Form No. 3358-628 Rev A Reelmaster® 6500-D and 6700-D Traction Unit Model No. 03806—Serial No. 270000001 and Up Model No. 03807—Serial No. 270000001 and Up Model No. 03808—Serial No. 270000001 and Up Register at www.Toro.com.
Warning Model No. CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Serial No. This manual identifies potential hazards and has safety messages identified by the safety alert symbol (Figure 2), which signals a hazard that may cause serious injury or death if you do not follow the recommended precautions.
Contents Replacing the Fuel Pre-Filter............................... 39 Bleeding Air From Injectors ............................... 40 Electrical System Maintenance................................ 41 Battery Care ....................................................... 41 Fuses.................................................................. 41 Optional Lighting............................................... 42 Drive System Maintenance .....................................
Safety • Inspect the area where the equipment is to be used and remove all objects such as rocks, toys and wire which can be thrown by the machine. This machine meets or exceeds CEN standard EN 836:1997, ISO standard 5395:1990, and ANSI B71.4-1999 specifications in effect at the time of production when, ballast is added; refer to Adding Rear Ballast in Setup , page 12. • Use extra care when handling diesel fuel. It is flammable and vapors are explosive. Use only an approved container.
This product is capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death. • Slow down and use caution when making turns and crossing roads and sidewalks. Stop reels if not mowing. • Do not operate the mower under the influence of alcohol or drugs. • Use care when loading or unloading the machine into a trailer or truck. • Use care when approaching blind corners, shrubs, trees, or other objects that may obscure vision.
This unit does not exceed a vibration level of .5 m/s² at the posterior based on measurements of identical machines per EN 1032 procedures. • When a person or pet appears unexpectedly in or near the mowing area, stop mowing. Careless operation, combined with terrain angles, ricochets, or improperly positioned guards can lead to thrown object injuries. Do not resume mowing until the area is cleared. • Do not park on slopes unless the wheels are chocked or blocked.
Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. 93-6686 1. Hydraulic oil 2. Read the Operator’s Manual. 104-5229 1. Read the Operator’s Manual. 2. Fuse for starter 3. Fuse for headlights (optional) 93-6699 1. Machine speed 2. Slow 105-7506 1. Read the Operator’s Manual. 2. Engine—stop 3. On 3. Continuous variable setting 4. Fast 1 2 4. Engine—preheat 5.
93-6687 1. Do not step here. 104-9298 1. Read the Operator’s Manual. 93-6689 1. Warning—do not carry passengers. 93-6681 1. Cutting/dismemberment—hazard, fan-stay away from moving parts.. 93-1263 93-1263 1. Read the Operator’s Manual. 2. To engage the parking brake, connect the brake pedals with the locking pin, push down on both pedals, and pull the brake latch out. 3. To release the parking brake, press both pedals until the parking brake latch retracts. 4. Danger—reels enabled. 93-1265 1.
67-7960 106-6754 1. Warning—do not touch the hot surface. 2. Cutting/dismemberment hazard, fan and entanglement hazard, belt—stay away from moving parts. 105-0123 Model 03807 1. 2. 3. 4. 5. 6. Throttle—slow Throttle—fast Reels raised and off Reels lowered and on when enabled—forward and backlap Reels—enabled Reels disabled—lift only 7. 8. 9. 10. 11. Reels disabled—lift and lower Headlights (optional) Headlights—On Headlights—Off Read the Operators Manual. 104-9296 Models 03806 and 03807 1.
4-9294 1. Read the Operator’s Manual. 3. Warning—Read the Operator’s Manual. 2. Do not tow the machine. 4. Cutting hazard of hand or foot—stay away from moving parts. 5. Warning—keep bystanders 7. Warning—use a rollover a safe distance from the protection system and wear machine. the seat belt. 6. Warning—lock the parking 8. Tipping hazard—lower the brake, stop the engine, and cutting unit when driving remove the ignition key down slopes. before leaving the machine.
2-6555 Models 03806 and 03807 Part no. 112–6556 for Model 03808 1. Reel—height of cut 2. Reel—mow and backlap 3. Read the Operator’s Manual. 4. Machine speed 5. Rear reels circuit controls 6. Front reels circuit controls Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 2. No fire, open flame, or smoking. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 5. Read the Operator’s Manual. 6. Keep bystanders a safe distance from the battery. 7.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure 1 2 3 4 5 6 7 Description Use Qty.
