVE OIL (Fig. 7) Figure 7 1. Check/Drain plug Check the oil if external leakage is noted.
CHECK TIRE PRESSURE The tires are over-inflated for shipping. Therefore, release some of the air to reduce the pressure. Correct air pressure in the front and rear tires is 103–138 kPa. IMPORTANT: Maintain even pressure in all tires to assure a good quality-of-cut and proper machine performance. DO NOT UNDER INFLATE. CHECK REEL-TO-BEDKNIFE CONTACT Each day before operating, check reel-to-bedknife contact, regardless of whether the quality of cut had previously been acceptable.
Controls Traction Pedal (Fig. 9)—Controls forward and reverse operation. Depress the top of the pedal to move forward and bottom to move backward. Ground speed depends on how far the pedal is depressed. For no-load, maximum ground speed, fully depress the pedal while the throttle is in FAST. ➂ ➃ ➂ ➀ To stop, reduce foot pressure on traction pedal and allow it to return to center position. Traction Speed Limiter (Fig.
Charge Indicator (Fig. 10)—Illuminates when the system charging circuit malfunctions. ➁ Enable/Disable Switch (Fig. 10)—Used with lower mow / raise control lever to operate the reels. Water-in-the-fuel Light (Fig. 10)—Warns of water in the fuel system. ➀ Low Water Level Light (Fig. 10)—Warns that the coolant water level is low. Height-of-Cut Selector Knob (Fig.
① ① Figure 14 1. 2. Seat adjusting lever Seat adjusting knob Operating Instructions CAUTION Before servicing or making adjustments to the machine, stop the engine and remove the key from the switch. STARTING AND STOPPING 1. Sit on the seat; keep your foot off the traction pedal. Assure the parking brake is engaged, the traction pedal is in NEUTRAL, the throttle is in the SLOW position and the ENABLE/ DISABLE switch is in the DISABLE position.
3. Run the engine at idle speed or partial throttle until the engine warms up. 4. To stop, move all controls to NEUTRAL and set the parking brake. Return the throttle to the idle position, turn the key to OFF and remove it from the switch. PRIMING THE FUEL SYSTEM (Fig. 15 & 16) IMPORTANT: The fuel system may need to be primed when a new engine is started for the first time, if it runs out of fuel or if maintenance is performed on the fuel system. 1. Unlatch and raise the hood. 2.
machine will maintain the desired clip. If the traction speed is too slow or too fast to allow the desired clip, the Reel Control light (on the front control panel) will illuminate, warning that the desired clip is not being maintained. For example, if the traction speed is zero, the reels will still run at the minimum speed of about 500 RPM, which will result in a clip smaller than desired and cause the Reel Control light to illuminate.
under the seat plate, listing either 5- or 11-blade reels, find the height of cut listing nearest the actual height-of-cut setting. Look across the chart to find the letter corresponding to that height of cut. 3. Turn the height-of-cut selector knob to the letter setting determined in step 2. 4. Operate the machine for several days, then examine the cut to ensure satisfaction with the quality of cut.
REEL CONTROL LIGHT The Reel Control light, located on the front control panel, is used to give feedback to the operator whether the machine controller can achieve the desired clip. If the machine is operated at a traction speed that is too low or too high, the machine controller may not be able to set the reel speed at the required value for the desired clip. If this occurs, the Reel Control light will illuminate. If the Reel Control light illuminates, it means one of the following things: 1. 2. 3.
2. Close the by-pass valve before starting the engine. However, do not exceed 7–11 Nm torque to close the valve. IMPORTANT: Running the engine with the by-pass valve open will cause the transmission to overheat. DIAGNOSTIC LIGHT (Fig. 19) The RM 6500-D is equipped with a diagnostic light which indicates whether or not the electronic controller is functioning correctly. The diagnostic light is located on the steering tower panel.
CHECKING THE INTERLOCK SWITCHES The purpose of the interlock switches is to prevent the engine from cranking or starting unless the traction pedal is in NEUTRAL, the Enable/Disable switch is in DISABLE and the Lower Mow/Raise control is in the neutral position. In addition, the engine will stop when the traction pedal is depressed with the operator off the seat.
ed. If the “inputs displayed’ LED is illuminated, press the toggle button on Diagnostic ACE to change LED to “outputs displayed”. hold the button down. 6. The Diagnostic ACE will illuminate the light associated with each of the inputs when that input switch is closed. Individually, change each of the switches from open to closed (i.e., sit on seat, engage the traction pedal, etc.), and note that the appropriate light on Diagnostic ACE will blink on and off when corresponding switch is closed.
