MODEL NO. 03800 ~ 50001 & UP MODEL NO. 03801 ~ 50001 & UP FORM NO. 3317418 OPERATOR’S MANUAL k REELMASTER® 6500—D WHEEL DRIVE TRACTION UNITS Helping you put quality info play.™ To understand this product, and for safety and optimum performance, read this manual before starting the engine. Pay special attention to SAFETY INSTRUCTIONS highlighted by this symbol. AL It means CAUTION, WARNING or DANGER personal safety instruction. Failure to comply with the instruction may result in personal injury.
FOREWORD This operator’s manual has instructions on safety, proper set—up and operation, adjustments and maintenance. Therefore, anyone involved with the product, including the operator, should read and understand this manual. Major sections are: Safety Instructions Know Your Controls ~ Specifications ~ Operating Instructions -~ Set—up Instructions — Maintenance ~ Before Operating — Schematics This manual emphasizes safety, mechanical and general product information.
TABLE OF CONTENTS IDENTIFICATION & ORDERING .. . 2 Model And Serial Number . SAFETY INSTRUCTIONS . .. Before Operating White Operating Maintenance .. SAFETY INSTRUCTIONS & DECALS 6~7 SPECIFICATIONS .8 LOOSE PARTS CHART SET-UP INSTRUCTIONS Install Cutting Units . 10 Rear Ballast . . .. BEFORE OPERATING . .11 Check Engine Ol h Check Cooling System .. .. ki Fill Fuel Tank -1 Check Hydraulic Fluid .. .12 Check Planetary Gear Drive Oif . .
A SAFETY INSTRUCTIONS The REEL MASTER 6500-D was tested and certified by TOR for compliance with the specifications of the American National Standards Institute. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern, and proper training of the personnel involved in the operation, transport, maintenance, and storage of the machine.
A SAFETY INSTRUCTIONS 16, Operator must be skilled and trained in how o drive on hillsides. Failure to use caution on slopes or hills may cause loss of control and vehicles to tip or roll possibly resulting in personal injury or death, On 4 wheel drive model, always use the seat belt and TOPS together. 17. I engine sails 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. 18.
SPECIFICATIONS Engine: Peugeot, 4 cylinder, 4 cycle, overhead cam, 116 cu. in (1.9 liter) displacement liquid cooled diesel engine. 38 hp (28 kW); governed to 2500 rpm high idle; 23.5:1 compression ratio, 3.27” (83 mm) bore x 3.46” (88 mim) stroke. Automatic glow plug/starter interlock stern, 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. Approx. 7.6 quart (7.
LOOSE PARTS CHART Note: Use this chart as a checklist to assure all parts necessary for assembly have been received. Without these parts, total set-up cannot be completed. Some parts may have already been assembled at factory. Operator's Manual (Traction Unit) Parts Catalog Read before aerating machine.
SET~UP INSTRUCTIONS Note: Before installing cutting unit motors or counterweights with speed sensors, lubricate internal splines of cutting unit reels shafts with grease. 4. Install a counter weight onto appropriate end of each cutting unit with cap screws provided (Fig. 3). 5. Install (2) shims on pivot saith of each cutting unit carrier frame (Fig. 4}. 6. Insert the pivot shalt of the carrier frame into the mounting hole at the end of the pivot knuckle (Fig. 4). Figure 4 4. Centering stops 5.
BEFORE OPERATING A\ caution Before servicing or making adjustments to the machine, stop engine and remove key from the switch. CHECK ENGINE OIL (Fig. 6 &7) Crankcase capacity is 5.3 gt. with filter 1. Park machine on a level surface. Release hood latch and open hood. Figure 6 1. Hood Latch 2. Remove dipstick from fuse cap, wipe clean and reinstall dipstick into tube cap. Pull it out again and check oil level on dipstick: Oif level must always be in notch area on dipstick. Figure 7 1. Dipstick / Tube Cap 3.
BEFORE OPERATING A\ lancer Because diesel fuel is flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not file fuel tank while engine is running, hot, or when machine is in an enclosed area. Always fill fuel tank outside and wipe up any spilled diesel fuel before starting the engine. Store fuel in a clean, safety~approved container and keep cap in place. Use diesel fuel for the engine only; not for any other purpose. CHECK HYDRAULIC FLUID (Fig.
