Toro 03800TE Reelmaster 6500-D User manual

OPERATOR’S
MANUAL
FORM NO. 3318-286 GB Rev A
MODEL NO. 03800TE—60001 & UP
MODEL NO. 03801TE—60001 & UP
2- & 4-WHEEL DRIVE TRACTION UNITS
REELMASTER®6500-D
®
© The TORO Company 1995

2
Replacement 26
Operating Characteristics 27
MAINTENANCE 28
Greasing Bearings And Bushings 28
Service Interval Chart 29
Air Cleaner Maintenance 30
Engine Oil And Filter 31
Fuel System 32
Engine Cooling System 32
Engine Fan Belt 32
Changing Hydraulic Fluid 33
Replacing Hydraulic Filter 33
Checking Hydraulic Lines And Hoses 34
Adjusting Traction Drive For Neutral 34
Adjusting Cutting Unit Lift Rate 35
Adjusting Service Brakes 35
Changing Planetary Gear Drive Oil 35
Rear Wheel Toe-in 36
Fuses 37
Backlapping 37
PREPARATION FOR SEASONAL STORAGE 48
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 18
Starting And Stopping 18
Priming Fuel System 19
Automatic Clip Control 19
Selecting Clip Rate (Reel Speed) 20
Clip Rate Selection Chart 21
Reel Control Light 22
Pushing or Towing Machine 22
Diagnostic Light 23
Diagnostic ACE Display 23
Checking Interlock Switches 24
Hydraulic Solenoid Valve Functions 26
Height-of-Cut Selection Potentiometer
Table of Contents

3
Training
1. Read the instructions carefully. Be familiar with the
controls and the proper use of the equipment.
2. Never allow children or people unfamiliar with these
instructions to use the lawn mower. Local regula-
tions 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. Do not carry passengers.
6. All drivers should seek and obtain professional and
practical instruction. Such instruction should empha-
size:
• the need for care and concentration when work-
ing with ride-on machines;
• control of a ride-on machine sliding on a slope
will not be regained by the application of the
brake. The main reasons for loss of control are:
– insufficient wheel grip;
– being driven too fast;
– inadequate braking;
– the type of machine is unsuitable for its
task;
– lack of awareness of the effects of ground
conditions, especially slopes;
– ##incorrect hitching and load distribution.
Preparation
1. While mowing, always wear substantial footwear
and long trousers. Do not operate the equipment
when barefoot or wearing open sandals.
2. Thoroughly inspect the area where the equipment is
to be used and remove all objects which may be
thrown by the machine.
3. WARNING—Petrol is highly flammable.
• Store fuel in containers specifically designed
for this purpose.
• Refuel outdoors only and do not smoke while
refueling.
• Add fuel before starting the engine. Never
remove the cap of the fuel tank or add petrol
while the engine is running or when the engine
is hot.
• If petrol is spilled, do not attempt to start the
engine but move the machine away from the
are of spillage and avoid creating any source of
ignition until petrol vapors have dissipated.
• Replace all fuel tanks and container caps
securely.
4. Replace faulty silencers.
Operation
1. Do not operate the engine in a confined space where
dangerous carbon monoxide fumes can collect.
2. Mow only in daylight or in good artificial light.
3. Before attempting to start the engine, disengage all
blade attachment clutches and shift into neutral.
4. Do not use on slopes of more than:
• Never mow side hills over 5°
• Never mow uphill over 10°
• Never mow downhill over 15°
5. Remember there is no such thing as a “safe” slope.
Travel on grass slopes requires particular care. To
guard against overturning:
• do not stop or start suddenly when going up or
downhill;
Safety

