Toro 652D, Reelmaster 4240-D Operator's Manual

Part No. 111-0473 Rev B

Reelmaster 4240-D

Code: 652D-Serial No. from 260000001

Operator’s Manual

Original Instructions (EN)

ATTENTION

THIS SYMBOL MEANS

BE ALERT!

YOUR SAFETY IS INVOLVED

READ THIS MANUAL BEFORE USING THE REELMASTER® 4240-D.

IT IS ESSENTIAL THAT OPERATORS STUDY IT FOR THEIR OWN SAFETY.

ALL OPERATORS SHOULD SEEK AND OBTAIN PROFESSIONAL AND

PRACTICAL INSTRUCTIONS ON THE SAFE USE OF THE MOWER. THESE

SERVICES ARE AVAILABLE THROUGH TORO APPROVED COMMERCIAL DEALERS.

CONTENTS

1.4

CONTENTS

SAFETY PRECAUTIONS.

Training.

Preparation.

Operation.

Handling and storage of fluids.

Maintenance and storage.

Decals.

EC CONFORMITY INFORMATION.

Noise levels.

EC Declaration of Conformity.

INTRODUCTION.

SPECIFICATIONS.

Engine.

Transmission system.

Cutterhead drive system.

Cutterhead lift system and steering.

Hydraulic system.

Vehicle specifications.

Operator controls.

Instrumentation.

Weight and dimensions.

Recommended lubricants and hydraulic fluids.

Cutterheads.

OPERATING THE MOWER.

Safety notice.

Operator presence controls.

Identification of controls.

Braking system.

Throttle control.

Travel.

Work/Transport modes.

Transport latches.

Differential lock.

Travel control pedals.

Forward travel speed backstop lever.

Operator platform latching mechanism.

Adjustable steering column.

Operator seat.

Warning systems.

Audible warning horn.

Ignition key.

Engine pre-heat indicator light.

Page No.

1.6 - 1.14

1.6

1.6 - 1.7

1.7 - 1.9

1.10

1.11

1.12 - 1.14

1.15 - 1.16

1.15

1.16

1.17

1.18 - 1.24

1.18

1.19

1.20

1.21

1.22

1.23

1.24

1.25 - 1.44

1.25

1.26

1.27

1.28

1.29

1.30

1.31

1.32

1.33

1.34

CONTENTS

1.5

CONTENTS Continued.

Fuel level gauge.

Hourmeter.

Transmission neutral indicator light.

Cutterhead drive switch indicator light.

Parking brake indicator light.

Hydraulic return filter indicator light.

Hydraulic transmission filter indicator light.

Transmission system ‘Work’ mode indicator light.

Cutterhead position control.

Dual lift configuration control.

Cutterhead drive engagement.

Weight transfer/traction assistance.

Starting the engine.

Stopping the engine.

General operating hints.

Unblocking cutting cylinders.

Cutterhead general information.

MK3 200mm Fixed Cutterhead.

MK3 254mm Fixed Cutterhead.

MK3 200mm Floating Cutterhead.

MAINTENANCE.

General safety and good practice.

Engine.

Running in period.

Running in period - at first 50 hours.

Daily and before use.

Every 50 hours.

Every 250 hours.

Every 500 hours.

Cutterhead cylinder to bottom blade adjustment.

Cutterhead backlapping.

Cutterhead grinding.

Cutterhead bottom blade replacement.

Raising the mower off the ground.

Towing the mower.

GRASS CUTTING FAULTS.

TROUBLE SHOOTING.

ELECTRICAL CIRCUIT DIAGRAM.

TRANSMISSION/BRAKE HYDRAULIC CIRCUIT.

HYDRAULIC CIRCUIT DIAGRAM.

WARRANTY.

NOTES.

CUSTOMER INFORMATION.

Page No.

1.34

1.35

1.36

1.37

1.38

1.38 - 1.39

1.39

1.40

1.41

1.42

1.43

1.44

1.45 - 1.64

1.45 - 1.46

1.47

1.47 - 1.48

1.49 - 1.52

1.53 - 1.54

1.55

1.56 - 1.58

1.59

1.60

1.61

1.62

1.63 - 1.64

1.65 - 1.67

1.68 - 1.74

1.75 - 1.78

1.79 - 1.80

1.81 - 1.82

1.83 - 1.84

1.85

1.86

SAFETY PRECAUTIONS

1.6

TRAINING

Read the instructions carefully. Be familiar with the controls and the proper use of the equipment. Learn how to stop the mower quickly in an emergency.

Never allow children or people unfamiliar with these instructions to use the mower. Local regulations may restrict the age of the operator.

Never mow while people, especially children, or pets are nearby.

Keep in mind that the operator or user is responsible for accidents or hazards occurring to other people or their property.

Do not carry passengers.

All drivers should seek and obtain professional and practical instruction. Such instruction should emphasise:

The need for care and concentration when working with this machine.

