MODEL NO. 03800 — 70001 & UP MODEL NO. 03801 — 70001 & UP FORM NO. 3319-145 OPERATOR’S MANUAL k REELMASTER® 6500—D WHEEL DRIVE TRACTION UNITS Helping you put quality into play.™ To understand this product, and for safety and optimum performance, read this manual before starting the engine. Pay special attention to SAFETY INSTRUCTIONS highlighted by this symbol. A It means CAUTION, WARNING or DANGER personal safety instruction. Failure 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 ~ Know Your Controls Specifications — Operating Instructions ~ Set—up Instructions — Maintenance Before Operating — Schematics This manual emphasizes safety, mechanical and general product information.
TABLE OF CONTENTS Page IDENTIFICATION & ORDERING Model And Serial Number SAFETY INSTRUCTIONS Before Operating .. While Operating . . Maintenance SAFETY INSTRUCTIONS & DECALS . SPECIFICATIONS LOOSE PARTS CHART . SET-UP INSTRUCTIONS Install Cutting Units .. Rear Ballast BEFORE OPERATING Check Engine Oil Check Cooling System . Fill Fuel Tank Check Hydraulic Fluid . . 12 Check Planetary Gear Drive Oil 12 Check Rear Axle Lubricant (Model 03801} . 13 Check Tire Pressure Check Reel To Bed knife Contact .
A SAFETY INSTRUCTIONS The REEL MASTER 8500-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 contort and vehicle to tip or roll possibly resulting in personal injury or death. On 4 wheel drive model, always use the seat belt and TOPS together. 17. If engine stalls or lenses power and cannot make it to the top of a slope, do not turn machine around. Always back slowly straight down the slope. 18.
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 die; 23,511 compression ratio, 3.27" (83 mm) bore x 3.48” {88 mm) stroke. Automatic glow plug/starter interlock system. Heavy duty, 2 stage, remote air cleaner. Main Frame: All waded formed steel frame, includes lops. Cooling System: Rear—mounted, cross—flow agricultural type radiator; 7 fins per inch. Approx. 7.5 quart {7.
LOOSE PARTS CHART Note: Use this chart as a checklist to assure all parts necessary for assembly have been received, Without these parts, total set-up cannot be completed. Some parts may have already been assembled at factory, DESCRIPTION QTY.
SET—UP INSTRUCTIONS Note: Before installing cutting unit motors or counterweights with speed sensors, lubricate internal splines of cutting unit reels shafts with grease. 4. Install a counter weight onto appropriate end of each cutting unit with cap screws provided (Fig. 3 ). 5. Install (2) shims on pivot shaft of each cutting unit carrier frame {Fig. 4). 8. Insert the pivot shaft of the carrier frame into the mounting hole at the end of the pivot knuckle (Fig. 4). Figure 4 1. Carrier frame 4.
BEFORE OPERATING A\ caution Before servicing or making adjustments fo the machine, stop engine and remove key from the switch. CHECK ENGINE OIL (Fig. 6 & 7) Crankcase capacity is 5.3 gt. with filter, 1. Park machine on a level surface. Release hood fats and open hood. Figure 6 1. Hood Latch 2. Remove dipstick from tube cap, wipe clean and reinstall dipstick into tube cap. Pull it out again and check ol level on dipstick: Oi level must always be in notch area on dipstick. Figure 7 1. Dipstick / Tube Cap 3.
BEFORE OPERATING A\ pang Er Because diesel fuel is flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running, hot, or when machine is in an enclosed area. Always fill fuel tank outside and wipe up any spilled diesel fuel before starting the engine. Store fuel in a clean, safety—approved container and keep cap in place. Use diesel fuel for the engine only; not for any other purpose. CHECK HYDRAULIC FLUID (Fig.
BEFORE OPERATING Figure 11 1. Check/Drain Plug CHECK REAR AXLE LUBRICANT {Model 03801 Only) (Fig. 12) The rear axle is shipped from the factory filled with SAE 85W 140 wt, gear lube. Check level before engine is first started and every 400 hours thereafter. Capacity is 80 oz, Visually inspect for leaks daily. 1. Position the machine on a level surface. 2. Remove a check plug from one end of axle and make sure Lubricant is up to bottom of hole.
KNOW YOUR CONTROLS Traction Pedal (Fig. 13) — Controls forward and reverse operation. Depress top of pedal to move forward and bottom to move backward. Ground speed depends on how far pedal is depressed. For no load, maximum ground speed, fully depress pedal while throttle is in FAST, To stop, reduces foot pressure on traction pedal and allow it to return to center position. Traction Speed Limiter (Fig.