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 hid-
den hazards;
• 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 equip-
ment.
• 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.
7. Watch out for traffic when crossing or near road-
ways.
8. Stop the blades rotating before crossing surfaces
other than grass.
9. When using any attachments, never direct discharge
of material toward bystanders nor allow anyone near
the machine while in operation .
10. Never operate the lawn mower with defective
guards, shields or without safety protective devices
in place.
11. Do not change the engine governor settings or over-
speed the engine. Operating the engine at excessive
speeds may increase the hazard of personal injury.
12. Before leaving the operator’s position:
• disengage the power take-off and lower the
attachments;
• change into neutral and set the parking brake;
• stop the engine and remove the key.
13. Disengage the drive to attachments when transport-
ing or not in use.
14. Stop the engine and disengage the drive to the
attachment
• before refueling;
• before removing the grass catcher;
• before making height adjustments unless the
adjustment can be made from the operator’s
position.
• before clearing blockages;
• before checking, cleaning or working on the
lawnmower;
• after striking a foreign object. Inspect the
lawnmower for damage and make repairs
before restarting and operating the equipment.
15. Reduce the throttle setting during engine runout and,
if the engine is provided with a shutoff valve, turn
the fuel off at the conclusion of mowing.
Maintenance and Storage
1. Keep all nuts, bolts and screws tight to be sure the
equipment is in safe working condition.
2. Never store the equipment with petrol in the tank
inside a building where fumes may reach an open
flame or spark.
3. Allow the engine to cool before storing in any enclo-
sure.
4. To reduce the fire hazard, keep the engine, silencer,
battery compartment and petrol storage area free of
grass, leaves, or excessive grease.
5. Check the grass catcher frequently for wear or dete-
rioration.
6. Replace worn or damaged parts for safety.
7. If the fuel tank has to be drained, this should be
done outdoors.
8. Be careful during adjustment of the machine to pre-
vent entrapment of the fingers between moving
blades and fixed parts of the machine.
9. On multi-bladed machines, take care as rotating one

5
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 posi-
tive 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 2.5 m/s2at the posteri-
or, based on measurements of identical machines per
ISO 2631 procedures.
This unit does not exceed a vibration level of 0.5 m/s2at
the posterior based on measurements of identical
machines per ISO 2631 procedures.

6
Symbol Glossary
Caustic liquids, 
chemical burns to 
fingers or hand
Poisonous 
fumes or toxic 
gases, asphyxiation
Electrical shock,
electrocution High pressure fluid, injection 
into body
High pressure
spray, erosion of
flesh
High pressure
spray, erosion of
flesh
Crushing of 
fingers or hand, 
force applied from 
above
Crushing of 
toes or foot, force
applied from above
Crushing of 
whole body, 
applied from 
above
Crushing of 
torso, force 
applied from side
Crushing of fingers 
or hand/, force 
applied from side
Crushing of 
whole body Crushing of  head, torso and 
arms
Cutting of 
fingers or hand Cutting of footCrushing of leg,  force applied 
from side
Cutting or 
entanglement of 
foot, rotating auger
Severing of 
foot, rotating 
knives
Severing of 
fingers or hand, 
impeller blade
Wait until all 
machine 
components have 
completely stopped 
before touching them
Severing of
fingers or hand, 
engine fan
Whole body entanglement, 
implement input drive line Fingers or  hand entangle-
ment, chain drive
Runover/back-
over, (relevant 
machine to appear 
in dashed box)
Machine tipping, 
riding mower Machine rollover, ROPS (relevant 
machine to appear 
in dashed box)
Stored energy
hazard, kickback
or upward motion
Hot surfaces, 
burns to fingers 
or hands
Hand & arm
entanglement,
belt drive
Thrown or fly-
ing objects, whole
body exposure
Thrown or 
flying objects, 
face exposure
Explosion Fire or open 
flame
Secure lifting 
cylinder with locking 
device before getting 
in hazardous area
Stay a safe 
distance from 
the machine
Stay clear of 
articulation area 
while engine is 
running
Do not open 
or remove safety 
shields while 
engine is 
running
Do not step on 
loading platform if 
PTO is connected to tractor 
& engine is running
Do not step
Shut off engine 
& remove key before 
performing mainten-
ance or repair work
Riding on this 
machine is allowed 
only on a passen-
ger seat & only if the 
driver’s view is not 
hindered
Consult 
technical manual 
for proper service 
procedures
Fasten seat belts Safety alert 
triangle outline safety alert symbol Read operator’s  manual

