Form No. 3375-301 Rev C Reelmaster® 6500-D and 6700-D Traction Unit Model No. 03806—Serial No. 313000001 and Up Model No. 03807—Serial No. 313000001 and Up Model No. 03808—Serial No. 313000001 and Up Model No. 03812—Serial No. 313000001 and Up Model No. 03813—Serial No. 313000001 and Up To register your product or download an Operator's Manual or Parts Catalog at no charge, go to www.Toro.com.
This product complies with all relevant European directives, for details please see the separate product specific Declaration of Conformity (DOC) sheet. WARNING 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. Figure 1 Important: This engine is not equipped with a spark arrester muffler.
Contents Fuel Lines and Connections................................ 42 Fuel Filter/Water Separator ................................ 42 Bleeding Air From Injectors ............................... 43 Electrical System Maintenance................................ 43 Battery Care ....................................................... 43 Fuses.................................................................. 44 Optional Lighting............................................... 44 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 B71.4-2004 specifications in effect at the time of production when ballast is added; refer to Adding Rear Ballast in Set Up section. • Use extra care when handling diesel fuel. It is flammable and vapors are explosive. Use only an approved container.
Toro Mower Safety • Slow down and use caution when making turns and crossing roads and sidewalks. Stop reels if not mowing. The following list contains safety information specific to Toro products or other safety information that you must know that is not included in the ANSI standards. • Do not operate the mower under the influence of alcohol or drugs. This product is capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death.
Sound Power Level or death. Always use the seat belt and Roll Over Protection System (ROPS) together. Reelmaster 6500 • If the engine stalls or loses headway and cannot make it to the top of a slope, do not turn the machine around. Always back slowly, straight down the slope. This unit has a guaranteed sound power level of 101 dBA, which includes an Uncertainty Value (K) of 1 dBA. • When a person or pet appears unexpectedly in or near the mowing area, stop mowing.
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. 105-7506 1. Read the Operator's Manual. 2. Engine—stop 93-6699 4. Engine—preheat 5. Engine—start 1. Machine speed 3. Continuous variable setting 2. Slow 4. Fast 3. On 1 2 93-6693 93-9425 1. Crushing hazard of hand—wait for moving parts to stop. 1. Read the Operator's Manual. 2.
93–6689 1. Danger—do not sit on the plastic shroud. 93–6681 1. Cutting/dismemberment hazard—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. 115-2047 4. Danger—reels enabled. 1. Warning—do not touch the hot surface. 104-9298 1.
105-0123 Model 03808 and 03813 1. Throttle—slow 2. Throttle—fast 7. Reels disabled—lift and lower 8. Headlights (optional) 3. Reels raised and off 9. Headlights—On 4. Reels lowered and on when enabled—forward and backlap 10. Headlights—Off 5. Reels—enabled 11. Read the Operators Manual. 6. Reels disabled—lift only 104-9296 Models 03806, 03807 and 03812 1. Throttle—slow 4. Reels lowered and on when 7. Reels disabled—lift and enabled—forward and lower backlap 10. Headlights—Off 2.
117–2718 106-6755 1. Engine coolant under pressure. 3. Warning—do not touch the hot surface. 2. Explosion hazard—read the Operator's Manual. 4. Warning—read the Operator's Manual. 115-2045 1. Warning—read the Operator's Manual. 2. Cutting hazard of hand or foot—stay away from moving parts; keep all guards in place. 3. Warning—do not operate this machine unless you are trained. 4. Tipping hazard—lower the cutting unit when driving down slopes; slow machine before turning, do not turn at high speeds. 5.
5-2046 (Affix over part no. 115–2045 for CE*) * This safety decal includes a slope warning required on the machine for compliance to the European Lawn Mower Safety Standard EN836:1997. The conservative maximum slope angles indicated for operation of this machine are prescribed by and required by this standard. 1. Warning—read the Operator's Manual. 2. Cutting hazard of hand or foot—stay away from moving parts; keep all guards in place. 3. Warning—do not operate this machine unless you are trained. 4.
93-6668 1. Read the Operator's Manual for information on charging the battery; contains lead; do not discard. 115-2049 Models 03806, 03807 and 03812 4. Machine speed 1. Reel—height of cut 2. Reel—mow and backlap 5. Rear reels circuit controls 3. Read the Operator's Manual. 6. Front reels circuit controls 115-8000 Model 03808 and 03813 106-6754 1. Reel—height of cut 4. Machine speed 1. Warning—do not touch the hot surface. 2. Reel—mow and backlap 5. Rear reels circuit controls 2.
Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 6. Keep bystanders a safe distance from the battery. 2. No fire, open flame, or smoking. 7. Wear eye protection; explosive gases can cause blindness and other injuries 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 8. Battery acid can cause blindness or severe burns. 9. Flush eyes immediately with water and get medical help fast. 5. Read the Operator's Manual. 10. Contains lead; do not discard.
