FORM NO. 3318-286 GB Rev A MODEL NO. 03800TE—60001 & UP MODEL NO.
Table of Contents IDENTIFICATION & ORDERING 2 SAFETY INSTRUCTIONS 4 SYMBOL GLOSSARY 7 SPECIFICATIONS 10 BEFORE OPERATING Check the Engine Oil Check the Cooling System Fill the Fuel Tank Check the Hydraulic Fluid Check the Planetary Gear Drive Oil Check the Rear Axle Lubricant (Model 03801) Check the Tire Pressure Check Reel-To-Bedknife Contact Check the Torque Of the Wheel Nuts 11 11 11 12 12 14 14 14 15 15 KNOW YOUR CONTROLS 16 OPERATING INSTRUCTIONS Starting And Stopping Priming Fuel System Au
Safety Training 1. 2. to be used and remove all objects which may be thrown by the machine. Read the instructions carefully. Be familiar with the controls and the proper use of the equipment. 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.
• 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. 14. Stop the engine and disengage the drive to the attachment 6. Use care when pulling loads or using heavy equipment. • Use only approved drawbar hitch points.
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. 2. Park the machine on a level surface. Release the hood latch and open the hood. 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. FILL THE FUEL TANK (Fig.
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. Group 2 Hydraulic Fluid (Biodegradable): ISO VG 32/46 anti-wear hydraulic fluid Mobil EAL 224 H Note: The fluid in this group is not compatible with the fluids in group 1.
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. CHECK THE PLANETARY GEAR DRIVE OIL (Fig. 7) Check the oil if external leakage is noted. Use high-quality SAE 85W-140 wt. gear lubrication as replacement. ➀ System capacity is 47.3 cl. 1. With the machine on a level surface, position the wheel so the check/drain plug is at either three or nine o'clock position. 2. Remove plug. Oil should be to bottom of the hole. 3.
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. There must be light contact across the full length of the reel and bedknife (refer to Adjusting Reel to Bedknife in Cutting Unit Operator's Manual).
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. ➃ To stop, reduce foot pressure on traction pedal and allow it to return to center position. ➂ Traction Speed Limiter (Fig.
Enable/Disable Switch (Fig. 10)—Used with lower mow / raise control lever to operate the reels. ➁ Water-in-the-fuel Light (Fig. 10)—Warns of water in the fuel system. Low Water Level Light (Fig. 10)—Warns that the coolant water level is low. Height-of-Cut Selector Knob (Fig. 11)—Turning the knob to the appropriate setting informs the electronic controller at what heightof-cut the machine is being operated so desired clip may be obtained. See section in manual for operating instructions.
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.
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. The approximate ranges of traction speed which will result in the desired clip are as follows for several of the possible heights of cut: Figure 17 1.
ensure satisfaction with the quality of cut. The height-of-cut knob may be set one position on either side of the position on the chart to account for differences in grass condition, grass length removed, and personal preference of the superintendent. For a cut with more grass removed but slightly more clip visibility, move the height-of-cut selector knob one position higher than specified.
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.
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. When the electronic controller is functioning correctly and the key switch is moved to the ON position, the controller diagnostic light will be illuminated for approximately 6 seconds.
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.
6. 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 LED on Diagnostic ACE will blink on and off when corresponding switch is closed. Repeat on each switch that is possible to be changed by hand. 7. Note: It may be necessary to toggle between “inputs displayed” and “outputs displayed” several times to do the following step. To toggle back and forth, press the toggle button once.
ACE in dry, secure location in the shop, not on the machine. HYDRAULIC SOLENOID VALVE FUNCTIONS Use the list below to identify and describe the different functions of the solenoids in the hydraulic manifold. Each solenoid must be energized to allow function to occur.
Maintenance GREASING BEARINGS AND BUSHINGS (Fig. 22–30) 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. 22); Rear axle tie rod (2), Steering cylinder ball joints (2), (Fig.
Figure 29 Figure 28 Figure 30 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. 31) shows red or every 400 hours (more frequently in extreme dusty or dirty conditions). Do not overservice the air filter. 2. ➀ Figure 31 1.
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. ➀ Keep the air hose nozzle at least 5 cm from the filter and move the nozzle up and down while rotating the filter element.
FUEL SYSTEM (Fig. 37 & 38) Fuel Tank Drain and clean the fuel tank every 800 hours of operation or yearly, whichever comes first. Also, drain and clean the tank if the fuel system becomes contaminated or if the machine is to be stored for an extended period. Use clean fuel to flush out the tank. ➀ DANGER Because diesel fuel is flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank.
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. ENGINE COOLING SYSTEM (Fig. 39–40) 1. Removing Debris—Remove debris from the rear screen, oil cooler and radiator daily. Clean more frequently in dirty conditions. ➀ IMPORTANT: Never spray water onto a hot engine as damage to the engine may occur. A.
operation. Replace belt as required. 1. Proper tension will allow 0.64 cm deflection on the belt midway between the pulleys, when pressed firmly with thumb. 2. If deflection exceeds 0.64, loosen the alternator mounting bolts. Adjust the alternator belt’s tension by adjusting the tension screw. Check the deflection of belt again to assure its tension is correct. CHANGING HYDRAULIC FLUID (Fig. 42) Change hydraulic fluid after every 800 operating hours, in normal conditions.
some components. 1. Position the machine on a level surface, lower the cutting units, stop the engine, engage the parking brakes and remove the key from the ignition switch. 2. Clean the area around the filter mounting area. Place the drain pan under the filter and remove the filter. 3. Lubricate the new filter gasket and fill the filter with hydraulic fluid. 4. Assure the filter mounting area is clean. Screw the filter on until gasket contacts mounting plate. Then tighten the filter one-half turn.
5. After wheel rotation ceases, tighten the jam nuts to secure adjustment. 6. Stop the engine and release the right brake. Remove the jack stands and lower the machine to the shop floor. Test drive the machine to make sure it does not creep. ➀ ADJUSTING THE CUTTING UNIT LIFT RATE (Fig. 45) The cutting unit lift circuit is equipped with an adjustable valve to ensure the front cutting units raise and lower evenly. Adjust the cutting units as follows: 1. Locate the valve under the seat. 2.
tion as replacement. 1. With the machine on a level surface, position the wheel so the check/drain plug is at its lowest position. 2. Place the drain pan under the hub, remove the plug and allow the oil to drain. 3. When all oil has been drained, position the wheel so the plug hole is at three or nine o'clock position. 4. ➀ Place the drain pan under the brake hub on other side of the wheel. Figure 47 1. 5. Remove the plug from the bottom of the hub and allow the oil to drain. 6.
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. Unlock and raise the seat to expose the controls. 3. Open the control cover and turn the height-of-cut selection knob to position “P”. Note: Backlapping speed may be increased by moving the height-of-cut selection knob toward to “A”.
10. To make an adjustment to the cutting units while backlapping, turn the reels OFF by moving the Lower Mow/Raise lever rearward; move the Enable/Disable switch to Disable and turn the engine OFF. After adjustments have been completed, repeat steps 5–9. 12. When you’ve completed the backlap operation, return the backlap switch to OFF, lower the seat and wash all lapping compound off the cutting units. Adjust the cutting unit reel to the bedknife as needed.