7
Fire, open light
& smoking
prohibited
Hydraulic
system Brake system Oil Coolant (water) Intake air Exhaust gas Pressure
Level
indicator Liquid level Filter Temperature Failure/ Malfunction Start switch/ mechanism On/start Off/stop
Plus/increase/
positive polarity
Engage Disengage Attachment
lower Attachment raise Spacing distance Snow thrower, collector auger Minus/decrease/
negative polarity
Horn Battery charging
condition
Hourmeter/elapsed
operating hours Fast Slow Continuous variable, linear Volume empty Volume full
Machine travel
direction,
forward/rearward
Control lever
operating
direction, dual
direction
Control lever
operating
direction, multiple
direction
Clockwise
rotation Counter-clock- wise rotation Grease lubrication
point
Oil lubrication
point Lift point
Jack or
support point Draining/ emptying Engine lubricat- ing oil Engine lubricating
oil pressure Engine lubricating oil level Engine lubricating oil filter Engine lubricating oil
temperature
Engine coolant
Flush with water Engine Transmission
Hearing
protection must
be worn
Caution, toxic
risk
Eye protection
must be worn Head protection must be worn First aid

8
Transmission
failure/malfunction Clutch Neutral High Low Forward Reverse Park
NHLFRP
First gear Second gear Third gear (other #'s
may be used until
the maximum # of for-
ward gears is reached.)
Hydraulic oil Hydraulic oil
temperature
231
Hydraulic oil
pressure Hydraulic oil level Hydraulic oil filter
Hydraulic oil
failure/malfunction Parking brake Fuel Fuel level Fuel filter Fuel system failure/malfunction
Diesel fuel Unleaded fuel
Headlights Lock Unlock Differential lock 4-Wheel drive Power Take-Off Power Take-Off,
rotational speed Reel cutting element
Reel cutting
element, height
adjustment
Traction Above working
temperature range
Drilling Manual metal arc
welding Manual 0356 Water pump 0626 Keep dry
0430 weight Do not dispose
in the garbage CE logo
Engine coolant
pressure Engine coolant f ilter Engine lubricating oil
pressure
Engine intake/
combustion air Engine intake/ combustion air
pressure
Engine intake/
air filter Engine start Engine stop
Engine failure/
malfunction Engine rotational speed/frequency Choke Primer (start aid) Electrical preheat (low temperature
start aid)
Transmission oil Transmission oil
pressure
n/min
Transmission oil
temperature

9
Brakes: Individual totally enclosed, multi-disc, wet brakes
and parking brakes on front traction wheels. Hydrostatic
braking through traction drive.
Electrical Features: 12-volt, 530 cold-cranking amperes
at 0° F (–18° C), 85-minute reserve capacity at 80° F (27°
C), maintenance-free battery. 55-amp alternator with l° C
regulator/rectifier. Automotive-type electrical system. Seat
switch, reel and traction interlock switches.
Controls: Foot-operated traction and brake pedals. Hand
operated throttle, speed control lever, parking brake lock,
ignition switch with automatic preheat cycle, single joy
stick control for cutting unit on/off and lift lower. Cutting
unit backlap switch under the operator's seat. Height-of-cut
selector knob located under the control panel.
Gauges: Hour meter, speedometer, fuel gauge, temperature
gauge, 4-bank warning lamp: oil pressure, water tempera-
ture, amps, and glow plug. 2-bank warning lamp: water in
fuel, water level.
Diagnostics; The Automatic Control Electronics, ACET
system allows precise timing and control of machine func-
tions for maximum reliability. Toro standard diagnostic
display connects to an electronic control unit to pinpoint
any electrical problems quickly and easily. Available
DATA LOGT system allows mechanic to find intermittent
problems.
General Specifications (approx.):
Width-of-Cut: 244 cm
Overall Width:
Transport 213 cm
Operational 279 cm
Overall Length: 305 cm
Height:
Without roll-over protection system installed: 152 cm
With roll-over protection system installed: 213 cm
Weight:
Model 03800 1,194 kg*
Model 03801 1,232 kg*
*With 5-Blade Cutting Units & full fluid levels
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. Air to
oil cooler mounted to the rear of the radiator tips outward
for cleaning. Removable oil cooler/radiator screen.
Fuel System: Rotary fuel injection pump with energized-
to-run (ETR) fuel flow solenoid. Replaceable spin-on
fuel filter/water separator with water sensor. Fuel capaci-
ty: 64 liter.
Traction System: Servo-controlled hydrostatic system
driving double-planetary, gear-reduction, front-wheel dri-
ves. Foot pedal control of forward/reverse ground speed.
Toro 4-MaticR 4-Wheel Drive System only: Rear drive
axle coupled to hydrostatic transmission via an overrun-
ning clutch for full-time, on-demand 4-wheel drive. A
Roll Over Protective Structure and seat belt are standard.
Ground Speed: 0–10 mph forward; 0–4 mph reverse.
Cutting Unit Drive System: Reel motors feature quick
disconnect for removal or installation onto the cutting
unit. Cutting units can be driven from either end.
Seat: Deluxe high-back suspension seat with adjustable
fore and aft travel, weight and height. Tool box at the left
side of the seat.
Steering System: Power steering with dedicated power
source.
Tires: Two rear steering tires: 20 x 10.00–10, tubeless, 6-
ply rating. Two front traction drive tires: 29 x 12.00–15
tubeless, 6-ply rating. Recommended tire pressure for
front and rear tires is 15–20 psi.
Specifications

