Form No. 3328–629 Rev A Reelmaster 6500-D 2 and 4 Wheel Drive Traction Unit Model No. 03806—230000001 and Up Model No.
Warning Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting and Stopping . . . . . . . . . . . . . . . . . . . . . . Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . Red Diagnostic Light . . . . . . . . . . . . . . . . . . . . . . Pushing or Towing the Machine . . . . . . . . . . . . . . Green Diagnostic Light . . . . . . . . . . . . . . . . . . . . Diagnostic ACE Display (Optional) . .
This manual uses two other words to highlight information. Important calls attention to special mechanical information and Note: emphasizes general information worthy of special attention. Introduction Read this manual carefully to learn how to operate and maintain your product properly. The information in this manual can help you and others avoid injury and product damage. Although Toro designs and produces safe products, you are responsible for operating the product properly and safely.
• the type of machine is unsuitable for its task; • Do not use on slopes of more than • lack of awareness of the effect of ground conditions, especially slopes; – 5° when mowing on side hills; – 10° when mowing uphill; • incorrect hitching and load distribution. – 15° when mowing downhill. • The owner/user can prevent and is responsible for accidents or injuries occurring to himself or herself, other people, or property. • Remember there is no such thing as a safe slope.
• Be careful during adjustment of the machine to prevent entrapment of the fingers between moving blades and fixed parts of the machine. • Disengage drive to attachments when transporting or not in use. • Stop the engine and disengage drive to attachment • On multi-cylinder/multi-reel machines, take care as rotating one cylinder/reel can cause other cylinders/reels to rotate.
• Do not operate the machine while wearing tennis shoes or sneakers. Maintenance and Storage • Make sure all hydraulic line connectors are tight and all hydraulic hoses and lines are in good condition before applying pressure to the system. • Wearing safety shoes and long pants is advisable and required by some local ordinances and insurance regulations. • Keep your body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure.
Safety and Instruction 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. 93-6693 1. Warning—crushing of fingers and hands. Stop the reels before proceeding. 93-7276 1. 2. 3. 4. Explosion hazard—wear eye protection. Caustic liquid hazard—flush with water and seek first aid. Fire hazard—no sparks, flame, or smoking Poison—keep children a safe distance from the battery. 93-6680 1.
93-9425 1. Danger—read the operator’s manual. 2. Hydraulic hoses are under pressure—stay away from moving parts. 93-6668 1. The battery contains lead. Do not throw it in the garbage. 104-9298 93-6696 1. Read the operator’s manual for further instructions. 1. Danger—spring loaded device. Read the operator’s manual for further instructions. 93-6687 1. Do not step on lift arms. 93-6689 1. Danger—do not carry riders. 93-1263 1. Read the operator’s manual for further instructions. 2.
105-0134 104-9296 1. Throttle—slow 2. Throttle—fast 3. Reels raised and off 4. Reels lowered and on when enabled—forward and backlap 5. Reels—enabled 6. Reels disabled—lift only 7. Reels disabled—lift and lower 8. Headlights (optional) 9 9. Headlights—on 10. Headlights—off 11. Read the operator’s manual for further instructions.
4-9294 1. Read the Operator’s Manual. 2. Do not tow the machine. 3. Warning—read the Operator’s Manual. 4. Cutting hazard of hand or foot—stay away from moving parts. 5. Warning—keep bystanders a safe distance from the machine. 6. Warning—lock the parking brake, stop the engine, and remove the ignition key before leaving the machine. 7. Warning—use a roll over protection system and wear the seat belt. 8. Tipping hazard—lower the cutting unit when driving down slopes.
105-7528 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.
Specifications Note: Specifications and design subject to change without notice. General Specifications Engine Main frame Kubota four cylinder, over head valve, liquid cooled, turbo diesel engine. 42.5 hp @ 3000 rpm. Governed to 3200 rpm. Heavy duty, 3-stage, remote mounted air cleaner. High water temperature shutdown switch. All welded formed steel frame, includes tie-down loops Cooling system Radiator capacity is approximately 10 qts. (9.4 l) of 50/50 mixture of ethylene glycol anti–freeze.