2 Installing Cutting Units Models 03860, 03861 and 03862 3 Parts needed for this procedure: 14/10 2 Figure 4 Large O-ring 1. Bearing housing 2. Large o-ring 7/5 Counter weight 7/5 Steering locking pin Cutting unit models 03860, 03861, and 03862 can be installed at any of the mounting locations on the traction unit. Figure 3 shows the orientation of the hydraulic drive motor for each of the locations.
10. If removed, insert the vertical shaft of the pivot knuckle into lift arm pivot hub (Figure 5). Guide the pivot knuckle in place between the two rubber centering bumpers in the under side of the lift arm steering plate. 11. Insert the lynch pin into the cross hole on the pivot knuckle shaft (Figure 5). 12. Remove nut securing turf compensation spring mounting bracket to cutting unit stabilizer ear (Figure 6). Insert tipper chain onto capscrew and secure with nut removed.
Mount the Lift Brackets and Chains 3 Mount a chain bracket to each lift arm with a U-bolt and 2 nuts. Position the brackets as follows: 1. On lift arms #1, #4 and #5, position the chain brackets and U-bolts 15 inches behind the center line of the pivot knuckle (Figure 10). On lift arms #1 and #5 the brackets should be rotated to the right 10 degrees from vertical (Figure 10). On lift arm #4 the bracket should be rotated to the left 10 degrees from vertical (Figure 10).
3. On lift arms #6 and #7, position the brackets and U-bolts 14.5 inches behind the center line of the pivot knuckle (Figure 12). Rotate the brackets 10 degrees to the outboard side of the machine. Figure 14 1. Rear shield 2. Cap screw Figure 12 Mount the Counter Weights 4. Tighten all the U-bolt nuts to 38–48 ft-lbs. All cutting units are shipped with the counter weight mounted to the left end of the cutting unit.
Figure 18 1. Carrier frame 2. Pivot knuckle 3. Lift arm steering plate Figure 16 4. Lynch pin 5. Steering locking pin 2. Insert the horizontal shaft of the pivot knuckle into the mounting tube of the carrier frame (Figure 18). 1. Counter weight 2. On right end of cutting unit, remove the plastic plug from the bearing housing (Figure 17). 3. Secure pivot knuckle to carrier frame with a thrust washer, flat washer and a flange head capscrew (Figure 18). 3.
Adjust the Turf Compensation Spring Tractors are setup at the factory appropriately for most fairway mowing applications. The following adjustments are available for fine-tuning of the machine to the application: The Turf Compensation Spring (Figure 21) transfers weight from the front to rear roller. This helps to reduce a wave pattern in the turf, also known as bobbing. Important: Make spring adjustments with cutting unit mounted to traction unit and lowered to shop floor. Figure 19 1. Lift chain 1.
4 6 Making Alternate Cutting Unit Adjustments Installing CE Decals Parts needed for this procedure: No Parts Required Procedure The factory sets the tractor appropriately for most fairway mowing applications.
Product Overview Figure 22 1. Steering wheel 3. Cutting unit 5. Manual tube 2. Brake pedals 4. Traction pedal 6. Hood 7. Roll over protection system (ROPS) Controls Traction Pedal The traction pedal (Figure 23) 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.
Forward Speed Limiter Lower Mow/Raise Control Lever (Joystick) Preset the forward speed limiter (Figure 23) to limit the amount the traction pedal can be depressed in the forward direction to maintain a constant mowing speed. The lever (Figure 24 and Figure 25) raises and lowers the cutting units and also starts and stops the reels. Red Diagnostic Light The red diagnostic light (Figure 23), located on steering tower, is used to convey several different messages.
Enable/Disable Switches The enable/disable switches (Figure 24 and Figure 25) are used in conjunction with the lower mow/raise control lever (Joystick) to operate reels. Reels can be raised but not lowered when in mid position. Hour Meter The hour meter (Figure 26) shows total hours that machine has been operated. Figure 25 Models 03806 and 03807 1. Lower mow/raise control lever 2. Fuel gauge 3. Engine coolant temperature gauge 4. Engine oil pressure warning light 5.