10
Figure 2
1. Hood latch
Figure 3
1. Dipstick/tube cap
Figure 4
1. Degasser tank
CHECKTHE 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.
2. Remove the dipstick from the tube cap, wipe clean and rein-
stall the dipstick into the tube cap. Pull it out again and check
the oil level on the dipstick: The oil level must always be in the
notch area on the dipstick.
3. If the oil level is low, remove the tube cap and add SAE 15W-
40 CD oil until the level reaches top of notch on the dipstick.
DO NOT OVERFILL.
4. Install the oil tube cap.
5. Close the hood and secure the latch.
CHECKTHE COOLING SYSTEM (Fig. 4)
Capacity of the system is 13 l.
Check the cooling system if the low water level light illuminates.
1. Park the machine on a level surface. Release the hood latch
and open the hood.
Before servicing or making adjustments to the machine,
stop the engine and remove the key from the switch.
CAUTION
Before Operating
If the engine has been running, pressurized hot coolant
can escape and cause burns if the degasser cap is
removed. Allow the engine to cool at least 15 minutes or
until the degasser cap is cool enough to touch without
burning your hand.
CAUTION
➀
➀
➀

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 ALCO-
HOL/METHANOL BASE COOLANTS.
4. Install the degasser tank cap.
5. Close the hood and secure the latch.
FILLTHE FUELTANK (Fig. 5)
Fuel tank capacity is 56 liters.
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. Then install the cap.
CHECK HYDRAULIC FLUID (Fig. 6)
The hydraulic system is designed to operate on anti-wear hydraulic
fluid. The machine’s reservoir is filled at the factory with approxi-
mately 32 liters of Mobil 424 hydraulic fluid. Check the level of
hydraulic fluid before the engine is first started and daily thereafter.
Group 1 Hydraulic Fluid (Recommended for ambient temperatures
consistently below 38° C.):
ISO type 46/68 anti-wear hydraulic fluid
Mobil Mobil Fluid 424
Amoco Amoco 1000
11
Figure 5
1. Fuel tank cap
Figure 6
1. Hydraulic tank cap
Because diesel fuel is flammable, use caution when stor-
ing or handling it. Do not smoke while filling the fuel
tank. Do not fill the fuel tank while the engine is run-
ning, 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.
DANGER
➀
➀

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.
IMPORTANT: These hydraulic fluids are specified to allow
optimal operation of the machine in a wide range of tempera-
tures encountered. The group 1 fluids are a multi-viscosity
hydraulic fluids which allows operation at lower temperatures
without the increased viscosity, which is associated with straight
viscosity fluids.
Note: When changing from one type of hydraulic fluid to the other,
be certain to remove all the old fluid from the system, because
some brands of one type are not completely compatible with
some brands of the other type of hydraulic fluid.
IMPORTANT: Use only types of hydraulic fluids specified.
Other fluids could cause system damage.
Note: A red dye additive for the hydraulic system fluid is available
in 20 ml bottles. One bottle is sufficient for 15–23 l. of
hydraulic fluid. Order Part No. 44-2500 from your Authorized
Toro Distributor
1. Position the machine on a level surface, lower the cutting units
and stop the engine.
2. Clean the area around the filler neck and the cap of the
hydraulic tank. Remove the cap from the filler neck.
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.
12