Measurements Width-of-cut Optional Equipment 96 in. Overall width Transport Operational Overall length 89 in. 5 Blade Cutting Unit (7 in.) Model No. 03860 7 Blade Cutting Unit (7 in.) Model No. 03861 11 Blade Cutting Unit (7 in.) Model No. 03862 110 in. Dethatching Cutting Unit Model No. 03872 120 in. Grass Basket Kit Model No. 03882 Rear Roller Brush Kit Model No. 03875 Height Without ROPS installed 60 in. Arm Rest Kit Model No. 30707 With ROPS installed 84 in.
Setup Note: Determine the left and right sides of the machine from the normal operating position. Note: Use this chart as a checklist to ensure that 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 the factory. Description Qty. Use Counterweight 5 Large o-ring 10 Mounting the counterweights and motors to the cutting units.
3. Lubricate and install a large O-ring into bearing housing groove on each end of cutting unit (Fig. 3 & 6). 8. Secure pivot knuckle to carrier frame with a thrust washer, flat washer and a flange head capscrew (Fig. 4). 9. Insert a thrust washer onto vertical shaft of pivot knuckle (Fig. 4). 10. If removed, insert the vertical shaft of the pivot knuckle into lift arm pivot hub (Fig. 4).
Alternate Adjustments Note: When cutting rough or undulating turf, increase compressed length (A) of spring to 8-1/2 in. (216 mm) and gap (C) between rear of spring bracket and front of washer to 1-1/2 in. (38 mm) (Fig. 7). Tractors are setup at the factory appropriately for most fairway mowing applications. Note: As compressed spring length (A) DECREASES, weight transfer from front roller to rear roller INCREASES and carrier frame/cutting unit rotation angle (B) DECREASES.
Rear Cutting Unit 1. Locate valve in front of rear axle for rear cutting units (Fig. 9). 2. Loosen locking ring securing knob (Fig. 9). 3 1 1 2 Figure 10 2 1. Lift arm switch 2. Carriage bolt nut 3. Lift arm flag • Move the lift switch bracket up in the slot to the desired position. Figure 9 1. Adjustment valve for rear cutting unit 2. Locking ring • Set the distance between the lift arm switch and the flag on the lift arm to approximately .062 inches. • Tighten carriage bolt nut. 3.
1 Figure 11 1. Carrier frame mounting bolts Rear Ballast The Reelmaster 6500–D Traction Units comply with the ANSI B71.4–1999 Standard when the following is installed on machine. • 100 lbs. of calcium chloride ballast is added to rear wheels. • Wheel weight kit (Part No. 104–1478) Important If a puncture occurs in a tire with calcium chloride, remove unit from turf area as quickly as possible. To prevent possible damage to turf, immediately soak affected area with water.
3. If oil level is low, remove filler cap and add SAE 10W30 CD, CE, CF, CF-4 or CG-4 oil until level reaches FULL mark on dipstick. Do not overfill. Before Operating Note: Determine the left and right sides of the machine from the normal operating position. 1 Checking the Engine Oil Crankcase capacity is 7.5 qt. (7 L) with filter. 1. Park machine on a level surface. Release hood latch and open hood (Fig. 12). Figure 14 1. Filler cap 4. Install filler cap. 1 5. Close hood and secure latch.
Filling the Fuel Tank Danger 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.
damage caused by improper substitutions, so use only products from reputable manufacturers who will stand behind their recommendation. 1 Multigrade Hydraulic Fluid – ISO VG 46 Normal Climate: 0 (–18 C) to 110 F (43 C) Mobil Amoco Chevron Conoco Exxon Pennzoil Shell Texaco DTE 15M Rykon Premium ISO 46 Rykon Premium Oil ISO 46 Hydroclear AW MV46 Univis N46 AWX MV46 Figure 18 Tellus T 46 1.
2 1 1 Figure 21 1. Check plug 2. Fill plug Figure 19 1. Check/drain plug Checking the Tire Pressure The tires are over-inflated for shipping. Therefore, release some of the air to reduce the pressure. Correct air pressure in the front and rear tires is 15–20 psi. Important Maintain even pressure in all tires to ensure a good quality-of-cut and proper machine performance. Do not under inflate.
Key Switch Operation The key switch (Fig. 22) has three positions: OFF, ON/Preheat and START. Note: Determine the left and right sides of the machine from the normal operating position. Speedometer Controls The speedometer (Fig. 22) indicates ground speed at which machine is traveling. Traction Pedal The traction pedal (Fig. 22) 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.