The need to slow down when making tight turning manoeuvres. Failure to take adequate care can affect stability leading to loss of control of the machine particularly when operating in transport mode.

Control of a ride-on-machine sliding on a slope will not be regained by 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 the task.

- Lack of awareness of the effect of ground conditions, especially slopes.

- Incorrect load distribution.

PREPARATION

Check that the machine complies with all applicable regulations, including those in force when used on the public highway.

While mowing, always wear substantial footwear and long trousers. Do not operate the equipment when barefoot or wearing open sandals. Eye protection should be worn.

Thoroughly inspect the area where the equipment is to be used and remove all objects which can be thrown by the machine.

Never operate the machine without first checking that the operator platform latching mechanism is fully engaged and in good working order, refer - ‘OPERATOR PLATFORM LATCHING MECHANISM’.

READ THIS MANUAL BEFORE USING THE REELMASTER® 4240-D, IT IS ESSENTIAL THAT OPERATORS STUDY IT FOR THEIR OWN SAFETY.

THE FOLLOWING PRECAUTIONS MUST BE TAKEN TO HELP PREVENT ACCIDENTS. A CAREFUL OPERATOR WHO USES COMMON SENSE IS THE SAFEST OPERATOR.

1.7

SAFETY PRECAUTIONS

PREPARATION Continued.

Ensure that the cutterheads are fully raised with the latches and safety locks engaged in position before transporting the mower.

Replace faulty silencers.

Check the condition of the tyres and ensure that they are inflated to the correct pressures, refer - SPECIFICATIONS. This is particularly important if the machine is to be taken on the public highway.

Check that the mower is in good working order, paying particular attention to the brakes and steering. Also ensure that the forward/reverse speed control pedals move freely to neutral when released.

Before use, always visually inspect to see that the blades, blade bolts and cutting cylinders are not worn or damaged. Replace worn or damaged components.

Check the mower hydraulic system, particularly the hydraulic hoses, fittings and hose supports. Worn, crushed or damaged hoses can burst, with risks to health and damage to the machine and surrounding turf areas.

After refuelling and adding oil to the hydraulic oil tank ensure that the caps are replaced securely.

Check that all linkages, connections and pivot nuts are secure and that wheel nuts are torqued correctly, refer - SPECIFICATIONS.

Before operating the machine, ensure that there are no foreign objects or liquids on the platform or pedals - ALWAYS KEEP THE OPERATOR PLATFORM CLEAR/CLEAN.

OPERATION

Do not operate the engine in a confined space where dangerous carbon monoxide fumes can collect.

Mow only in daylight or in good artificial light.

Before attempting to start the engine, engage the parking brake, disengage the cutterhead drive system and ensure that the forward/reverse speed controls are in the neutral position.

Never operate the machine without first checking that the operator platform latching mechanism is fully engaged and in good working order, refer - OPERATOR PLATFORM LATCHING MECHANISM.

Stored energy devices are charged when the outer wing units are in the transport position. Always operate the relevant lift controls to provide hydraulic support for the wing units suspensions before attempting to release the transport latches.

1.8

SAFETY PRECAUTIONS

OPERATION Continued.

Do not use on a slope of more than 19 degrees. Care should be taken when using the mower on any slope where ground conditions are such that there may be a risk of the mower rolling over. The requirements of SI 1998 No. 2306 “Provision and Use of Work Equipment Regulations” should be considered. R.O.P.S (Roll Over Protective Structures) are available, refer to INTRODUCTION - Optional Extras.

Stability angles given are maximum figures and are for guidance only. Particular conditions such as wet grass or uneven ground may not permit safe operation on the slope limits stated.

Remember there is no such thing as a "safe" slope. Travel on grass slopes requires particular care. To guard against overturning or loss of traction when travelling or mowing on a slope:

- Exercise extreme care when changing direction on a slope.

- Do not stop or start suddenly.

- Engage drive slowly.

- Keep machine speed low.

- Avoid tight turns.

- Stay alert for humps, hollows and other hidden hazards.

- Keep away from sharp inclines and steep drops.

- A thorough risk assessment should be carried out by a competent person before travelling or mowing on a slope.

Never park on a slope.

3DA176

19 Degree slope

Ground level

SAFETY PRECAUTIONS

1.9

OPERATION Continued.

Watch out for traffic when crossing or near roadways.

Use extreme caution when reversing.

Disengage the cutterhead drive system before crossing surfaces other than grass.

When using the machine, never direct the discharge of material towards bystanders or allow anyone near the machine while in operation.

Never operate the mower with damaged guards, shields or without safety protective devices in place and in good working order.

Do not change the engine governor settings or overspeed the engine. Operating an engine at excessive speed may increase the risk of personal injury.

Before leaving the operator's position:

- Disengage the drive to the cutterheads.