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.
CHECKTHE 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 REAR AXLE LUBRICANT
(Model 03801 Only) (Fig. 8)
The rear axle is shipped from the factory filled with SAE 85W-140
wt. gear lubrication. Check the level before the engine is first start-
ed and every 400 hours thereafter. Capacity is 2.3 l. Visually inspect
for leaks daily.
1. Position the machine on a level surface.
2. Remove a check plug from one end of the axle and make sure
lubricant is up to bottom of hole. If the level is low, remove the
fill plug and add enough lubricant to bring the level up to the
bottom of the check plug holes.
CHECKTIRE 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.
13
Figure 7
1. Check/Drain plug
Figure 8
1. check plug
2. Fill plug
➀
➀➁

CHECK REEL-TO-BEDKNIFE CONTACT
Each day before operating, check reel-to-bedknife contact, regard-
less 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).
CHECKTHETORQUE OFWHEEL NUTS
OR BOLTS
14
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.
CAUTION

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.
To stop, reduce foot pressure on traction pedal and allow it to return
to center position.
Traction Speed Limiter (Fig. 9)—Preset this lever to limit the
amount the traction pedal can be depressed in the forward direction
to maintain a constant mowing speed.
Reel Control Light (Fig. 9)—When lit, indicates the machine is
being operated in a way in which the automatic reel speed control
cannot obtain the desired clip.
Speedometer (Fig. 9)—Indicates ground speed at which the
machine is traveling.
Lower Mow/Raise Control Lever (Fig. 10)—The lever raises and
lowers the cutting units and also starts and stops the reels.
Fuel Gauge (Fig. 10)—Indicates the level of fuel in the tank.
Engine Oil Pressure Warning Light (Fig. 10)—Indicates danger-
ously low engine oil pressure.
Key Switch (Fig. 10)—Three positions: OFF, ON / Preheat and
START.
Throttle Control (Fig. 10)—Move the control forward to increase
engine speed, rearward to decrease speed.
Engine Coolant Temperature Warning Light (Fig.10 )—The light
illuminates and the engine shuts down when coolant reaches a dan-
gerously high temperature.
Glow Plug Indicator Light (Fig. 10)—When lit, indicates the glow
plugs are on.
Charge Indicator (Fig. 10)—Illuminates when the system charging
circuit malfunctions.
15
Figure 9
1. Traction pedal
2. Traction speed limiter
3. Reel control light
4. Speedometer
Figure 10
1. Lower mow/raise control lever
2. Fuel gauge
3. Engine coolant temperature gauge
4. Engine oil pressure warning light
5. Engine coolant temperature warning light
6. Glow plug indicator light
7. Charge indicator
8. Key switch
9. Throttle control
10. Enable/disable switch
11. Water-in-fuel light
12. Low-water level light
Controls
The engine will not crank over until the glow plug lamp
goes out. Glow plugs must complete their cycle before
the controller will allow the engine to crank.
WARNING
➂
➃➂
➀
9
12 11 453
8
6
7
10
2
1

16
Figure 11
1. HOC selector knob
2. Hour meter
Figure 12
1. Backlap switch
Figure 13
1. Brake pedals
2. Parking brake latch
3. Locking pin
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 sys-
tem.
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. 11)—Shows total hours the machine has been
operated.
Backlap Switch (Fig. 12)—Used with the lower mow / raise con-
trol lever for backlapping operation. This switch is located under
seat plate. Refer to Cutting Unit Maintenance, Backlapping.
Brake Pedals (Fig. 13)—Two foot pedals operate individual wheel
brakes for turning assistance, parking and to aid better sidehill trac-
tion. A locking pin connects the pedals for parking brake operation
and transport.
Parking Brake Latch (Fig. 13)—A knob on the left side of the
console actuates the parking brake lock. To engage the parking
brake, connect the pedals with the locking pin, push down on both
pedals and pull the parking brake latch out. To release the parking
brake, depress both pedals until the parking brake latch retracts.
Seat (Fig. 14)—Seat adjusting lever allows 10 cm fore and aft
adjustment. Seat adjusting knob adjusts seat for operator’s weight.
To adjust the seat fore and aft, pull the lever on the left side of the
seat assembly outward. After moving the seat, release the lever to
lock the seat into position. To adjust for operator’s weight, turn the
spring tension knob: clockwise to increase tension, counterclock-
wise to decrease spring tension
➁
➀
➀
➁➀
➂