Diagnostic ACE, disconnect it from the machine and reconnect the loopback connector to the harness connector. The machine will not operate without the loopback connector installed on the harness. Store the Diagnostic ACE in dry, secure location in the shop, not on the machine. • Turn ignition key to the “ON” position to start the system. The system will reset itself whenever the ignition key is turned to the “OFF” position. Wait 5 seconds, then move key to “ON” position to restart the system.
a. No beeps are heard when the ignition switch is turned to “ON”. b. Any time the machine gives a series of four short beeps. 1. When the “Inputs displayed” light is lit, the actual float position (1 or 2 lights on the left row) and the “Oil level OK” light, should be displayed (Fig. 25). 2. Press the toggle button until the green “Outputs displayed” light is lit. “Valve ON”, “data line” and “self-diagnostic” lights should glow steadily.
• Note: Only large air leaks can be detected by the hand-held Diagnostic ACE. A leak-down test is required to identify small air leaks. Consult your Authorized Toro Distributor for assistance. 2. secure on the tank. Contact your local authorized Toro Distributor for further assistance with an air leak problem. Air leak in the system: Assure the tank cap is tight or check for a leak in the tank. 4. When toggling “output” a light should display (Fig.
Diagnostic ACE Display Functions 1. Overlay decal (English shown) 2. “Inputs Displayed” light (Red) 3. “Outputs Displayed” light (Green) 4. Toggle button Figure 24 Using “Inputs Displayed” (Red Text) 1. Light lit if oil level is too high 2. Light lit if oil level is OK 3. Light lit if oil level is too low 4. Light lit if oil is too hot 5. Light lit if system air leak has been detected 6. One or two lights lit displaying the relative position of the Turfdefender's internal float. 7.
TURFDEFENDER RAPID TROUBLESHOOTING GUIDE The following is a quick guide to the most common problems likely to be encountered. The hand-held diagnostic ACE is helpful for identifying specific problems.
turn pedal gradually and intermittently until the uphill wheel stops slipping, thus, increasing traction on the downhill wheel. IMPORTANT Before mowing grass, practice operating the machine in turns. Turf damage in turns may occur—especially under soft or wet grass conditions—if the turn is completed at a high speed or at a small turning radius. Maintain a speed below 4.8 km/h during a turn and a turning radius greater than eight feet to minimize turf damage from tires or cutting units.
Maintenance Minimum Recommended Maintenance Intervals Maintenance Procedure Lubricate all grease fittings Inspect air filter, dust cap and baffle Check battery fluid level Check battery cable connections Maintenance Interval & Service Every 50 hours Every 100 hours Every 200 hours Every 400 hours Every 800 hours ‡ Change engine oil and filter Inspect cooling system hoses ✝ Check fan and alternator belt tension ✝Torque wheel lug nuts ▼ Service air filter Replace the fuel filter Inspect fuel lines and c
GREASING BEARINGS AND BUSHINGS (Fig. 27–35) The machine has grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease. If the machine is operated under normal conditions, lubricate all bearings and bushings after every 50 hours of operation or immediately after every washing. 1. The grease fitting locations and quantities are: Cutting unit carrier frame and pivot (2 ea.) (Fig. 27); Rear axle tie rod (2), Steering cylinder ball joints (2), (Fig.
Figure 34 Figure 33 Figure 35 Reelmaster 6500-D, 2-Wheel Drive Quick Reference Aid Check/Service (daily) Check/Service (See 1. Oil level, engine Operator’s Manual) 2. 3. 4. 5. 6. 7. 8. Oil level, hydraulic tank Coolant level, radiator Fuel/Water separator Air filter service indicator Radiator screen Brake function Tire pressure 9. Battery 10. Belts (fan, alternator) 11.
CAUTION Before servicing or making adjustments to the machine, stop the engine and remove the key from the switch. GENERAL AIR CLEANER MAINTENANCE 1. Check the air cleaner body for damage which could possibly cause an air leak. Replace a damaged air cleaner body. 2. Service the air cleaner filters whenever the air cleaner indicator (Fig. 36) shows red or every 400 hours (more frequently in extreme dusty or dirty conditions). Do not overservice the air filter. 2.