BEFORE OPERATING Figure 11 1, Check/Drain Plug CHECK REAR AXLE LUBRICANT (Model 03801 Only) (Fig. 12) The rear axle is shipped from the factory filled with SAE B5W—140 wt. gear lube. Check level before engine is first started and every 400 hours thereafter. Capacity is BO oz, Visually inspect for leaks daily. 1. Position the machine on a level surface. 2. Remove a check plug from one end of axle and make sure lubricant is up to bottom of hole.
KNOW YOUR CONTROLS Traction Pedal (Fig. 13} — Controls forward and reverse operation. Depress top of pedal to move forward and bottom ta 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 aglow it to return to center position. Traction Speed Limiter {Fig.
KNOW YOUR CONTROLS Hour Meter (Fig. 15) — Shows total hours that machine has been operated. Figure 15 1. HOC Selector Knob 2. Hour Meter Back lap Switch (Fig. 16) — Used in conjunction with lower mow / raise control lever for backslapping operation. Switch is located under seat plate. Refer to Cutting Unit Maintenance, Backslapping. Figure 16 1. Back lap Switch Brake Pedals (Fig.
OPERATING INSTRUCTIONS A caution Before servicing or making adjustments to the machine, stop engine and remove key from the switch. STARTING AND STOPPING 1. Synthesis seat, keep foot off traction pedal. Assure parking brake is engaged, traction pedal is in NEUTRAL, throttle is in SLOW position and the ENABLE / DISABLE switch is in the DISABLE position. A\ warning Engine will not crank over until Glow Plug Lamp goes out {(Delay in interlock.
OPERATING INSTRUCTIONS SAMPLES OF TRACTION SPEED RANGES FOR VARIOUS HEIGHTS OF CUT No. of Blades Minimum Traction Maximum Traction per C.U. Speed Speed " .38in. 1.9 mph 6.0 mph Ak 50in. 2.6 mph 7.6 mph mph 4.5 mph mph 6.0 mph * Procedure for maintaining proper clip rate: 1. Set HOC selector knob to correct letter setting (Per chart located under seat plate). 2.
OPERATING INSTRUCTIONS CLIP RATE (REEL SPEED) SELECTION CHART 11 Blade C.U. HOC Knob Position Height—of—Cut FULL SPEED .38 in. (9.6 mm} 42 in. (10.7 mm) 4B in. (11.7 mm) B0 in, (12.7 mm} 54 in, (13.7 mm} 58 in. (14.7 mm) 62 in. (15.7 mm) 66 in. {16.8 mm) 70 in. (17.8 mm) 74 in. (18.8 mm) 78in. (19.8 mm) 82 in. (20.8 mm) .86 in. (21,8 mm) .80 in. (22.9 mm) B4 in. (23.9 mm} FULL SPEED — Cutting units will always run at full speed in this position. 5 Blade C.U. HOC Knob Position FULL SPEED 463 in. (16.
OPERATING INSTRUCTIONS 2. Close by—pass valve before starting the engine. However, do not exceed 58 fib N mj torque to close the valve. IMPORTANT: Running the engine with the bypass valve open will cause the transmission to overheat. e Figure 22 1. By~ Pass Valve DIAGNOSTIC LIGHT (Fig. 23) The BM 6500-D is equipped with a diagnostic light which indicates # the electronic controller is functioning correctly. The diagnostic lights located on the steering tower panel.
Figure 24 1. Wire Harness and Connectors 4. Turn the key switch to the ON position, but do not start machine. Note: The red text on the overlay decal refers to input switches and the green text refers to outputs. Figure 25 1. Diagnostic ACE 5. The “inputs displayed” LED, on wore 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”. Do not hold button down, 8.
OPERATING INSTRUCTIONS if each input switch is in the correct position and functioning correctly, but the output LED's are not correctly illuminated, this indicates an ECU problem. if this occurs, contact your Torah Distributor for assistance. IMPORTANT: The Diagnostic ACE display must not be left connected to the machine. it is not designed to withstand the environment of the machine’s every day use.
LUBRICATION A\ caution Before servicing or making adjustments to the machine, stop engine and remove key from the switch. GREASING BEARINGS AND BUSHINGS (Fig. 26-34) The machine has grease fittings that must be y lubricated regularly with No. 2 General Purpose Figure 28 Lithium Base Grease. if machine is operated under normal conditions, lubricate all bearings and bushings after every 80 hours of operation or immediately after every washing. 1.