- Lift cutterheads to the transport position and securely lock the safety latches or alternatively lower cutterheads to the ground.

- Change into neutral and set the parking brake.

- Stop the engine and remove the ignition key.

Engage the parking brake, disengage the drive to the cutterheads, stop the engine and remove ignition key :

- Before releasing blockages.

- Before checking, cleaning or working on the mower.

- After striking a foreign object. Inspect the mower for damage and make repairs before restarting and operating the equipment.

- If the machine starts to vibrate abnormally ( check immediately ).

- Before refuelling.

- Before making cutterhead adjustments.

Disengage the drive to the cutterheads when transporting or not in use.

Reduce the throttle setting during engine run - out.

Never work on the mower when the engine is running.

Always keep feet and hands well away from the cutting cylinders when making adjustments.

Never operate the mower without first checking that the operator platform is securely latched.

SAFETY PRECAUTIONS

1.10

HANDLING AND STORAGE OF FLUIDS

Hydraulic Oil

- Avoid contact with eyes and prolonged contact with skin.

- Protective goggles should be worn when pouring.

- Use of gloves or barrier cream is recommended.

- Wash hands thoroughly after contact.

- Store under cover, away from heat and sources of ignition.

Diesel Oil

- Avoid skin and eye contact.

- Wear impervious gloves when regular contact is likely and goggles when there is risk of splashing.

- Wash hands thoroughly after contact.

- Store in a cool dry well ventilated place away from heat and sources of ignition, in vessels specifically designed for storing fuel oils.

Lubricating Oil

- Avoid skin and eye contact.

- Wear impervious gloves when regular contact is likely and goggles when there is risk of splashing.

- Wash hands thoroughly after contact.

- Store in a cool dry well ventilated place away from heat and sources of ignition.

Anti- Freeze

- Keep away from heat, sparks, and flames.

- Avoid skin and eye contact and breathing vapours.

- Store in a closed container in a cool dry well ventilated area.

SAFETY PRECAUTIONS

1.11

MAINTENANCE AND STORAGE

Take care when rotating a cutting cylinder as this can cause other cylinders to rotate.

When the machine is to be parked, stored or left unattended, lift the cutterheads to the transport position and engage the safety locks or lower the cutterheads to the ground.

Keep all nuts, bolts, and screws tight to be sure the equipment is in safe working condition.

Allow the engine to cool before storing in any enclosure.

To reduce the risk of fire, keep the engine, silencer, fuel tank and battery compartment free of grass, leaves or excessive grease.

Frequently check fuel lines and fittings for cracks or leaks and replace if necessary.

Replace worn or damaged parts for safety.

Ensure that all safety decals are properly secured and in good condition.

If the fuel tank has to be drained, this should be done outdoors.

Be careful during adjustment of the machine to prevent entrapment of the fingers between moving blades and fixed parts of the machine.

Never attempt to disconnect any part of the hydraulic system before de-pressurisation. This may be achieved by lowering all cutterheads to the ground, stopping the engine and removing the ignition key.

Avoid skin or eye contact with hydraulic or diesel fluids. Wear protective clothing.

Leaking fluids under pressure can penetrate the skin or eyes, causing serious injury. Always use a piece of cardboard or paper when searching for leaks.

Health and Safety at Work Act:

In accordance with section 6 of the Health and Safety at Work Act 1974, the Reelmaster® 4240-D has been designed and constructed so that, in so far as is reasonably practical, it will not endanger the safety and health of those working with it. This is, however, subject to the machine being properly used and maintained according to the conditions stated in this manual and elsewhere, which have been found necessary as a result of the research and testing of The Toro Company.

994912 (REV. 1)

III

SAFETY PRECAUTIONS

1.12

DECALS

Decal - Control Panel Part No: 994912

Location: Control Panel. a) Ignition Switch h) Cutters - Off b) Engine Speed - Slow i) Cutters - Forward c) Engine Speed - Fast j) Horn d) Parking Brake - Engage k) Cutters - Lift e) Parking Brake - Disengage l) Cutters - Hold f) Weight Transfer - Control m) Cutters - Drop/Float g) Cutters - Reverse n) Hour Meter

Decal - Inclines Part No: 924857 (1)

Location: Centre Platform. a) Warning - Travel slowly when turning and on slopes b) Warning - Maximum slope without ROPS c) Warning - Seat belt must be worn with a ROPS fitted. d) Caution e) Read operators manual f) Stop engine/Remove ignition key before servicing or

maintenance g) Beware of flying objects h) Keep bystanders clear

Decal - Danger Latch Part No: 70-13-077 Location: LH / RH / Centre Arms a) Caution b) Stop engine/Remove ignition key before releasing or

operating safety latches

Decal - Diesel Part No: 70-13-078 Location: Fuel Tank Diesel fuel only

Decal - Transmission Oil Part No: 70-13-071 Location: Oil Filler Bracket mounted behind Fuel Tank. a) Transmission oil b) Read and understand the operators manual.

