FORM NO. 3318-403 GB Rev A MODEL NO. 03802—50001 & UP MODEL NO.
Table of Contents IDENTIFICATION & ORDERING 2 SAFETY INSTRUCTIONS 4 SYMBOL GLOSSARY 7 SPECIFICATIONS 10 BEFORE OPERATING 11 Check the Engine Oil 11 Check the Cooling System 11 Fill the Fuel Tank 12 Check the Hydraulic Fluid 12 Check the Planetary Gear Drive Oil 14 Check the Rear Axle Lubricant (Model 03801)14 Check the Tire Pressure 14 Check Reel-To-Bedknife Contact 15 Check the Torque Of the Wheel Nuts 15 KNOW YOUR CONTROLS 16 OPERATING INSTRUCTIONS Starting And Stopping Priming Fuel System Autom
Safety Training • Store fuel in containers specifically designed for this purpose. 1. Read the instructions carefully. Be familiar with the controls and the proper use of the equipment. • Refuel outdoors only and do not smoke while refueling. 2. Never allow children or people unfamiliar with these instructions to use the lawn mower. Local regulations may restrict the age of the operator. • Add fuel before starting the engine.
• never mow across the face of the slope, unless the lawn mower is designed for this purpose. 6. 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 instruction handbook.
Sound & Vibration Levels Sound Levels This unit has an equivalent continuous A-weighted sound pressure at the operator ear of: 82.5 dB(A), based on measurements of identical machines per 84/538/EEC. Vibration Levels This unit has a vibration level of 2.5 m/s2 at the posterior, based on measurements of identical machines per ISO 2631 procedures. 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.
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 force applied from applied from above flesh 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. 42 hp (31 kW); governed to 2750 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. CHECK THE ENGINE OIL (Fig. 2 & 3) ➀ 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.
3. If coolant is low, remove the degasser tank cap and add a 50/50 mixture of water and Peugeot-recommended antifreeze (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 FILL THE FUEL TANK (Fig. 5) Fuel tank capacity is 56 liters. Figure 5 1. 1. Remove the fuel tank cap. 2. Fill the tank to about one inch below the top of the tank (not the filler neck) with No. 2 diesel fuel.
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. IMPORTANT: These hydraulic fluids are specified to allow optimal operation of the machine in a wide range of temperatures encountered.
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. 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. Add gear oil, if necessary, to bring fluid up to the correct level and install the plug. 4. Repeat steps 1–3 on the opposite gear assembly.
CHECK THE TORQUE OF WHEEL NUTS OR BOLTS CAUTION Torque the front wheel nuts to 61–74 kPa and the rear wheel nuts to 115–135 kPa after 1–4 hours of operation and again after 10 hours of operation and every 200 hours thereafter. Failure to maintain proper torque could result in failure or loss of the wheel and may result in personal injury.
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.
Water-in-the-fuel Light (Fig. 10)—Warns of water in the fuel system. ➁ 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 height-of-cut the machine is being operated so desired clip may be obtained. See section in manual for operating instructions. The knob is located under the control panel. Hour Meter (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.
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. Insert a 3/16" hose over the bleed screw and run the other end into a container to catch the fuel. 3.
The approximate ranges of traction speed which will result in the desired clip are as follows for several of the possible heights of cut: SAMPLES OF TRACTION SPEED RANGES FOR VARIOUS HEIGHTS OF CUT No. of Blades per C.U. Height of Cut Minimum Traction Speed Maximum Traction Speed 11 11 5 5 .97 cm 1.27 cm 1.60 cm 2.24 cm 3 kmh 4.2 kmh 2.4 kmh 3.4 kmh 9.6 kmh 12.2 kmh 7.2 kmh 5.5 kmh * Procedure for maintaining proper clip rate: 1.
grass removed and slightly less clip visibility, move the height-of-cut selector one position lower than specified. Full Speed—There may be times when it is desirable for the reels to run at full speed regardless of the machine’s traction speed. Examples of this are vertical cutting or heavy scalping. In such cases, the height-of-cut selector knob may be set to position "A" which will command the machine controller to run the reels at full speed at all times.