C. Dry the filter element using warm, flowing air (71° C) max), or allow element to air-dry. Do not use a light bulb to dry the filter element because damage could result. Compressed Air Method A. Blow compressed air from the inside to the outside of the dry filter element. Do not exceed 689 kPa to prevent damage to the element. B. Keep the air hose nozzle at least 5 cm from the filter and move the nozzle up and down while rotating the filter element.
with the filter. FUEL SYSTEM (Fig. 42 & 43) DANGER Because diesel fuel is flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill the fuel tank while the engine is running, hot, or when the machine is in an enclosed area. Always fill the fuel tank outside and wipe up any spilled diesel fuel before starting the engine. Store fuel in a clean, safety-approved container and keep the cap in place. Use diesel fuel for the engine only; not for any other purpose.
1. Loosen the bolt and unscrew the bottom filter cap from the filter assembly. Remove the cap, gaskets, o-ring and filter from the assembly. Note the position of the gaskets and o-ring when disassembling from the filter. 2. Install a new filter, gaskets, o-ring with the filter assembly cap. 3. Prime the fuel system, refer to Priming The Fuel System. ➀ ENGINE COOLING SYSTEM (Fig. 44–45) Figure 44 1. Removing Debris—Remove debris from the rear screen, oil cooler and radiator daily.
B. After every 2 years, drain and flush the cooling system. Add anti-freeze (refer to Check The Cooling System). ENGINE FAN BELT (Fig. 46) Check condition and tension of fan belt after every 100 hours of operation. Replace belt as required. ➁ 1. Proper tension will allow 0.64 cm deflection on the belt midway between the pulleys, when pressed firmly with thumb. ➀ Figure 46 2. If deflection exceeds 0.64, loosen the alternator mounting bolts.
REPLACING THE HYDRAULIC FILTER (Fig. 48) ➁ The hydraulic system filter head is equipped with a service interval indicator. With the engine running, view the indicator. It should be in the GREEN zone. When the indicator is in the RED zone, the filter element should be changed. ➀ Use the Toro replacement filter (Part No. 94-2621). IMPORTANT: Use of any other filter may void the warranty on some components. 1.
ADJUSTING THE TRACTION DRIVE FOR NEUTRAL (Fig. 49) The machine must not creep when the traction pedal is released. If it does creep, an adjustment is required. 1. 2. Park the machine on a level surface, shut the engine off and lower cutting units to the floor. Depress only the right brake pedal and engage the parking brake. Jack up the left side of the machine until front tire is off the shop floor. Support the machine with the jack stands to prevent it from falling accidentally. ➀ ➁ Figure 49 1. 2.
ADJUSTING THE SERVICE BRAKES (Fig. 51) ➀ Adjust the service brakes when there is more than 2.5 cm of “free travel" of the brake pedal, or when the brakes do not work effectively. Free travel is the distance the brake pedal moves before braking resistance is felt. 1. Disengage the locking pin from the brake pedals so both pedals work independently of each other. 2. To reduce free travel of brake pedals, tighten the brakes—loosen the front nut on the threaded end of the brake cable.
8. Repeat this procedure on the opposite gear assembly. CHANGING REAR AXLE LUBRICANT (Model 03801 only) (Fig. 54) After every 800 hours of operation, the oil in the rear axle must be changed. 1. Position the machine on a level surface. 2. Clean the area around the (3) drain plugs, (1) on each end and (1) in the center. 3. Remove check plugs to ease draining of oil. 4. Remove drain plugs and drain oil into pans. 5.
BATTERY CARE ➀ CAUTION Wear safety goggles and rubber gloves when working with electrolyte. Charge the battery in a well ventilated space so gases produced while charging can dissipate. Since the gases are explosive, keep open flames and electrical sparks away from the battery; do not smoke. Nausea may result if the gases are inhaled. Unplug the charger from the electrical outlet before connecting or disconnecting charger leads to or from battery posts. Figure 56 1. IMPORTANT.
proceeding. BACKLAPPING CAUTION Reels may stall while backlapping. do not attempt to restart the reels by hand or touch the reels while backlapping. Stop the engine and turn the Height-ofCut knob one position toward “A”. Note: When backlapping, the front units all operate together, and the rear units operate together. 1. Position the machine on a level surface, lower the cutting units, stop the engine, engage the parking brake, and move the Enable/Disable switch to the Disable position. 2.
Preparation for Seasonal Storage Traction Unit 6. Flush the fuel tank with fresh, clean diesel fuel. 1. Thoroughly clean the traction unit, cutting units and the engine. 7. Secure all fuel system fittings. 8. 2. Check the tire pressure. Inflate all tires to 103–138 kPa. Thoroughly clean and service the air cleaner assembly. 9. Seal the air cleaner inlet and the exhaust outlet with weatherproof tape. 3. Check all fasteners for looseness; tighten as necessary. 4.