IMPOR TANT / WICHTIG / BELANGRIJK

BEFORE USE : FILL MACHINE WITH RECOM- MENDED OIL TOCORRECTLEVEL. F AILURE TO DOSOWILL CAUSE SERIOUS DAMAGEANDIN- VALIDATE WARRANTY.

AVANT L'UTILISA TION : IL EST IMPERATIF DE REMPLIR LA TONDEUSE AVEC UNE HUILE SPECIFIEE AUNIVEAU EXACT POUR NE PAS L'ENDOMMAGER SERIEUSEMENT ET ANNULER LAGARANTIE.

VOR DEM GEBRAUCH: F ÜLLEN SIE DIE MASCHINE MIT EMPFOHLENEM ÖL NACH,BIS AUF DEN RICHTIGEN ST AND. DIE NICHTBEACHTUNG DIESER INSTRUKTIONEN KANN ZU ERNSTHAFTEN SCHADEN F ÜHREN UNDDABEI WIRD DIE GARANTIEUNGÜLTIG.

VOOR GEBRUIK: VUL MACHINE MET VORRGESCHREVEN OLIE TOT HET JUISTE NIVEAU. HET NIET VOLGEN VANDEZE INSTRUKTIE LEIDT TOT ERNSTIGE SCHADE EN VER VAL VANDE GARANTIE.

0 - 19°19°+

924857 (1)

SAFETY PRECAUTIONS

1.13

DECALS Continued.

Decal - Jacking / Support Point

Part No: 70-13-072 Location: Front Axle - 2 Points

Rear Towing Eye

Jacking and support point

Decal - Engine Fan / Radiator

Part No: 70-13-073 Location: Engine Fan Cowl a) Danger of severing fingers b) Caution c) Warning - Hot surfaces

Decal - Tyre Pressure

Part No. 950832 Location: LH/RH Chassis - 4 Places a) Mowing b) Road travel

Decal - Diff Lock / Control Pedal

Part No: 953876 Location: Centre Platform a) Differential lock b) Depress to engage diff-lock c) Release to dis-engage diff-lock d) Reverse speed - directional control e) Forward speed - directional control

Decal - Noise

Part No. 922854 Location: Base of Seat on GRP

HEIZKORPERDECKELENTFERNEN ERST WENNDERMOTORKUHL IST.

ONLY REMOVE RADIATOR CAP WHEN ENGINE IS COOL.

VERWIJDERDE RADIATORDOPPASNADAT DE MOTORIS AFGEKOELD.

IL FAUTTOUJOURSATTENDRE LE REFROIDISSEMENTDU MOTEUR AVANTDE RETIRER LE BOUCHONDURADIATEUR.

70-13-073 REV (.0.)

953876 REV.(0)

{

0.7 BAR

950832 Rev.2

10 PSI

1.4 BAR 20 PSI

SAFETY PRECAUTIONS

1.14

DECALS Continued.

Decal - Serial Number

Location: Rear Bulkhead

Decal - Prevent Platform Damage

Part No. 924828 Location : Platform, Seatwell

Decal - Warning Platform Latch

Part No. 924868 Location: Next to Platform Latch Warning - Prevent Accidents: Ensure platform is correctly seated and the latch is fully locked before operating the machine.

Decal - Maintenance RM4240-D

Part No. 953812 Location: Underside of Engine Cover next to Latch.

Decal - Warning Crush Hazard

Part No. 953829 Location: Platform LH/RH Sides a) Warning of Cutterheads being Lowered b) Do Not Stand in the Area Indicated

When the Cutterheads are being Lowered or Raised

Decal - Pedal Backstop

Part No. 953877 Location: Platform RH Side

RPM

:2800 kW:35.3

2005

- PARKBREMSE

ZET

924828 REV.0.

924868 REV .0

RM4240-D REELMASTER

kg:1750

Code Serial No:

652D

260000001

105

PREVENT PLATFORM DAMAGE !

ENGAGE PARKING BRAKE AND DROP CUTTERHEADS BEFORE RAISING/LOWERING PLATFORM.

POUR EVITER DES DOMMAGES

METTRE LE FREIN DE PARKING ET POSER LES TETES DE COUPES AVANT DE BOUGER LA PLATE-FORME.

SCHADEN VERMEIDEN

FESTSETZEN UND DIE SCHNEIDEINHEITEN HERUNTERLASSEN BEVOR DIE SITZPLATTFORM GEKIPPT WIRD.

VOORKOM BESCHADIGING!

MACHINE OP HANDREM EN LAAT DE KOOIEN ZAKKEN, VOORDAT HET BEDIENINGS PLATFORM NAAR VOREN GEKANTELD OF TERUG GEPLAATST WORDT.