LUBRICATION e Figure 34 SERVICE INTERVAL CHART S QUICK REFERENCE AID CHECK/SERVICE (daily} CHECK/SERVICE 1. OIL LEVEL, ENGINE {SEE OPERATOR’S MANUAL) 2. OIL LEVEL, HYDRAULIC TANK 9. BATTERY 3. COOLANT LEVEL, RADIATOR 10. BELTS (FAN, ALT) 4, FUEL WATER SEPARATOR 11. PLANETARY GEAR DRIVE 5. AIR FILTER SERVICE INDICATOR REEL MASTER 6500-D, 2WD m Figure 33 10 6. RADIATOR SCREEN = 7. BRAKE FUNCTION 8.
Maintenance Check stem » DAILY MAINTENANCE CHECKLIST Daily Maintenance: (duplicate this page for routine use) Check proper section of Operator’s Manual for fluid specifications ail Maintenance Check For Week Of MON TUES WED THURS FRI SAT SUN Safety Interlock Operation Brake Operation Engine Oil & Fuel Level Cooling System Fluid Level Drain Water/Fuel Separator Air Filter Restriction indicator Radiator & Screen for Debris Unusual Engine Noises! Unusual Operating Noises Hydraulic System Oil Level Hydraulic Fi
MAINTENANCE SCHEDULE Minimum Recommended Maintenance Intervals Maintenance Procedure Maintenance Interval & Service Every Every Lubricate All Grease Fittings inspect Air Filter, Dust Gup, and Baffle Check Battery Level/Cable Connections Every 50hrs Every Even o | 200hrs 100hrs 400hrs 800hrs $ Change Engine Oil and Fitter inspect Cooling System Hoses T Check Fan and Alternator Belt Tension 1 Torque Wheel Lug Nuts € Service Air Filter Change Fuel Filter inspect Fuel Lines and Connections $ Check Engine RPM (i
AIR CLEANER MAINTENANCE 2. Gently slide primary filter {Fig. 37) out of air cleaner body to reduce the amount of dust dislodged. Avoid knocking filter_against uncleaner body. Do not remove safety filter, A\ caution Before servicing or making adjustments to the machine, stop engine and remove key from the switch, GENERAL AIR CLEANER MAINTENANCE 1. Check air cleaner body for damage which could possibly cause an air leak. Replace a damaged air cleaner body. 2.
AIR CLEANER MAINTENANCE Compressed Air Method A. Blow compressed air from inside to the outside of dry filter element. Do not exceed 100 psi to prevent damage to the element. B. Keep air hose nozzle at least 2" from filter and move nozzle up and down while rotating the filter element. Inspect for holes and tears by looking through the filter toward a bright light. 5. Inspect new filter for shipping damage. Check sealing end of filter. Do not install a damaged filter. 6.
ENGINE MAINTENANCE A\ caution Before servicing or making adjustments to the machine, stop engine and remove key from the switch. ENGINE OIL AND FILTER (Fig. 39-40) Change oil and filter initially after the first 50 hours of operation, thereafter change oil and filter every 100 hours. 1. Remove drain plug {Fig. 38} and let oil flow into drain pan. When oif stops, install drain plug and new plug seal, Part No, 74-7850. 1 Figure 39 1. Drain Plug 2. Remove oil filter {Fig. 40}.
ENGINE ure 42 1. Fuel Merle after Separator 2, Drain Screw 3. Primer Plunger Changing Fuel Filter Replace duet filter if fuel flow becomes restricted, after every 400 hours of operation or annually, whichever comes first. 1. Loosen bolt and unscrew bottom filter cap from filter assembly. Remove cap, gaskets, o-ring and filer from assembly. Note position of gaskets and o-ring when disassembling from filter. 3. Install new filter, gaskets, o-ring with filter assembly cap. 4.
ENGINE MAINTENANCE ENGINE FAN BELT (Fig. 45) 2. 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. Check condition and tension of fan belt after every 100 hours of operation (Fig. 45). Replace belt as required. 1. Proper tension will allow 1/4 in. deflection on the belt midway between the pulleys, when pressed firmly with thumb. 5 § % Figure 45 1.Fan Belt 2.
HYDRAULIC MAINTENANCE A\ caution Before servicing or making adjustments to the machine, stop engine and remove key from the switch. CHANGING HYDRAULIC FLUID (Fig. 46) Change hydraulic fluid after every 800 operating hours, in normal conditions. If fluid becomes contaminated, contact your local TOR distributor because the stern must be flushed. Contaminated fluid looks milky or black when compared 1o clean oil. 1. Tum engine off and raise hood. 2.