Green Diagnostic Light The machine is equipped with a diagnostic light which indicates if the electronic controller is functioning correctly. The green diagnostic light (Figure 29) is located under the control panel, next to the fuse block. When the electronic controller is functioning correctly and the key switch is moved to the ON position, the controller diagnostic light will be illuminated. The light will blink if the controller detects a malfunction in the electrical system.
Operation determines what function is required for various input switches (i.e. seat switch, key switch, etc.) and turns on the outputs to actuate solenoids or relays for the requested machine function. Note: Determine the left and right sides of the machine from the normal operating position. For the electronic controller to control the machine as desired, each of the input switches, output solenoids and relays must be connected and functioning properly.
If the engine has been running, pressurized hot coolant can escape and cause burns if the radiator cap is removed. Allow the engine to cool at least 15 minutes or until the radiator cap is cool enough to touch without burning hands. 1. Carefully remove radiator cap and expansion tank cap (Figure 33). 2. Check level of coolant in radiator and in expansion tank (Figure 33). Figure 31 1. Dipstick Radiator should be filled to the top of the filler neck and the expansion tank filled to the Full mark. 3.
Figure 35 1. Fuel tank cap 2. Fill tank to about one inch below top tank, not filler neck with No. 2 diesel fuel. Then install cap. Figure 34 1. Vent plug Checking the Hydraulic Fluid 4. Install radiator cap and expansion tank cap. Service Interval: Before each use or daily 5. Close hood and secure latch. The machines reservoir is filled at the factory with approximately 8.5 U.S. gallons (32 l) of high quality hydraulic fluid.
Checking the Reel to Bedknife Contact Biodegradable Hydraulic Fluid - Mobil 224H Toro Biodegradable Hydraulic Fluid (Available in 5 gallon pails or 55 gallon drums. See parts catalog or Toro distributor for part numbers.) Alternate fluid: Mobil EAL 224H Service Interval: Before each use or daily Note: This is vegetable-oil based biodegradable oil tested and approved by Toro for this model.
Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive. A fire or explosion from fuel can burn you and others and can cause property damage. • Use a funnel and fill the fuel tank outdoors, in an open area, when the engine is off and is cold. Wipe up any fuel that spills. • Do not fill the fuel tank completely full. Add fuel to the fuel tank until the level is 1 in. (25 mm) below the bottom of the filler neck. This empty space in the tank allows the fuel to expand.
1 2. Open control panel cover. Locate wire harness and loopback connector. Carefully unplug loopback connector from harness connector (Figure 40). G000746 G000748 Figure 39 1 1. Bypass valve Figure 40 1. Loop-back connector 2. Close the bypass valve before starting the engine. However, do not exceed 5-8 ft.-lb. (7-11 N·m) torque to close the valve. 3. Connect the Diagnostic ACE display connector to the harness connector (Figure 41).
pedal, etc.), and note that the appropriate LED on Diagnostic ACE will blink on and off when corresponding switch is closed. Repeat on each switch that is possible to be changed by hand. 7. If switch is closed and appropriate LED does not turn on, check all wiring and connections to switch and/or check switches with an ohm meter. Replace any damaged switches and repair any damaged wiring.
the 8th record. Each record will be displayed for 10 seconds. Be sure to have the Diagnostic Tool display on Outputs to see fault. The Problem circuit will be flashing. Records will repeat until key is turned off. Unit will not start in this mode. Solenoid Clearing the Fault Memory (Diagnostic Tool not required) Operating Tips Left rear wing cutting unit SV 7 Right rear wing cutting unit Load Holding Familiarization Before mowing grass, practice operating machine in an open area.
continuing operation. Serious damage could occur if the machine is operated with a malfunction. Important: The Red Diagnostic Light , on the steering tower, indicates when the glow plugs are On. The machine should not be started until the glow plug cycle is complete. Mowing Start engine and move throttle to FAST so engine is running at maximum speed.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 8 hours • Check the torque of the wheel nuts or bolts (after the first 1–4 hours of operation and then after 10 hours of operation). After the first 50 hours • Change the engine oil and oil filter. After the first 200 hours • Change the planetary gear drive oil. • Change the rear axle lubricant.