DAILY MAINTENANCE DAILY MAINTENANCE

FUEL LEVEL

ENGINE OIL

FUEL

TYRES

FASTENERS

AIR CLEANER

DAILY 50 HOURS (WEEKLY)DAILY (IF FITTED)

50 HOURS MAINTENANCE

CLEAN AND INSPECT THE MACHINE.

WHEEL NUT TORQUE

FRONT: 200Nm REAR: 54Nm

GREASE POINTS

SEAT SWITCH

HOSE LINES HYDRAULIC OIL

RADIATOR/SCREENS COOLANT LEVELCUTTERHEADS

953829(Rev.1.)

30 - 40mm

953812(Rev 1)

EC CONFORMITY INFORMATION

1.15

NOISE LEVELS

Operators Daily Personal Noise Exposure: The Toro Company has no

control over site conditions, duration of use, state of maintenance or

adjustment of the mower. All of these factors will affect the operator's daily

personal noise exposure level - L

EP,d

Under typical working conditions operators could be exposed to a daily per-

sonal noise exposure level in excess of 85 dB (A) L

EP,d

Sound pressure level:

The maximum sound pressure level at the operator's position is 85 dB (A)

measured in accordance with European Standard EN836.

Sound power level:

The maximum sound power level is 105 dB(A) measured in accordance with

EC Directive 2000/14/EC.

If hearing protection is required, ear protectors with good attenuation in the

63 - 8000 Hz frequency range should be used.

Employers of personnel using this machine are advised to read the 'Noise at

Work Regulations' as the operator's daily personal exposure level could be

above the 'First Action Level'.

Wear Hearing

Protection

RM4240-D REELMASTER

RPM

kg:1750

Code Serial No:

652D

:2800 kW:35.3

260000001

105

2005

EC CONFORMITY INFORMATION

1.16

EC DECLARATION OF CONFORMITY

Manufact ured for The Toro Company By: HAYTE R LIMITED, Spellbrook, Bishop’s Stortford, Herts. CM23 4BU. ENGLAND

declare that th e lawnmower:

Model name: Type: Model No: Cutting width: Speed of rotation of the cutting device: Engine manufacturer: Speedofrotationofengine:

RM4240-D Ride-on Cylinder CODE 652D 3460mm

1050 rpm Kubota 2800 rpm

Complies with the provisions of D irective: 98/37/EC Essential Health & Safety Requirements Relating to the Design & Construction of Machinery and Safety Components, as amended and the regulation s transposed into national law.

Also Directive 89/336/EEC Electromagnetic Compatibility, as amended and the regulations transposed into national law.

Also Directi ve 2000/14/EC Noise emission in the environm ent by equipment for use outdoors and the regulations transposed into national law. Procedure applied for the conformity assessment: ANNEX VI, proc edure 1.

Notified Body: Sound Research Laboratories Ltd. Holbrook House, Little Waldingfield, Sudbury , Suffolk. CO10 0TH. ENGLAND Notified body identification No: 1088

Measured sound power level:

Guaranteed sound power level:

Complies with harmonized standards: EN 292, EN 836 and EN ISO 14982

Signed

S.A Maryniak (Technical Director)

104 dB(A)

105 dB(A)

Date: 23.12.05 Declaration done and technical do cumentation k ept at: HAYTER LIMITED Spellbrook, Bishop’s Stortford, Herts. CM23 4BU ENGLAND

VIBRATION INFORMATION

The vibration level at the oper ator contact positions, measured in accordance with European Standard EN 836

CODE652D Steering Wheel Does not exceed 2.5ms-2Seat Does not exceed 0.5ms

-2

INTRODUCTION

The Toro Reelmaster® 4240-D is a diesel engine powered self propelled machine with hydraulic systems for ground drive, cutterhead drive, cutterhead lift and steering. The machine operates in four wheel drive at all times, however, the transmission system can be operated in both ‘work’ and ‘transport’ modes. These modes can be selected by the operator. In order to optimise machine performance and reduce transmission system wear it is advisable to operate the machine in the appropriate mode. ‘Work’ signifies cutting operations and ‘Transport’ signifies travelling between work sites. A differential lock function may be selected.

The Toro Reelmaster® 4240-D is a precision built machine designed solely for cutting grass and similar low lying ground vegetation within the limitations stated in this manual. Use in any other way is considered as contrary to the intended use. Compliance with and strict adherence to the conditions of operation, service and repair as specified in this Operators Manual also constitute essential elements of the intended use. The way in which this machine is operated and maintained will have a profound effect on its performance and reliability.

This manual contains advice on the Toro Reelmaster® 4240-D which should be operated, serviced and repaired only by persons who are familiar with its particular characteristics and who are acquainted with the relevant safety procedures.

The safety precautions listed herein and all other generally recognised regulations on safety and all road traffic regulations must be observed at all times.