HYDRAULIC MAINTENANCE HYDRAULIC SYSTEM TEST PORTS (Fig. 48-50) The test ports are used to test pressure in the hydraulic circuits. Contact your local Toto distributor for assistance, 1. Test Port #1 (Fig. 48} is used to assist in trouble shooting the hydraulic circuit for the front cutting units and fight cylinders. Figure 48 1. Test Port #1 2. Test Port #2 (Fig. 49) is used to assist in trouble shooting the hydraulic circuit for the rear cutting units. Figure 49 1. Test Port #2 3.
HYDRAULIC MAINTENANCE ADJUSTING CUTTING UNIT LIFT RATE 2. Loosen setscrew on valve. Rotate valve clockwise (Fig. 52) to slow down drop rate of front outside cutting units. The cutting unit fight circuit is equipped with a adjustable 3. Verify lift rate adjustment by raising and lowering valve to ensure the front cutting units raise and lower cutting units several times. Readjust as required. evenly. Adjust cutting units as follows: 4. After desired lift rate is attained, tighten set screw 1.
ADMIRE 266 ONY Wl 0057 1Y GROVELLING elvish MO 21088 T 1481392 7400.
BRAKE MAINTENANCE ADJUSTING SERVICE BRAKES (Fig. 53) Adjust. the. service brakes..when. there. is. more. than. inch of “free travel” of the brake pedal, or when the brakes do not quark effectively. Free travel is the distance the brake pedal moves before braking resistance is felt, 1. Disengage locking pin from brake pedals so both pedals work independently of each other. 2.
AXLE MAINTENANCE A\ caution Before servicing or making adjustments to the machine, stop engine and remove key from the switch, CHANGING PLANETARY GEAR DRIVE OIL (Fig. 54) Change ol initially after 200 hours operation and every 800 hours, or yearly. Use high quality SAE wi. gear lube as replacement. 1. With machine on level surface, position wheel so the brainchildren plug is at lowest position. 2. Place drain pan under hub, remove plug and allow oil to drain. Figure 54 1. Drain/Check Plug 3.
AXLE MAINTENANCE REAR WHEEL TOE-IN (Fig. 57) After every 800 operating hours or annually, check rear wheel toe~in. 1. Measure distance (at axle height} at front and rear of steering tires. Front measurement must be 1/4 in. less than rear measurement. 2. To adjust, loosen clamps at both ends of tie rods. 3. Rotate tie rod to move front of tire inward or outward, Figure 57 4. Tighten tie rod clamps when adjustment is correct. 1.
ELECTRICAL MAINTENANCE BATTERY CARE IMPORTANT: Before welding on the machine, disconnect both cables from the battery, disconnect both wire harness plugs from the electronic control unit and the terminal connector from the alternator to prevent damage to the electrical system. A\ rumination Wear safely goggles and rubber gloves when working with electrolyte, Charge the battery in a well ventilated so gases produced while charging can dissipate.
CUTTING UNIT MAINTENANCE BACKSLAPPING A DANGER REELS MAY STALL WHILE BACKSLAPPING. DO NOT ATTEMPT TO RESTART REELS BY HAND OR TOUCH REELS WHILE BACKSLAPPING. STOP ENGINE AND TURN H.0.C. KNOB ONE POSITION TOWARD "A". Note: When backslapping, the front units all operate together, and the rear units operate together. 1. Position the machine on a level surface, lower the cutting units, stop the engine, engage the parking brake, and move the Enable/Disable switch to disable position. 2.
PREPARATION FOR SEASONAL STORAGE Traction Unit 1. Thoroughly clean the traction unit, cutting units and the engine. 2. Check the tire pressure. Inflate all tires to 15-20 psi, 3. Check all fasteners for looseness; tighten as necessary. 4. Grease or ol all grease fittings and pivot points, Wipe up any excess lubricant. 5. Lightly sand and use touch—up paint on painted ragas that are scratched, chipped, or rusted. Repair any dents in the metal body. 6. Device the battery and cables as follows: a.
The Toto Promise i A One Year Limited Warranty . The Toto Company promises to repair your TOR product if defective in materials or workmanship, The following time periods from the date of purchase apply: Commercial Products The cost of parts, labor and transportation are included. yourself feel your TOR Product is defective and wish to Some states do not allow limitations on how long rely on The Toto Promise, the following procedure is an implied warranty lasts, so the above limitation recommended: 1.