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.
DIAGNOSTIC LIGHT (Fig. 19) The RM 6700-D is equipped with two diagnostic lights which indicate whether or not the electronic controllers are functioning correctly. The diagnostic light for the main (#1 controller is located on the steering tower panel. When the #1 electronic controller is functioning correctly and the key switch is moved to the ON position, the (#1) 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.
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. If switch is closed and appropriate LED does not turn on, check all wiring and connections to switch and/or check switches with an ohm meter. Replace any defective switches and repair any defective wiring.
occur.
WARNING: When operating the machine, always use the seat belt and roll-over protection system together. Warning System—If a warning light comes on during operation, stop the machine immediately and correct the problem before continuing. Serious damage could occur if the machine is operated with a malfunction. Mowing —Start the engine and move throttle to FAST so the engine is running at maximum speed.
Maintenance 11. 12. 13. 14. 15. 16 17. 18. 19. Daily Maintenance Checklist 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Minimum Recommended Maintenance Intervals Maintenance Procedure Lube all grease fittings Inspect the air filter, dust cup and baffle Check battery level and con nections Maintenance Interval & Service Every 50 hours Every Every 100 200 hours hours Every 400 hours Every 800 hours ✓Change the engine oil filter Inspect cooling system hoses ✝Check the fan and alternator belt tension ✝Torque the wheel lug nuts ◆Service the air filter Change the fuel filter Inspect the fuel lines and connections ✓Check eng
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 30
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.
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. Inspect for holes and tears by looking through the filter toward a bright light. 5. Inspect the new filter for shipping damage. Check the sealing end of the filter. Do not install a damaged filter. 6.
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. Fuel Lines and Connections Check lines and connections every 400 hours or yearly, whichever comes first. Inspect for deterioration, damage, or loose connections. ➀ DANGER Because diesel fuel is flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank.
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. IMPORTANT: Never spray water onto a hot engine as damage to the engine may occur. ➀ A. Turn the engine off, release the hood latch and raise the hood. Clean the engine area thoroughly of all debris. Close the hood. B. Unlatch and remove rear screen (Fig. 39). Clean screen thoroughly. C. Unscrew knobs and pivot the oil cooler rearward.
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. If the fluid becomes contaminated, contact your local TORO distributor because the system must be flushed. Contaminated fluid looks milky or black when compared to clean the oil. 1. Turn the engine off and raise the hood. 2.
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. Start the engine and let it run for about two minutes to purge air from the system. Stop the engine and check for leaks. CHECKING HYDRAULIC LINES AND HOSES Inspect hydraulic lines and hoses daily for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration and chemical deterioration.
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. Loosen the setscrew on the valve. Rotate the valve clockwise to slow down drop rate of the front outside cutting units. 3. Verify lift rate adjustment by raising and lowering the cutting units several times. Readjust as required. 4.
4. Place the drain pan under the brake hub on other side of the wheel. 5. Remove the plug from the bottom of the hub and allow the oil to drain. 6. When all oil has drained, re-install the plug in the hub. 7. Add high-quality SAE 85W-140 wt. gear lubrication to bring the level up to the bottom of the hole and install the plug. 8. ➀ Repeat this procedure on the opposite gear assembly. Figure 47 1. Drain/Check plug REAR WHEEL TOE-IN (Fig.
Note: Backlapping speed may be increased by moving the height-of-cut selection knob toward to “A”. Each position will increase speed 60 rpm. After changing selector, wait 30 seconds for the system to respond to the new speed target. 4. Make initial reel-to-bedknife adjustments appropriate for backlapping on all cutting units that are to be backlapped. 5. Start the engine and run it at idle speed.
IMPORTANT: If the backlap switch is not returned to the OFF position after backlapping, the cutting units will not raise or function properly. Preparation for Seasonal Storage Traction Unit Engine 1. Thoroughly clean the traction unit, cutting units and the engine. 1. Drain the engine oil from the oil pan and replace the drain plug. 2. Check the tire pressure. Inflate all tires to 103–138 kPa. 2. Remove and discard the oil filter. Install a new oil filter. 3.