Any arbitrary modifications carried out to this machine may relieve The Toro Company of liability for any resulting damage or injury.

In the pursuit of continuous product development The Toro Company reserves the right to alter specifications without notice.

Cutterhead Variants: The Toro Reelmaster® 4240-D can be fitted with a range of cutterhead configurations and optional extras:

Optional Extras:

Beacon Kit - Amber flashing warning light.

Lighting Kit - Complies with EC traffic regulations.

R.O.P.S ( Roll Over Protective Structure ) 2 post design.

Cab R.O.P.S. - Full weather protection and roll - over protection.

We recommend the fitting of a Hayter approved R.O.P.S only, to increase operator safety in the event of a machine rolling over.

Note: with a R.O.P.S. fitted stability angle is decreased to 14 degrees, due to the higher centre of gravity of the machine

Left and Right: Throughout this manual the terms 'Left' and 'Right' refer to the machine when looking in the

direction of forward travel.

Fixed Heads

Cutterhead

Number of bladesCylinder diameter

MK3 Cutterhead

200mm

4, 6, 8, 10.

✓

Floating Heads with smooth or grooved front rollers

254mm

4, 6

✓

INTRODUCTION

1.17

SPECIFICATIONS

1.18

SPECIFICATIONS

ALL FIGURES ARE NOMINALLY QUOTED AT THE RATED ENGINE SPEED OF 2800 RPM UNLESS OTHERWISE STATED.

ENGINE

Type:

Power Rating:

Capacity:

Air Cleaner:

Cooling System:

Battery:

Alternator:

Starter:

Cold Starting:

Idle Speed:

Fuel Type:

Fuel Tank Capacity

IMPORTANT: PREVENT DAMAGE - for further information regarding the engine, refer to ENGINE MANUAL .

Kubota V2203 Diesel. 4 Cylinders in line.

47.3hp (35.3 kw) @ 2800 RPM. DIN 70020.

2197 cc.

Clean air drawn through screened air intake in-front of radiator via a cyclonic air cleaner with built in pre-cleaner.

Water-Cooled.

12V. 480 Amps S.A.E.

40 Amps.

1.4 KW Electric.

Glow Plug.

1250(+50) R.P.M.

Diesel.

70 Litres

SPECIFICATIONS

1.19

TRANSMISSION SYSTEM

Drive Type:

Pump:

Wheel Motors:

Differential Lock:

Drive:

Relief Valve Setting:

CUTTERHEAD DRIVE SYSTEM

Drive Type:

Pump:

Delivery Rate:

Cutterhead Motors:

Control:

Relief Valve Settings:

Hydraulic.

Variable displacement hydraulic piston pump with integral charge pump servo assisted.

Front Axle - ‘Twin Lock’ Radial piston, fixed displacement, with integral disc brake (pressure released). Rear Axle - Radial piston, fixed displacement.

Electro - hydraulic control valve with pedal control (only available in ‘Work’ mode).

Four wheel drive in ‘Work’ and ‘Transport’ modes.

Main service relief 350 bar (5075 psi) differential. Charge pressure relief 29 bar (421 psi) differential.

Hydraulic.

Tandem hydraulic gear type.

31 Litres per minute. (each circuit)

Hydraulic gear type, reversible, pressure balanced with integral differential pressure sensing relief check valve. Direct drive.

Electro-hydraulic. Automatic diverter valve safety cut-off.

250 bar (3625 psi) differential.

SPECIFICATIONS

1.20

CUTTERHEAD LIFT SYSTEM AND STEERING

Drive Type:

Pump:

Delivery Rate:

Steering:

Cutterhead Lift Control:

Wing Units:

Relief Valve:

Weight Transfer:

HYDRAULIC SYSTEM

Hydraulic Oil Type:

Capacity:

Cooling:

Suction Line Filtration:

Return line Filtration:

Transmission Filtration:

Cleanliness Level:

Maximum Oil Temperature:

Hydraulic.

Hydraulic gear pump with integral relief valve.

11 Litres per minute.

Power beyond hydrostatic steering valve with priority flow to steering and auxiliary flow to cutterhead lift system. Manual emergency steering.

Mechanical-hydraulic.

Mechanical spring power assistance to lower.

105 bar (1522 psi).

Variable hydraulic applied weight transfer acting on all cutterheads.

Refer - RECOMMENDED LUBRICANTS AND HYDRAULIC FLUIDS.

77 Litres.

Forced air finned tube oil cooler.

125 micron no bypass mesh filter.

10 micron with 2 bar (29 psi) bypass check valve.

10 micron no bypass pressure filter.

ISO Code 18/13 or better (ISO 4406) 1300 - 2500 Particles/ml<15μ 40 - 80 Particles/ml>15μ

95 C

SPECIFICATIONS

1.21

Wheel Nut Torque Setting: Front axle 200Nm

Service Brakes: Closed loop hydrostatic service braking operating on front wheels only.