Glow Plug Indicator Light When the indicator light (Fig. 23) is lit, indicates glow plugs are on. 1 Charge Indicator The charge indicator (Fig. 23) illuminates when system charging circuit malfunctions. Enable/Disable Switch The enable/disable switch (Fig. 23) is used in conjunction with lower mow/raise control lever (Joystick) to operate reels. Reels can be raised but not lowered when in mid position. 8 Figure 24 1. Hour meter 1 2 Backlap Knobs The backlap knobs (Fig.
Seat Bleeding the Fuel System The seat adjusting lever (Fig. 26) allows 4 inch fore and aft adjustment. The seat adjusting knob (Fig. 26) adjusts seat for operators weight. To adjust seat fore and aft, pull lever on left side of seat assembly outward. After moving seat to desired location, release lever to lock seat into position. To adjust for operators weight, turn spring tension knob; clockwise to increase tension, counterclockwise to decrease spring tension. 1. Park the machine on a level surface.
1 1 Figure 29 1. Reel control light Figure 28 1. Fuel injection pump bleed screw Pushing or Towing the Machine In an emergency, the machine can be moved by actuating the bypass valve in the variable displacement hydraulic pump and pushing or towing the machine. 6. Turn key in ignition switch to the ON position. Electric fuel pump will begin operation, thereby forcing air out around air bleed screw. Leave key in ON position until a solid stream of fuel flows out around screw.
Green Diagnostic Light Diagnostic ACE Display (Optional) The machine is equipped with a diagnostic light which indicates if the electronic controller is functioning correctly. The green diagnostic light (Fig. 31) 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.
3. Connect the Diagnostic ACE display connector to the harness connector (Fig. 33). Make sure correct overlay decal is positioned on Diagnostic ACE display. 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.
If the output LEDs are on as specified, but the machine does not function properly, this indicates a non-electrical problem. Repair as necessary. 2. Turn Backlap Switch to the Front or Rear Backlap position. 3. Turn the Reel Control Switch to Enable position. Note: Due to electrical system constraints, the output LED’s for “START”, “PREHEAT” and “ETR/ALT” may not blink even though an electrical problem may exist for those functions.
Mowing Individual turning brakes may also be used to help maintain traction. For example, in some slope conditions, the uphill wheel slips and loses traction. If this situation occurs, depress uphill turn pedal gradually and intermittently until the uphill wheel stops slipping, thus, increasing traction on the downhill wheel. 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 Maintenance Service Interval Maintenance Procedure After first 10 hours • Check the fan and alternator belt tension. • Torque the wheel lug nuts. After first 50 hours • Change the engine oil and filter. • Check the engine RPM (idle and full throttle). After first 200 hours • Change the planetary gear oil • Change the 4 WD rear axle lubricant.
Caution 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. Daily Maintenance Checklist Duplicate this page for routine use. For the week of: Maintenance Check Item Mon. Tues. Wed. Thurs. Check safety interlock operation.
Lubrication 1 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. The grease fitting locations and quantities are: • Cutting unit carrier frame and pivot (2 ea.) (Fig. 34) • Rear axle tie rod (2)(Fig. 35) • Steering cylinder ball joints (2) (Fig. 35) • King pin bushings (2) (Fig. 35).
Figure 37 Figure 40 Figure 38 Figure 41 Figure 39 Figure 42 34
Service Interval Chart 35
Servicing the Air Cleaner Check air cleaner body for damage which could possibly cause an air leak. Replace a damaged air cleaner body. 1 Service the air cleaner filters whenever air cleaner indicator (Fig. 43) shows red or every 400 hours (more frequently in extreme dusty or dirty conditions). Do not over-service the air filter. 1 Figure 45 1. Air cleaner primary filter 3. Inspect primary filter and discard if damaged. Do not wash or reuse a damaged filter.
Fuel System 6. Insert new filter properly into air cleaner body. Make sure filter is sealed properly by applying pressure to outer rim of filter when installing. Do not press on flexible center of filter. Fuel Tank 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. 7. Reinstall cover and secure latches. Make sure cover is positioned with TOP side up. 8.