17
Figure 14
1. Seat adjusting lever
2. Seat adjusting knob
Operating Instructions
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 NEU-
TRAL, the throttle is in the SLOW position and the ENABLE/
DISABLE switch is in the DISABLE position.
2. Turn the ignition switch to ON/Preheat position. An automatic
timer will control preheat for approximately 6 seconds. The
engine will not crank until preheat light goes off. After preheat,
turn the key to START position. CRANK THE ENGINE FOR
NO LONGER THAN 15 SECONDS. Release the key when
the engine starts. If additional preheat is required, turn the key
to the OFF position, then to ON/preheat position. Repeat this
process as required.
Before servicing or making adjustments to the machine,
stop the engine and remove the key from the switch.
CAUTION
The engine will not crank over until the glow plug lamp
goes out. Glow plugs must complete their cycle before
the controller will allow the engine to crank.
WARNING
①
①

18
Figure 15
1. Primer plunger
2. Bleed screw
Figure 16
1. Injection pump fitting
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.
PRIMINGTHE 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. Loosen the fuel filter/water separator bleed screw (Fig. ) a few
turns. Pump the priming plunger until a steady stream of fuel
comes out of the hole in the bleed screw. When the fuel stops
foaming, tighten the bleed screw during the downstroke of the
priming plunger. Wipe up any spilled fuel.
4. Pump the priming plunger until you feel resistance. Try to start
the engine. If the engine does not start, repeat step 3.
Note: It may be necessary to bleed the air out of the fuel line
between the fuel filter/water separator and the injection pump. To
do this, loosen the fitting on the injection pump (Fig. 16) and repeat
the bleeding procedure.
AUTOMATIC CLIP CONTROL
The RM 6500-D is equipped with an electronic controller which is
programmed to achieve automatic clip control. The machine will
automatically adjust the reel speed to attain the desired clip as the
traction speed changes. For the controller to know what clip is
desired, the software must have been properly set, by your distribu-
tor or dealer, to either 5 or 11 blade and the height-of-cut selector
knob must be properly set.
The range of possible reel speeds is a minimum of about 500 RPM
and a maximum of about 1400 RPM. As long as the desired clip
requires a reel speed within this range, the 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)
➀
➁
➀

will illuminate, warning that the desired clip is not being main-
tained. 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 illumi-
nate. The approximate ranges of traction speed which will result in
the desired clip are as follows for several of the possible heights of
cut:
SELECTING CLIP RATE (REEL SPEED)
To achieve a consistent, high quality of cut, and a uniform after-cut
appearance, the reel speed be matched to the height of cut. The
machine controller is programmed to automatically control the reel
speed to give the correct clip, even as traction speed changes. To
control the reel speed, the controller must know the height of cut of
the machine, and whether the machine is equipped with 5- or 11-
blade reels.
Adjust the height-of-cut selector knob as follows:
1. Insure the configuration screen, set by the distributor, is on the
correct setting. (5 or 11 blade.)
2. Verify the height-of-cut setting on the cutting units. Using the
column of the chart above or the chart under the seat plate, list-
ing 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 deter-
mined in step 2.
4. Operate the machine for several days, then examine the cut to
19
Figure 17
1. Height-of-cut selector knob
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
SAMPLES OF TRACTION SPEED RANGES FOR VARIOUS HEIGHTS OF CUT
* Procedure for maintaining proper clip rate:
1. Set HOC selector knob to correct letter setting (Per chart located under seat plate).
2. Maintain ground speed which prevents reel control light from illuminating
➀

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 visi-
bility, move the height-of-cut selector knob one position higher
than specified. For a cut with less 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.
20
CLIP RATE (REEL SPEED) SELECTION CHART
11-Blade Cutting Unit 8-Blade Cutting Unit
Height-of-Cut Knob
Selection
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Height of Cut
FULL SPEED
9.6 mm
10.7 mm
11.7 mm
12.7 mm
13.7 mm
14.7 mm
15.7 mm
16.8 mm
17.8 mm
18.8 mm
19.8 mm
20.8 mm
21.8 mm
22.9 mm
23.9 mm
Height-of-Cut Knob
Selection
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Height of Cut
FULL SPEED
16.0 mm
17.3 mm
18.5 mm
19.6 mm
20.8 mm
21.8 mm
22.9 mm
23.9 mm
24.9 mm
25.9 mm
26.9 mm
27.9 mm
29.0 mm
30.1 mm
31.0 mm
FULL SPEED—Cutting units will always run at full speed in this position