Parking Brake: Lever operated oil immersed disc brakes on front wheels only. Pressurised hydraulic oil

release with mechanical override for emergency towing purposes.

Ground Clearance: 180mm at 13mm cut height and with cutterheads raised.

Steering: Hydrostatic rear wheel steering, emergency manual steering.

Features: Tilting operator platform.

Lockable engine cover. Adjustable suspension seat with folding arms. Adjustable steering column. Cutterhead parking latches with safety locks. Backlapping facility. Differential lock. Engine coolant and hydraulic oil overheat audible warning (horn). Variable cutterhead weight transfer/traction assistance. Four wheel drive in ‘Work’ and ‘Transport’ modes. Hydraulic oil filter blocked telltales on control panel. Wing arm breakback.

Safety Features: Neutral start interlock on transmission pump, parking brake and

cutterhead drive switch. Operator presence control (seat switch).

VEHICLE SPECIFICATIONS

Travel Speed:

0-25 km/h (0-15 mph) forward. 0-11 km/h (0-7 mph) reverse.

Tyre s Tyre Ty p e

Front axle

Rear axle

0.7 bar

(10 psi )

0.7 bar

(10 psi).

1.4 bar (20 psi)

Recommended Tyre Pressures

Turf Conditions

Max Pressure

Road Conditions

26 x 12 - 12 4 ply Trelleborg turf pattern.

20x10.0-8 4 ply Dico turf pattern.

1.7 bar (25 psi)

Rear axle 54Nm

SPECIFICATIONS

1.22

Automotive padded steering wheel with adjustable steering column.

Electrical switch (forward - off - reverse).

Hand operated lever.

Separate foot operated pedals.

Key start, shut - off and engine preheat.

Foot pedal.

Electrical Switch.

Hand operated lever.

Electrical Switch (Two Positions).

Button switch.

Hand wheel.

Engine oil pressure. Battery charge. Engine coolant temperature. Hydraulic transmission oil temperature.

Digital hour meter. Fuel level. Hydraulic oil level sight glass.

Engine pre-heat. Hydraulic return filter blocked. Hydraulic transmission filter blocked. Cutterdeck drive switch off. Parking brake engaged. Transmission neutral. ‘Work’ mode active.

Steering:

Cylinder Drive:

Engine Speed:

Parking Brake:

Forward and Reverse:

Ignition:

Differential Lock:

‘Work’ or ‘Transport’ modes:

Cutterhead Position:

Cutterhead Lift Configuration:

Horn:

Weight Transfer:

OPERATOR CONTROLS

INSTRUMENTATION

Warning Lights:

Gauges:

Indicator Lights:

SPECIFICATIONS

1.23

Wheel Base:

Working Width:

Cutting Width:

Transport Width:

Overall Length:

Overall Height:

Approx. Working Weight:

WEIGHT AND DIMENSIONS

RECOMMENDED LUBRICANTS AND HYDRAULIC FLUIDS

Grease Points: A good quality medium grease.

Engine: Refer - ENGINE OPERATORS MANUAL.

Hydraulic System:

Should you be in any doubt please contact your Toro dealer. Using incorrect grades will cause

premature wear of hydraulic components and invalidate warranty.

1610 mm.

3640 mm.

3460 mm.

1850 mm at 13mm height of cut.

2930 mm.

1570 mm.

1800 kg less operator, no options fitted. (The exact weight depends on the cutterhead configuration).

Ambient Temperature Range

0 - 30 C (32 - 86 F)

I S O viscosity grade 46 hydraulic oil.

15 - 40 C (59 - 104 F)

I S O viscosity grade 68 hydraulic oil.

SPECIFICATIONS

1.24

CUTTERHEADS

Cutting Width:

Cylinder Diameter:

Cylinder Speed:

Height of Cut:

Number of Blades:

Smooth Rear Roller:

Smooth Front Roller:

Grooved Front Roller:

Configuration:

MK3 200mm Cutterhead

762 mm.

200 mm.

1050 rpm approx.

12 - 80 mm.

4, 6, 8, 10

Standard.

Optional.

Fixed / Floating.

MK3 254mm Cutterhead

762 mm.

254 mm.

1050 rpm approx.

12 - 80 mm.

4, 6

Standard.

Fixed.

OPERATING THE MOWER

1.25

OPERATOR PRESENCE CONTROLS

Cutting Cylinder Drive Lockout: Drive to the cutting cylinders is only possible when the operator is

seated. If the operator raises off the seat for a period of more than one second, a switch is activated and drive to the cutting cylinders is automatically disengaged. To re-engage drive to the cutting cylinders, the operator must return to the seat, then operate the cutterhead drive switch to the ‘OFF’ position before moving it back to the ‘ON’ position. If the operator rises off the seat for a brief moment during normal work, drive to the cutting cylinders is not affected.