KNOW YOUR CONTROLS Hour Meter (Fig. 15) Shows total hours that machine has been operated. Figure 15 1. HOC Selector Nab 2. Hour Meter Back lap Switch {Fig. 18} — Used in conjunction with lower mow [ raise control lever for backslapping operation. Switch is located under seat plate, Refer to Cutting Unit Maintenance, Backslapping. Figure 16 1. Back lap Switch Brake Pedals (Fig.
OPERATING INSTRUCTIONS A caution Before servicing or making adjustments to the machine, stop engine and remove key from the switch. STARTING AND STOPPING 1. Synthesis seat, keep foot off traction pedal. Assure parking brake is engaged, traction pedal is in NEUTRAL, throttle is in SLOW position and the ENABLE / DISABLE switch is in the DISABLE position, A\ WARNING Engine will not crank over until Glow Plug Lamp goes out (Delay in Interlock).
OPERATING INSTRUCTIONS SAMPLES OF TRACTION SPEED RANGES FOR VARIOUS HEIGHTS OF CUT No. of Blades Height—of—Cut Minimum Traction Maximum Traction per C.U. Speed Speed 11 38in. 1.9 mph 6.0 mph mph 7.6 mph mph 4.5 mph mph 6.0mph * Procedure for maintaining proper clip rate: 1. Set HOC selector knob to correct letter setting (Per chart located under seat plate). 2.
OPERATING INSTRUCTIONS CLIP RATE (REEL SPEED) SELECTION CHART 11 Blade C.U. HOC Knob Position Height—of—Cut FULL SPEED .38in. (9.6 mm) 42 in. (10.7 mm) A6 in. (11.7 mm) B0 in. (12.7 mm) 54 in. {13.7 mm) .58 in. (14.7 mm) 621in. (15.7 mm) .66 in. (16.8 mm) 700N, (17.8 mm) 74 1n. (18.8 ram) 78 in. (19.8 mm) .82 in. (20.8 mm) .86 in. (21.8 mm) .90 in. (22.9 mm) 94 in. (23.9 mm) voZE2rXLa™Iraogmmuoowd> FULL SPEED ~ Cutting units will always run at full speed in this position.
OPERATING INSTRUCTIONS 2. Close by—pass valve before starting the engine. However, do not exceed 5-8 ft—ib (711 N m} torque to close the valve. IMPORTANT: Running the engine with the by -pass valve open will cause the transmission to overheat, Figure 22 1. By—Pass Valve DIAGNOSTIC LIGHT (Fig. 23) The RM 6500-D is equipped with a diagnostic light which indicates if the electronic controller is functioning correctly. The diagnostic fights located on the steering tower panel.
Figure 24 1. Wire Harness and Connectors 4. Turn the key switch to the ON position, but do not start machine. Note: The red text on the overlay decal refers to input switches and the green text refers to outputs. OPERATING IN ST RUCTIONS The Diagnostic ACE also has the ability to detect which output solenoids or relays are turned on. This is a quick way to determine if a machine malfunction is electrical or hydraulic. To verify output function: 1.
OPERATING INSTRUCTIONS IMPORTANT: The Diagnostic ACE display must not be left connected to the machine. Iris not designed to withstand the environment of the machine’s every day use. When done using Diagnostic ACE, disconnect it from the machine and reconnect loop back connector to harness connector, Machine will not operate without loop back connector installed on harness.
OPERATING INSTRUCTIONS c. False alarms are observed. Note: Refer to Troubleshooting Guide on page 25 for. additional information. 1. Park machine on a level surface and engage the parking brake. 2. Open control pane! cover Locate leak detector harness loop back connector with hydraulic | 4 symbol tag. Carefully unplug loop back l_[J connector from shames connector. 3. Connect the Diagnostic ACE display connector to the correct shames loop back connector.
OPERATING INSTRUCTIONS Note: If machine must be operable with leak detector disabled, unplug leak detector 4-pin connector from connector of main harness. Do not unplug leak detector alarm. 1. Oil level may be low causing air to be drawn out of system. Check oil level. 2. Extremely hard left turns can cause oil to slosh to the right, exposing suction line and purging air out of system. Normal maneuvering should not cause this condition. 3. Air leak in system, Check to make sure cap is securely on tank.
OPERATING INSTRUCTIONS TURF DEFENDER V1.0 PROGNOSTICATE wren Tr, pancreatic | O O Diagnostic ACE Display Functions washerwomen 3 O 1. Overlay decal (English shown) termagant “Inputs Displayed” LED (Red) “Outputs Displayed” LED (Green) Toggle button memo \ s Figure 28 ] D Using “Inputs Displayed” (Red Text LED It # oil level is too high LED lit if ol level Leitmotif oil level is too low LED lit if oil is too hot & 5. LED it if system air leak has been s —® detected vote @ 6.