1. Locate fuel filter, under hood, and place a clean container under it. 3. Remove filter from bowl and replace with new filter. 4. Install filter bowl by hand until O-ring contacts mounting surface. 2. Loosen drain plug on bottom of filter canister. Tighten plug after draining. Note: Bleeding fuel system is required after replacing the fuel filter/water separator filter or the fuel filter.
1. After every 100 operating hours, inspect and tighten hose connections. Replace any deteriorated hoses. 2. After every 2 years, drain and flush the cooling system. Add anti-freeze (refer to Check Cooling System). Check Engine Belt Check condition and tension of alternator belt after every 100 hours of operation (Fig. 55). Replace belt as required. 1 Alternator Belt To Check Tension: Figure 53 1. Open hood. 1. Rear screen 2.
2. Loosen the throttle cable connector on the lever arm at the injection pump. 1 1 Figure 57 2 1. Hydraulic reservoir 3. Fill reservoir with approximately 8.5 gallons of hydraulic fluid; refer to Checking the Hydraulic Fluid. Figure 56 1. Injection pump lever arm 2. Connector Important Use only hydraulic fluids specified. Other fluids could cause system damage. 3. Hold the injection pump lever arm against the high idle stop and tighten the cable connector. 4. Install reservoir cap.
Hydraulic System Test Ports The test ports are used to test pressure in the hydraulic circuits. Contact your local Toro distributor for assistance. 1. Test Port “A” (Fig. 59) is used to assist in trouble shooting the hydraulic circuit for the lift cylinders. 1 2 Figure 58 1. Hydraulic filter 2. Service interval indicator 3. Lubricate new filter gasket and fill the filter with hydraulic fluid. 4. Ensure that the filter mounting area is clean. Screw filter on until gasket contacts mounting plate.
Adjusting the Traction Drive for Neutral 5. Test Port “E” is used to measure traction forward pressure (Fig. 61). 6. Test Port “F” is used to measure traction reverse pressure (Fig. 61). The machine must not creep when traction pedal is released. If it does creep, an adjustment is required. 7. Test Port “G” is used to measure steering circuit pressure (Fig. 61). 1. Park machine on a level surface, shut engine off and lower cutting units to the floor.
Hydraulic Schematic—2 Wheel Drive 43 Sheet No.
Hydraulic Schematic—4 Wheel Drive 44 Sheet No.
Adjusting the Service Brakes 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 by loosening the front nut on the threaded end of the brake cable (Fig. 63).
Changing the Rear Axle Lubricant Battery Care Warning Change the oil initially after the first 200 hours of operation and every 800 hours of operation thereafter. CALIFORNIA 1. Position the machine on a level surface. Proposition 65 Warning 2. Clean the area around the 3 drain plugs, 1 on each end and 1 in the center (Fig. 66). Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm.
Optional Lighting Danger Important If optional lighting is be added to the traction unit, use the schematic in Figure 69 and part numbers listed below to prevent damage to the traction units electrical system. Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns. • Do not drink electrolyte and avoid contact with skin, eyes or clothing. Wear safety glasses to shield your eyes and rubber gloves to protect your hands.
Electrical Schematic 48 Sheet No.
Backlapping 4. Make initial reel to bedknife adjustments appropriate for backlapping on all cutting units which are to be backlapped. Danger 5. Start engine and run at idle speed. The reels may stall while backlapping and could restart suddenly. Contact with the reels during backlapping will cause personal injury. Caution Contact with the reels or other moving parts can result in personal injury. • Never place hands or feet in the reel area while the engine is running.
Figure 72 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. Note: If the backlap knobs are not returned to the forward flow position after backlapping, the cutting units will not raise or function properly.
Engine Storage 1. Drain the engine oil from the oil pan and replace the drain plug. Traction Unit 2. Remove and discard the oil filter. Install a new oil filter. 1. Thoroughly clean the traction unit, cutting units and the engine. 3. Refill oil pan with 7.5 qts. (7 l) of SAE10W-30 CD, CE, CF, CF-4, or CG-4 motor oil. 2. Check the tire pressure. Inflate all tires to 15–20 psi. 3. Check all fasteners for looseness; tighten as necessary. 4.
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 1996 or newer Toro Commercial Product (“Product”) purchased after January 1, 1997, to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first.