If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the ignition and disconnect the wire from the spark plug before you do any maintenance. Set the wire aside so that it does not accidentally contact the spark plug. Service Interval Chart Figure 42 Daily Maintenance Checklist Duplicate this page for routine use. Maintenance Check Item For the week of: Mon. Tues. Check safety interlock operation.
Maintenance Check Item For the week of: Mon. Check the hydraulic filter Tues. Wed. Thurs. Fri. Sat. Sun. indicator.2 Check the hydraulic hoses for damage. Check for fluid leaks. Check the tire pressure. Check instrument operation. Check the reel-to-bedknife adjustment. Check the height-of-cut adjustment. Lubricate all grease fittings.3 Touch up damaged paint. 1. Check the glow plug and injector nozzles if hard starting, excess smoke, or rough running is noted. 2.
• Rear axle pivot (Figure 49) G000753 Figure 45 Figure 49 • Rear lift arm pivots (2) (Figure 50) Figure 46 • Rear lift cylinder pivot (2) (Figure 47) Figure 50 G000754 • Brake pedal shaft (1) (Figure 51) G000760 Figure 47 • Lift arm pivot (3) (Figure 48) Figure 51 Figure 48 36
Engine Maintenance which could force dirt through the filter into the intake tract. Servicing the Air Cleaner This cleaning process prevents debris from migrating into the intake when the primary filter is removed. Service Interval: Every 400 hours 3. Remove and replace the primary filter (Figure 54). Check the air cleaner body for damage which could cause an air leak. Replace if damaged. Check the whole intake system for leaks, damage or loose hose clamps.
5. Install the cover orienting the rubber outlet valve in a downward position—between approximately 5:00 to 7:00 when viewed from the end. 6. Reset the indicator (Figure 52) if it shows red. 2. Loosen the throttle cable connector on the lever arm at the injection pump (Figure 58). Servicing the Engine Oil and Filter Service Interval: After the first 50 hours Every 150 hours Change oil and filter initially after the first 50 hours of operation, thereafter change oil and filter every 150 hours. 1.
Fuel System Maintenance Check lines and connections every 400 hours or yearly, whichever comes first. Inspect for deterioration, damage, or loose connections. Fuel Filter/Water Separator Fuel Tank Service Interval: Before each use or daily Every 400 hours Service Interval: Every 2 years Drain and clean fuel tank every 2 years. 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.
Note: Do not use water to clean engine, as damage may occur. them with the hose clamps. Be sure that the arrow on the side of the filter points toward the injection pump. Figure 61 1. Fuel pre-filter Note: Bleeding fuel system is required after replacing the fuel filter/water separator filter or the fuel filter.
Electrical System Maintenance Note: Check battery condition weekly or after every 50 hours of operation. Keep terminals and entire battery case clean because a dirty battery will discharge slowly. To clean the battery, wash the entire case with solution of baking soda and water. Rinse with clear water. Coat the battery posts and cable connectors with Grafo 112X (skin-over) grease (Toro Part No. 505-47) or petroleum jelly to prevent corrosion.
prevent damage to the traction units electrical system. Installation Instructions 4 1. Install a relay into the open connector under console. 2. Install light switch. Note: Punch out in control panel provided for switch installation. G000775 3. Crimp a ring or fork terminal onto each of the orange wires (J 24 & J 25) under console. Secure them to light switch terminals #2 & #3. Figure 64 4. Splice power (+) wires from lights to red wire at J 23. Optional Lighting 5.
Drive System Maintenance Checking the Torque of the Wheel Nuts or Bolts Service Interval: After the first 8 hours Every 200 hours Figure 67 1. Brake housing Failure to maintain proper torque of the wheel nuts could result in personal injury. 2. Check plug location 3. Add gear oil to the hole in the planetary, if necessary, to bring the oil up to the proper level. Install the plug. 4. Repeat steps 1 through3 on the opposite gear assembly. Torque the front wheel nuts and rear wheel bolts to 85-100 ft.-lb.
2 1 G000743 Figure 70 2. Fill plug 1. Check plug Figure 69 1. Drain plug location 2. Check plug location Changing the Rear Axle Lubricant 4. When all of the oil has drained, install the bottom plug in the brake housing. Service Interval: After the first 200 hours 5. Position the wheel so that the plug hole is at the ten or two o’clock position on the planetary. Every 800 hours Change the oil initially after the first 200 hours of operation and every 800 hours of operation thereafter. 6.