The engine can only be started with the cutterhead drive switch in the ‘OFF’ position.

Engine Start Lockout: The engine can only be started when the forward/reverse travel pedal is released to the 'NEUTRAL' position, the cutterhead drive switch is in the ‘OFF’ position and the parking brake is engaged. When these circumstances are satisfied, switches are activated permitting the engine to be started.

Engine Run Interlock: Once the engine is started the operator must be seated before the parking brake is released for the engine to continue to run.

Note: The engine will cut out if the operator leaves the seat.

WARNING: PREVENT ACCIDENTS - Do not operate the Reelmaster® mower if the operator presence controls are defective in any way. ALWAYS replace faulty parts and check that they function correctly before operating the mower.

SAFETY NOTICE

WARNING: PREVENT ACCIDENTS - Before operating the mower it is essential that;

- The operator reads and understands this manual.

- The operator platform latching mechanism is fully engaged and in good working order, refer - ‘OPERATOR PLATFORM LATCHING MECHANISM’.

- The daily maintenance checks have been properly carried out and the turf mower is in good working order.

- The operator should wear safety clothing and eye protection. Failure to do so could result in risk to health and safety.

- The area where the equipment is to be used is inspected and all objects which may be thrown by the machine are removed.

Operate safely on slopes;

It is essential to follow safe working practices when working on slopes. In order to avoid potentially hazardous situations, it is essential that the operator understands and observes the relevant safety precautions listed in this manual, refer - ‘SAFETY PRECAUTIONS’.

OPERATING THE MOWER

1.26

1. Parking brake lever.

2. Lighting switch (supplied with lighting kit).

3. Warning beacon switch (supplied with beacon kit).

4. Hazard warning switch (supplied with lighting kit).

5. Cutterhead position controls.

6. Throttle control lever.

7. Ignition key.

8. Cutterhead drive switch.

9. Dip beam / main beam light switch (supplied with lighting kit).

10. Direction indicator switch (supplied with lighting kit).

11. Horn button.

12. Transmission oil filter indicator.

13. Oil pressure indicator.

14. Transmission temperature indicator.

15. Return oil filter indicator.

16. Battery warning indicator.

17. Engine temperature warning indicator.

18. Glow plug indicator.

19. Cutterhead drive off indicator.

20. Parking brake indicator.

21. Transmission neutral indicator.

22. Weight transfer control.

23. ‘Work/Transport’ mode switch.

24. Centre cutterhead transport latch.

25. LH front cutterhead transport latch.

26. RH front cutterhead transport latch.

27. Centre cutterhead transport latch.

28. LH wing unit transport latch.

29. RH wing unit transport latch.

30. Differential lock pedal.

31.Dual lift configuration switch.

32. Wash / wipe switch (supplied with cab kit).

33. Forward travel pedal.

34. Reverse travel pedal

35. Forward travel speed backstop lever.

36. Forward travel speed backstop cam.

37. Hour Meter

4A953B01A

HOURS

QUARTZ

CURTIS

1 10

1D953S01A

IDENTIFICATION OF CONTROLS

OPERATING THE MOWER

1.27

BRAKING SYSTEM

Parking Brake : Move the parking brake lever to its rear position to engage

the parking brake. Do not operate the mower with the parking brake engaged.

WARNING : PREVENT ACCIDENTS - The parking brake operates on the front wheels only. Do not park the mower on a slope.

Service brakes : Service braking is achieved by the hydraulic transmission system. When the forward

or reverse travel pedals are released or the engine speed reduced, service braking becomes effective and travel speed is automatically reduced. To increase the braking effect, push the transmission pedals into the neutral position.

WARNING : PREVENT ACCIDENTS - The service braking system will not hold the mower at a standstill. ALWAYS ensure the parking brake is engaged to park the mower at a standstill.

Emergency Braking : In the event of service brake failure, switch off the

ignition to bring the mower to a standstill.

WARNING: PREVENT ACCIDENTS - Take care when operating the braking system. Remain seated and hold on to the steering wheel to prevent ejection from the mower caused by the front wheel brakes being applied suddenly when travelling.

THROTTLE CONTROL

Operate the throttle control in a forward direction to increase engine speed.

Operate the throttle control in a rearward direction to reduce engine speed.

Note that the engine speed dictates the speed of the other functions, i.e. travel, cutting cylinder, position controls.

TRAVEL

Forward travel: Depress the forward travel pedal to increase forward travel

speed. Release the pedal to reduce speed.

Reverse travel: Depress the reverse travel pedal to increase reverse travel speed. Release the pedal to reduce speed.

Stop (Neutral): Release the forward and reverse travel pedals.

Parking Brake EngagedParking Brake Engaged

Parking Brake Engaged

Engine Speed Engine Speed Fast Slow

+ 60 hidden pages

Toro 652D, Reelmaster 4240-D Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual