# " # # " ! # !" = % $ " " # "! "4 :3*+789'3* 9./8 574*:)9 '3* ,47 8',+9< '3* 459/2:2 5+7,472'3)+ 7+'* 9./8 2'3:'1 (+,47+ 89'79/3- 9.+ +3-/3+ '< 85+)/'1 '99+39/43 94 ! "& !" # " ! ./-.1/-.9+* (< 9./8 8<2(41 9 2+'38 #" % 47 5+7843'1 8',+9< /3897:)9/43 '/1:7+ 94 )4251< ;/9. 9.+ /3897:)9/43 2'< 7+8:19 /3 5+7843'1 /30:7< ".
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 - Schematics - Before Operating This manual emphasizes safety, mechanical and general product information.
............. 2 Model And Serial Number . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . . . . . . . . 4 Before Operating . . . . . . . . . . . . . . . . . . . . . . . . 4 While Operating . . . . . . . . . . . . . . . . . . . . . . . . . 4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 . . . . . . . 6-7 . . . . . . . . . . . . . . . . . . . . . . . . . . 8 .
The REELMASTER 6500ĆD was tested and certified by TORO for compliance with the B71.4Ć1990 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.
!% ! " ! Operator must be skilled and trained in how to drive on hillsides. Failure to use caution on slopes or hills may cause loss of control and vehicle to tip or roll possibly resulting in personal injury or death. On 4 wheel drive model, always use the seat belt and ROPS together. If engine stalls or loses power and cannot make it to the top of a slope, do not turn machine around. Always back slowly straight down the slope.
# The following safety and instruction decals are affixed to the traction unit. If any decal becomes illegible or damaged, install a new decal. Part numbers are listed below and in your Parts Catalog.
# " $*+ ) $*+ ) $*+ ) ! $*+ ) $*+ ) $*+ ) )%&' )(', $*+ ) $*+ ) $*+ ) )%&' )(',
' "' 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. "' * & All welded formed steel frame, includes tie-down loops. ((%"' 1+, & Rear-mounted, cross-flow agricultural type radiator; 7 fins per inch. Approx. 7.5 quart (7.
! "! " 04) Use this chart as a checklist to assure all parts necessary for assembly have been received. Without these parts, total setĆup cannot be completed. Some parts may have already been assembled at factory.
,1# Before installing cutting unit motors or counterweights with speed sensors, lubricate internal splines of cutting unit reels shafts with grease. Install a counter weight onto appropriate end of each cutting unit with capscrews provided (Fig. 3 ). Install (2) shims on pivot shaft of each cutting unit carrier frame (Fig. 4). Insert the pivot shaft of the carrier frame into the mounting hole at the end of the pivot knuckle (Fig. 4).
" #" *+46* 7*6:.(.3, 46 2&0.3, &)/9782*387 84 8-* 2&(-.3* 7845 *3,.3* &3) 6*24:* 0*< +642 8-* 7;.8(- Park machine on a level surface. Release hood latch and open hood. Remove degasser tank cap and check coolant level. 441&38 1*:*1 7-491) '* 95 84 46 &'4:* 8&'7 3 )*,&77*6 8&30 ;-*3 *3,.3* .7 (41) #" ., Crankcase capacity is 5.3 qt. with filter. Park machine on a level surface. Release hood latch and open hood. + *3,.3* -&7 '**3 6933.
! ! # ! +)'97+ */+7+1 ,9+1 /7 ,1'22'(1+ 97+ )'98/43 ;.+3 7846/3- 46 .'3*1/3- /8 4 348 7240+ ;./1+ ,/11/3- 8.+ ,9+1 8'30 4 348 ,/11 ,9+1 8'30 ;./1+ +3-/3+ /7 6933/3- .48 46 ;.+3 2')./3+ /7 /3 '3 +3)147+* '6+' 1;'<7 ,/11 ,9+1 8'30 4987/*+ '3* ;/5+ 95 '3< 75/11+* */+7+1 ,9+1 (+,46+ 78'68/3- 8.+ +3-/3+ "846+ ,9+1 /3 ' )1+'3 7',+8< '5564:+* )438'/3+6 '3* 0++5 )'5 /3 51')+ $7+ */+7+1 ,9+1 ,46 8.+ +3-/3+ 431< 348 ,46 '3< 48.
! ! " The tires are over-inflated for shipping. Therefore, release some of the air to reduce the pressure. Correct air pressure in the front and rear tires is 15 -20 psi. ! ! Maintain even pressure in all tires to assure a good quality-of-cut and proper machine performance. DO NOT UNDER INFLATE.
" # ! 3$&5,10 ('$. (Fig. 13) - Controls forward and reverse operation. Depress top of pedal to move forward and bottom to move backward. Ground speed depends on how far pedal is depressed. For no load, maximum ground speed, fully depress pedal while throttle is in FAST. To stop, reduce foot pressure on traction pedal and allow it to return to center position. 3$&5,10 2((' ,/,5(3 (Fig.
',) + ) (Fig. 15) - Shows total hours that machine has been operated. " ,) ) $ %* )$"& ) $ + ! ' $"& "& " ,) % +') &' ',) + ) $% ( ."+ ! (Fig. 16) - Used in conjunction with lower mow / raise control lever for backlapping operation. Switch is located under seat plate. Refer to Cutting Unit Maintenance, Backlapping. )$"& ) $ + ! (Fig. 17) - A knob on the left side of console actuates parking brake lock.
injection pump. To do this, loosen the fitting on the injection pump (Fig. 20) and repeat bleeding procedure. &'02& 3&26*$*/( 02 .",*/( "%+534.&/43 40 4)& ."$)*/& 3401 &/(*/& "/% 2&.06& ,&8 '20. 4)& 37*4$) Sit on the seat, keep foot off traction pedal. Assure parking brake is engaged, traction pedal is in NEUTRAL, throttle is in SLOW position and the ENABLE / DISABLE switch is in the DISABLE position.
. .& +!$%1 /%0 )-),3, 0!#2). /%%$ !6),3, 0!#2). /%%$ .38 in. 1.9 mph 6.0 mph 11 .50 in. 2.6 mph 7.6 mph 7 .62 in. 2.1 mph 6.0 mph 7 .75 in. 2.5 mph 7.2 mph 5 .63 in. 1.5 mph 4.5 mph 5 .88 in. 2.1 mph 6.0 mph 11 %)'(2 .& 32 0.#%$30% &.0 ,!)-2!)-)-' /0./%0 #+)/ 0!2% %2 1%+%#2.0 *-." 2. #.00%#2 +%22%0 1%22)-' %0 #(!02 +.#!2%$ 3-$%0 1%!2 /+!2% !)-2!)- '0.
! " $ #$"% $ # ! " $ " #! # $ "$ 34( !47/8/43 1'*+ % +/-.8 4, 98 34( !47/8/43 1'*+ % +/-.8 4, 98 1'*+ % 34( +/-.
Close by-pass valve before starting the engine. However, do not exceed 5-8 ft-lb (7-11 N m) torque to close the valve. 5//+/) 4*' '/)+/' 7+4* 4*' %8 1$33 6$-6' 01'/ 7+-- &$53' 4*' 42$/3.+33+0/ 40 06'2*'$4 Check electrical connections, input fuses and diagnostic light bulb to determine malfunction. Make sure loopback connector is secured to wire harness connector.
"!)& "& &# '' # $## ($&' 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. "!)& " !#$'(" The inputs displayed" LED, on lower right column of the Diagnostic ACE, should be illuminated. If outputs displayed" LED is illuminated, press and release the toggle button, on Diagnostic ACE, to change LED to inputs displayed".
'$ ( &-.12(" #(1/+ 6 ,312 -.2 !$ +$%2 ".--$"2$# 2. 2'$ , "'(-$ 2 (1 -.2 #$1(&-$# 2. 5(2'12 -# 2'$ $-4(0.-,$-2 .% 2'$ , "'(-$ 1 $4$06 # 6 31$ '$- #.-$ 31(-& ( &-.12(" #(1".--$"2 (2 %0., 2'$ , "'(-$ -# 0$".--$"2 +../! "* ".--$"2.0 2. ' 0-$11 ".--$"2.0 "'(-$ 5(++ -.2 ./$0 2$ 5(2'.32 +../! "* ".--$"2.0 (-12 ++$# .- ' 0-$11 2.0$ ( &-.12(" (- #06 1$"30$ +." 2(.- (- 1'./ -.2 .
False alarms are observed. $( Refer to Troubleshooting Guide on page 25 for additional information. Park machine on a level surface and engage the parking brake. Open control panel cover. Locate leak detector harness loopback connector with hydraulic symbol tag. Carefully unplug loopback connector from harness connector. Connect the Diagnostic ACE display connector to the correct harness loopback connector.
'+ If machine must be operable with leak detector disabled, unplug leak detector 4-pin connector from 4-pin connector of main harness. Do not unplug leak detector alarm. $* $ )%* ) ' * )- : Oil level may be low causing air to be drawn out of system. Check oil level. 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. Air leak in system.
! +#)/034+% +31-#9 5/%4+0/3 6'2-#9 &'%#- /)-+3* 3*07/ : /1543 +31-#9'& '& : 541543 +31-#9'& 2''/ 0))-' $5440/ +)52' !3+/) : /1543 +31-#9'& '& '84 -+4 +( 0+- -'6'- +3 400 *+)* -+4 +( 0+- -'6'- +3 -+4 +( 0+- -'6'- +3 400 -07 -+4 +( 0+- +3 400 *04 -+4 +( 3934'.
'$ %.++.6(-& (2 04("* &4(#$ 3. 3'$ ,.23 ".,,.- /1.!+$,2 +(*$+7 3. !$ $-".4-3$1$# '$ ' -# '$+# ( &-.23(" (2 '$+/%4+ %.1 (#$-3(%7(-& 2/$"(%(" /1.!+$,2 !$$/ % 4+32 1$ .""411(-& (+ +$5$+ (2 (-".11$"3 "'(-$ 23 13$# .- '$"* 3 -* #(/23("* .2+./$ .(+ +$5$+ $11.1 17 & (- .1$04(1$# 41% $%$-#$1 .1 +../! "* 4-/+4&&$# $".--$"3 .+$-.(# 5 +5$ 4-/+4&&$# $".--$"3 7#1 4+(" 3 -* " / (2 +..2$ (&'3$- +$5$+ 241% "$ +$5$+ 241% "$ ## .
"-*,*"1*8"3*/. - Before mowing grass, practice operating machine 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 turning the machine.
"#+-" ."-1& &*$ +- ) (&*$ !'0./)"*/. /+ /%" ) %&*" ./+, "*$&*" *! -")+1" ("3 #-+) /%" .2&/ % &$ 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.
Daily Maintenance: (duplicate this page for routine use) Check proper section of Operator's Manual for fluid specifications Daily Maintenance Check For Week Of _________________ Maintenance C Check Item b MON n Safety Interlock Operation n Brake Operation n Engine Oil & Fuel Level n Cooling System Fluid Level TUES WED THURS FRI SAT SUN Drain Water/Fuel Separator n Air Filter Restriction Indicator n Radiator & Screen for Debris n Unusual Engine Noises1 n Unu
! " ! Lubricate All Grease Fittings Inspect Air Filter, Dust Cup, and Baffle Check Battery Level/Cable Connections " " Every 50hrs Every 100hrs Every 200hrs Every 400hrs Every 800hrs } Change Engine Oil and Filter Inspect Cooling System Hoses { Check Fan and Alternator Belt Tension { Torque Wheel Lug Nuts ~ Service Air Filter Change Fuel Filter Inspect Fuel Lines and Connections } Check Engine RPM (idle a
!*, - ,0$ $)" *, ( &$)" %/-.( ).- .* .# ( #$) -.*+ )"$) ) , (*0 & 2 !,*( .# -1$. # Gently slide primary filter (Fig. 42) out of air cleaner body to reduce the amount of dust dislodged. Avoid knocking filter against air cleaner body. * )*. , (*0 - ! .2 !$'. , Check air cleaner body for damage which could possibly cause an air leak. Replace a damaged air cleaner body.
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. Inspect new filter for shipping damage. Check sealing end of filter. Do not install a damaged filter.
! # ,* ! 7(/ $1. ()24( 5(48,&,1* 24 0$.,1* $'-7560(165 62 6+( 0$&+,1( 5623 (1*,1( $1' 4(028( .(: )420 6+( 59,6&+ ,* Drain and clean fuel tank every 800 hours of operation or yearly, whichever comes first. Also, drain and clean tank if fuel system becomes contaminated or if machine is to be stored for an extended period. Use clean fuel to flush out the tank.
'%0-$ '%0-$ $ - "-$$* 0$( '(/$- /$- $, - /+ - '* "-$2 -')$- (0*%$- C. Unscrew knobs and pivot oil cooler rearward. Clean both sides of oil cooler and radiator area thoroughly with compressed air. + *+/ 0.$ 2 /$- Open hood and blow debris out toward back of machine. Pivot oil cooler back into position and tighten knobs.
Check condition and tension of fan belt after every 100 hours of operation (Fig. 50). Replace belt as required. Proper tension will allow 1/4 in. deflection on the belt midway between the pulleys, when pressed firmly with thumb. If deflection exceeds 1/4 in., loosen alternator mounting bolts. Adjust alternator belt tension by adjusting tension screw. Check deflection of belt again to assure tension is correct.
! &'02& 3&26*$*/( 02 .",*/( "%+534.&/43 40 4)& ."$)*/& 3401 &/(*/& "/% 2&.06& ,&8 '20. 4)& 37*4$) 3& 0' "/8 04)&2 '*-4&2 ."8 60*% 4)& 7"22"/48 0/ 30.& $0.10/&/43 Position machine on a level surface, lower the cutting units, stop the engine, engage the parking brakes and remove key from ignition switch. Clean area around filter mounting area. Place drain pan under filter and remove filter.
! ! (& ! The test ports are used to test pressure in the hydraulic circuits. Contact your local Toro distributor for assistance. Test Port #1 (Fig. 53) is used to assist in trouble shooting the hydraulic circuit for the front cutting units and lift cylinders. %01 -/1 %01 -/1 (&2/% %01 -/1 %01 -/1 (& (&2/% %01 -/1 Test Port #2 (Fig.
! The cutting unit lift circuit is equipped with a adjustable valve to ensure the front cutting units raise and lower evenly. Adjust cutting units as follows: Locate valve under seat. ! )& )((!% )%!( ")'($ %( * #* Loosen setscrew on valve. Rotate valve clockwise to slow down drop rate of front outside cutting units. Verify lift rate adjustment by raising and lowering cutting units several times. Readjust as required.
G1A S2A P1A S1A M4A R3 R3 R1A M9 R 12:1 M8 R R2A S5A 12:1 T2A S4A M5A D4 F S3A R3 R3 M5 .047 S7A R6 C1A C4 S6A C4A .060 R6 C1 C5 P4 R5 C2A P2A C5A P1 G1B P2 P3 S2B M2B P1B R3 S1B LH RH R7 R3 M2 V1 R1B R4 PC1B R3 VS1B R3 M3 T1B S3B M3B OUT IN C3B C3 C2B P2B 4000 1250 R5 R6 R7 3 50 180 R4 86 276 12 159 103 1500 2.01 .66 M9 V1 R3 32.9 10.8 2.01 M8 207 19 32.9 1.16 M5 2300 19 1.16 M4 R2A 19 1.16 M3 207 19 1.
G1A S2A P1A S1A M4A R3 R3 R M10 R R F M9 F R2A S5A 12:1 T2A S4A M5A D4 M8 F T1A S3A R3 R3 M5 .047 S7A R6 C1A C4 S6A C4A .060 R6 C1 C5 P4 R5 C2A P2A C5A P1 G1B P2 P3 S2B M2B P1B R3 LH RH R7 S1B R3 M2 V1 R1B R4 PC1B R3 VS1B R3 M3 T1B S3B M3B OUT IN C3B C3 C2B P2B 207 207 3000 3000 2300 1500 50 180 4000 1250 40.6 19 19 19 19 19 32.9 32.9 40.6 10.8 2.48 1.16 1.16 1.16 1.16 1.16 2.01 2.01 2.48 .
BRAKE MAINTENANCE ADJUSTING SERVICE BRAKES (Fig. 58) Adjust the service brakes when there is more than 1 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 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.
$" After every 800 operating hours or annually, check rear wheel toe-in. Measure center-to-center distance (at axle height) at front and rear of steering tires. Front measurement must be 1/4 in. less than rear measurement. To adjust loosen clamps at both ends of tie rods. Rotate tie rod to move front of tire inward or outward. $"-* Tighten tie rod clamps when adjustment is correct. * $' %-"+ Remove check plugs to ease draining of oil.
#! # ## !& ! !# # +,46+ ;+1*/3- 43 8.+ 2')./3+ */7)433+)8 (48. )'(1+7 ,642 8.+ ('88+6= */7)433+)8 (48. ;/6+ .'63+77 519-7 ,642 8.+ +1+)8643/) )438641 93/8 '3* 8.+ 8+62/3'1 )433+)846 ,642 8.+ '18+63'846 84 56+:+38 *'2'-+ 84 8.+ +1+)86/)'1 7=78+2 $# %+'6 7',+8= -4--1+7 '3* 69((+6 -14:+7 ;.+3 ;460/3- ;/8. +1+)8641=8+ .'6-+ 8.+ ('88+6= /3 ' ;+11 :+38/1'8+* 74 -'7+7 564*9)+* ;./1+ ).'6-/3- )'3 */77/5'8+ "/3)+ 8.
BLACK ORANGE BLACK BLUE/GREEN FUEL GAGE G S I G S HOC POT "P" 1 WARNING LIGHTS #1 2 BLACK 3 "M" 4 5 6 SPEEDOMETER BLACK STARTER + - BATTERY 12 VOLTS RED BLACK B A RED/BLUE KEY SWITCH A #2B 7.
TO LEAK DETECTOR CONNECTOR OF MAIN HARNESS A B C D RED/Y OR/BLK BLK RED BLK/W BLK/BU RED/W + (RED) - BLK/Y ALARM YELLOW BLK/OR ELECTRIC SOLENOID VALVE GN/WT BLK 2D 1B TURF DEFENDER 3B 2C 1E 2E 1C 3C 2A 2F 1F 3F A A E E B B C C TURF DEFENDER COMMUNICATION PORT AND LOOPBACK CONNECTOR TURF DEFENDER LOOPBACK I.D.
"!! " ! ! $ ! # ! !! ! ! ! ! $ ! " # ! !" ! ! # 37) #,)2 &%'/0%44-2+ 7,) *5327 82-76 %00 34)5%7) 73+)7,)5 %2( 7,) 5)%5 82-76 34)5%7) 73+)7,)5 Position the machine on a level surface, lower the cutting units, stop the engine, engage the parking brake, and move the Enable/Disable switch to disable position.
! " " Thoroughly clean the traction unit, cutting units and the engine. Drain the engine oil from the oil pan and replace the drain plug. Check the tire pressure. Inflate all tires to 15-20 psi. Check all fasteners for looseness; tighten as necessary. Grease or oil all grease fittings and pivot points. Wipe up any excess lubricant. Lightly sand and use touch-up paint on painted areas that are scratched, chipped, or rusted.
*' 030 0..'3%+#- 30&6%54 80 "'#3 +.+5'& !#33#/5: *' 030 0.1#/: 8#33#/54 :063 03 /'8'3 030 0..'3%+#- 30&6%5 ; 30&6%5 163%*#4'& #(5'3 #/6#3: 50 $' (3'' (30. &'('%54 +/ .#5'3+#-4 03 803,.#/4*+1 (03 5*' 1'3+0& 0( 5+.