Rear Wheel Toe-In Note: On 4 wheel drive models, left rear tire must also be off the shop floor. Service Interval: Every 800 hours 3. Start engine and allow run at low idle. After every 800 operating hours or annually, check the rear wheel toe-in. 4. Adjust jam nuts on pump rod end to move pump control tube forward to eliminate forward creep or rearward to eliminate rearward creep (Figure 73). 1. Measure the center-to-center distance (at axle height) at the front and rear of the steering tires.
Cooling System Maintenance Removing Debris Service Interval: Before each use or daily Remove debris from rear screen, oil cooler and radiator daily, clean more frequently in dirty conditions. Important: Never spray water onto a hot engine as damage to engine may occur. Figure 75 1. Oil cooler 1. Turn engine off, release hood latch and raise hood. Clean engine area thoroughly of all debris. Close hood. 2. Radiator Maintaining the Cooling System 2. Unlatch and remove rear screen (Figure 74).
Brake Maintenance Belt Maintenance Adjusting the Service Brakes Checking the Alternator Belt 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. Service Interval: Every 100 hours Check condition and tension of alternator belt after every 100 hours of operation (Figure 77). Replace belt as required. Check the tension as follows: 1.
Hydraulic System Maintenance 1. Position machine on a level surface, lower the cutting units, stop the engine, engage the parking brakes and remove key from ignition switch. Changing the Hydraulic Fluid 2. Clean area around filter mounting area. Place drain pan under filter and remove filter (Figure 79). Service Interval: Every 800 hours Change hydraulic fluid after every 800 operating hours, in normal conditions.
Hydraulic fluid escaping under pressure can penetrate skin and cause injury. • Make sure all hydraulic fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to the hydraulic system. • Keep your body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid. • Use cardboard or paper to find hydraulic leaks.
Cutting Unit Maintenance Cutting Unit Kickstand Models 03863 and 03864 Whenever the cutting unit has to be tipped to expose the bedknife/reel, prop up the rear of the cutting unit with the kickstand (supplied with the traction unit) to make sure the nuts on the back end of the bedbar adjusting screws are not resting on the work surface (Figure 84). Figure 83 1. Test port D (Charge pressure) 2. Test port E (Traction forward pressure) 3. Test port F (Traction reverse pressure) 4.
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. 7. Move Enable/Disable switch to Enable position. Move Lower Mow/Lift control forward to start backlapping operation on designated reels. 8. Apply lapping compound with a long handle brush (Toro Part No. 29-9100). Never use a short handled brush (Figure 86). 2. Unlock and raise the seat to expose controls. 3.
Figure 88 Model 03808 1. Adjustment valve for front center cutting unit 2. Adjustment valve for front outside cutting units 3. Adjustment valves for wing cutting units Figure 87 12. Repeat procedure for all cutting units to be backlapped. When backlap operation has been completed, return the backlap knobs to the forward flow position, lower seat and wash all lapping compound off cutting units. Adjust cutting unit reel to bedknife as needed. Figure 89 Models 03806 and 03807 1.
Figure 90 1. Adjustment valve for rear cutting unit Figure 91 2. Locking pin 1. Lift arm switch 2. Carriage bolt nut 6. Loosen locking ring securing knob (Figure 90). 7. Rotate valve clockwise to slow down drop rate of rear cutting units. 8. Verify the lift rate adjustment by raising and lowering cutting units several times. Readjust as required. Tighten locking ring securing adjustment. 3. Lift arm flag • Move the lift switch bracket up in the slot to the desired position.
Figure 92 1.
Storage 9. Seal the air cleaner inlet and the exhaust outlet with weatherproof tape. Traction Unit 10. Check anti freeze protection and add a 50/50 solution of water and anti freeze as needed for expected minimum temperature in your area. 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 oil all grease fittings and pivot points.
Schematics Electrical Schematic (Rev.
G000801 Hydraulic Schematic, Model 03806 (Rev.
G000802 Hydraulic Schematic, Model 03807 (Rev.
P G000800 Hydraulic Schematic, Model 03808 (Rev.
The Toro General Commercial Products Warranty A Two-Year Limited Warranty Conditions and Products Covered The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your Toro Commercial Product (“Product”) to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first.