TURF DEFENDER RAPID TROUBLESHOOTING GUIDE The following is a quick guide to the most common problems likely to be encountered.
OPERATING INSTRUCTIONS OPERATING CHARACTERISTICS Familiarization — Before mowing grass, practice operating mariachi In an open area. Start and stop the engine. Operate in forward and reverse. Lower and raise cutting units and engage and disengage reels. When you feel familiar with the machine, practice operating up and down slopes at different speeds. The brakes can be used to assist in muting the machine.
LUBRICATION A\ caution Before servicing or making adjustments to the machine, stop engine and remove key from the switch. GREASING BEARINGS AND BUSHINGS (Fig. 31-39) The machine has grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease. If machine is operated under normal conditions, Lubricate all bearings and bushings after every 50 hours of operation or immediately after every washing. 1.
Figure 37 LUBRICATION Figure 38 Figure 39 SERVICE INTERVAL CHART REEL MASTER 6500-D, 2WD QUICK REFERENCE AID CHECK/SERVICE {dairy) 1. OlL LEVEL, ENGINE 2. OIL LEVEL, HYDRAULIC TANK 3. COOLANT LEVEL, RADIATOR 4. FUEL /WATER SEPARATOR 5. AIR FILTER SERVICE INDICATOR CHECK/SERVICE (SEE OPERATOR'S MANUAL) 9. BATTERY 10. BELTS (FAN, ALT) 11. PLANETARY GEAR DRIVE 6. RADIATOR SCREEN = 7. BRAKE FUNCTION 8. TIRE PRESSURE (15-20 PSY) .
DAILY MAINTENANCE CHECKLIST Daily Maintenance: (duplicate this page for routine use) Check proper section of Operator's Manual for fluid specifications Maintenance ally Maintenance Check Item » MON [ TUES | weD [THURS | FRI SAT SUN = Safety Interlock Operation 1~ Brake Operation 1~ Engine Oil & Fuel Level 1+ Cooling System Fluid Level Drain Water/Fuel Separator Alr Filter Restriction Indicator Radiator & Screen for Debris Unusual Engine Noises! Unusual Operating Noises Hydraulic System Qil Level Hydraulic F
MAINTENANCE SCHEDULE Minimum Recommended Maintenance Intervals Maintenance Procedure Maintenance Interval & Service Every Every E: Lubricate All Grease Fittings Every Every 400hrs 800hrs rs Inspect Air Filter, Dust Cup, and Baffle 8ohrs 100m Check Battery Level/Cable Connections $ Change Engine Oil and Fitter Inspect Cooling System Hoses 1 Check Fan and Alternator Belt Tension 1 Torque Wheel Lug Nuts ) Service Air Filter Change Fuel Filter inspect Fuel Lines and Connections $ Check Engine RPM (idle and full
AIR CLEANER MAINTENANCE A\ caution Before servicing or making adjustments to the machine, stop engine and remove key from the switch. GENERAL AIR CLEANER MAINTENANCE 1. Check air cleaner body for damage which could possibly cause an air leak. Replace a damaged air cleaner body. 2. Service the air cleaner filters when ever air cleaner indicator (Fig. 40) shows red or every 400 hours {more frequently in extreme dusty or dirty conditions). Do not over service air filter, Figure 40 1. Air cleaner indicator 2.
AIR CLEANER MAINTENANCE Compressed Air Method A. Blow compressed air from inside to the outside of dry filter element. Do not exceed 100 psi to prevent damage to the element. B. Keep air hose nozzle at least 2" from filter and move nozzle up and down while rotating the filter element. Inspect for holes and tears by looking through the filter toward a bright light. 8. Inspect new filter for shipping damage. Check sealing end of filter. Do not install a damaged filter. 32 6.
ENGINE MAINTENANCE A\ caution Before servicing or making adjustments to the machine, stop engine and remove key from the switch. ENGINE OfL AND FILTER (Fig. 44-45) Change oil and filter initially after the first 50 hours of operation, thereafter change oil and filter every 100 hours. 1. Remove drain plug (Fig. 44) and let oif flow into drain pan. When oil stops, install drain plug and new plug seal, Part No. 74—7850. oo 5 1 Figure 44 1. Drain Plug 2. Remove oil filter (Fig. 45}.
ENGINE MAINTENANCE Failure 47 1. Fuel Filter / Water Separator 2. Drain Screw 3. Primer Plunger Changing Fuel Fitter Replace fuel filter if fuel flow becomes restricted, after every 400 hours of operation or annually, whichever comes first. 1. Loosen bolt and unscrew bottom filter cap from filter assembly. Remove cap, gaskets, o-ring and filter from assembly. Note position of gaskets and o-ring when disassembling from filter. 3. Install new filter, gaskets, o-ring with filter assembly cap 4.
ENGINE MAINTENANCE ENGINE FAN BELT (Fig. 50) 2. I deflection exceeds 1/4 in., loosen alternator mounting bolts. Adjust alternator belt tension by adjusting tension screw. Check deflection of belt again to assure tension is correct. Hack condition and tension of fan belt after every 100 hours of operation {Fig. 50}. Replace belt as required. 1. Proper tension will allow 1/4 in. deflection on the belt midway between the pulleys, when pressed firmly with thumb. s Figure 50 1. Fan Belt 2.
HYDRAULIC MAINTENANCE A&\ caution Be tore servicing or making adjustments to the machine, stop engine and remove key from the switch. CHANGING HYDRAULIC FLUID (Fig. 51) Change hydraulic fluid after every 800 operating hours, in normal conditions. If fluid becomes contaminated, contact your local TOR distributor because the system must be flushed. Contaminated fluid looks milky or black when compared to clean oil. 1. Turn engine off and raise hood. 2.
HYDRAULIC MAINTENANCE HYDRAULIC SYSTEM TEST PORTS (Fig. 53—55) The test ports are used 1o test pressure in the hydraulic circuits. Contact your local Toto distributor for assistance. 1. Test Port #1 (Fig. 53) is used to assist in trouble shooting the hydraulic circuit for the front cutting units and fight cylinders. Figure 53 1. Test Port #1 2. Test Port #2 (Fig. 54) is used to assist in trouble shooting the hydraulic circuit for the rear cutting units. Figure 54 1. Test Port #2 3.
HYDRAULIC MAINTENANCE ADJUSTING CUTTING UNIT LIFT RATE (Fig. 57) The cutting unit lift circuit is equipped with a adjustable valve to ensure the front cutting units raise and lower evenly. Adjust cutting units as follows: 1. Locate valve under seat. . Cutting unit adjustment valve 38 2. Loosen setscrew on valve. Rotate valve clockwise to slow down drop rate of front outside cutting units. 3. Verify lift rate adjustment by raising and lowering cutting units several times. Readjust as required. 4.
BRAKE MAINTENANCE ADJUSTING SERVICE BRAKES (Fig. 58) Adjust the service brakes when there is more than inch 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 locking pin from brake pedals so both pedals work independently of each other. 2. To reduce free travel of brake pedals, tighten the brakes — loosen front nut on threaded end of brake cable.
AXLE MAINTENANCE Figure 61 1. Drain Plugs (3) 3. Remove check plugs to ease draining of oil, 4. Remove drain plugs allowing oil to drain info pans. 5. After oil Is drained, apply thread sealing compound on drain plug threads and reinstall in axis. 6. Remove a check plug and fill ade with approximately 80 oz, of 85W~140 wt. gear lube or until lubricant is up to bottom of hole. 42 REAR WHEEL TOE~IN (Fig. 62) Alter every 800 aerating hours or annually, check rear wheel toe~in. 1.
ELECTRICAL MAINTENANCE BATTERY CARE IMPORTANT: Before welding on the machine, disconnect both cables from the battery, disconnect both wire harness plugs from the electronic control unit and the terminal connector from the alternator o prevent damage to the electrical system. A CAUTION Wear safety goggles and rubber gloves when working with electrolyte. Charge the battery in a well ventilated so gases produced while charging can dissipate.
CUTTING UNIT MAINTENANCE BACKSLAPPING A DANGER REELS MAY STALL WHILE BACKSLAPPING. DO NOT ATTEMPT TO RESTART REELS BY HAND OR TOUCH HEELS WHILE BACKSLAPPING. STOP ENGINE AND TURN H.0.C. KNOB ONE POSITION TOWARD "A”. Note: When backslapping, the front units all operate together, and the rear units operate together. 1. Position the machine on a level surface, lower the outing units, stop the engine, engage the parking brake, and move the Indispensable switch to disable position. 2.
PREPARATION FOR SEASONAL STORAGE Traction Unit 1. Thoroughly clean the traction unit, cutting units and the engine. 2. Check the tire pressure. Inflate all tires to 158~20 psi. 3. Check all fasteners for looseness; tighten as necessary, 4. Grease or oil all grease firings 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. Service the battery and cables as follows: a.
The Toto Promise A One Year Limited Warranty The Toto Company promises to repair your TOR product if defective in materials or workmanship. The following time periods from the date of purchase apply: Commercial Products The cost of parts, flavor and transportation are included. If you feel your TOR Product is defective and wish to rely on The Toto Promise, the following procedure is recommended: 1.