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 Parts needed for this procedure: Figure 4 14/10 Large O-ring 1. Bearing housing 7/5 Counter weight 7/5 Steering locking pin 3. Counterweight 2. Large o-ring Note: Before installing cutting unit motors or counterweights, lubricate internal splines of cutting unit reel shafts with grease. 4. Install a counter weight onto appropriate end of each cutting unit with capscrews provided (Figure 4). 5.
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.
knuckle (Figure 10). Rotate the brackets 45 degrees to the outboard side of the machine. 3 Installing Cutting Units Models 03863 and 03864 Parts needed for this procedure: 5/7 Lift chain 5/7 Chain bracket 5/7 U-bolt 10/14 Nut 5/7 Screw 5/7 Washer 5/7 Nut 5/7 Large O-ring Figure 10 Mount the Lift Brackets and Chains 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 11).
Mount the Counter Weights All cutting units are shipped with the counter weight mounted to the left end of the cutting unit. Use the following diagram to determine the position of the counter weights and reel motors. Figure 12 1. Lift chain 2. Chain bracket Figure 14 Adjust the Rear Shield 1. On the #2, #4 and #6 cutting units, remove the 2 cap screws securing the counter weight to the left end of the cutting unit. Remove the counter weight (Figure 15).
the pivot knuckle in place between the two rubber centering bumpers in the under side of the lift arm steering plate. 6. Insert the lynch pin into the cross hole on the pivot knuckle shaft (Figure 17). 7. Secure the lift arm chain to the cutting unit chain bracket (Figure 18) with the snapper pin as follows: 1 A. On cutting units #1, 4, 5, 6 and 7, only use 6 of the chain links. G003321 B. On cutting units #2 and 3, use all 7 of the chain links. 2 Figure 16 1. Plastic plug 2. Cap screw (2) 4.
Figure 20 2. Tighten hex nuts on front end of spring rod until the compressed length (A) of spring is 6.25in. (159 mm) (Figure 20). Figure 19 1. Reel drive motor 2. Capscrew Note: When operating on rough terrain, decrease the spring length by 1/2 inch. Ground following will be slightly decreased. Note: If fixed cutting unit position is required, insert steering locking pin into pivot knuckle mounting hole (Figure 17).
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 • The machine is being operated faster than the maximum speed value initially programmed into the ECU. • An electrical malfunction has been detected (open or shorted output. • A hydraulic leak has been detected (Only if Turfdefender leak detector is installed on machine) • A communications error has been detected (Only if Turfdefender leak detector is installed on machine) Controls Traction Pedal The traction pedal (Figure 21) controls forward and reverse operation.
3 2 4 5 6 7 8 1 2 3 4 5 9 10 6 11 7 8 1 G019448 Figure 22 Model 03808 and 03813 9 G019449 1. Throttle control 7. Glow plug indicator light 2. Lower mow/raise control lever 8. Engine coolant temperature gauge 3. Fuel gauge 9. Enable/disable switch (#7) right rear 4. Charge indicator 10. Enable/disable switch (Master) 5. Engine oil pressure warning light 11. Enable/disable switch (#6) left rear Figure 23 Models 03806, 03807 and 03812 6. Engine coolant temperature warning light 1.
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 G019525 Figure 24 1 1.
1 The Diagnostic ACE display is a tool to help the user verify correct electrical functions of the machine. Specifications Note: Specifications and design are subject to change without notice. Width-of-cut, model 03806, 03807 and 03812 Width-of-cut, model 03808 and 03813 Overall width, Transport 96 inches (244 cm) 133 inches (338 cm) 89 inches (226 cm) Overall width, Operational 110 inches (279 cm) Overall length 120 inches (305 cm) G019452 Figure 27 Height With ROPS installed 1.
Operation 1 Note: Determine the left and right sides of the machine from the normal operating position. Checking the Engine Oil Service Interval: Before each use or daily The engine is shipped with oil in the crankcase; however, the oil level must be checked before and after the engine is first started. Crankcase capacity is approximately 7.5 qt. (7 l) with the filter. G019454 Figure 29 Use high-quality engine oil that meets the following specifications: 1.
1 at the beginning of each day before starting the engine. Capacity of cooling system is 10 quarts (9.4 l). CAUTION 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 31). G019456 Figure 32 1. Vent plug 2.
flash point and cold flow characteristics which will ease starting and reduce fuel filter plugging. DANGER In certain conditions, fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property. Use of summer grade fuel above 20° F (-7° C) will contribute toward longer fuel pump life and increased power compared to winter grade fuel. • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any fuel that spills.
1 Note: Many hydraulic fluids are almost colorless, making it difficult to spot leaks. A red dye additive for the hydraulic system oil is available in 2/3 oz. (20 ml) bottles. One bottle is sufficient for 4-6 gal (15-22 1) of hydraulic oil. Order part no. 44-2500 from your authorized Toro distributor. 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.
Checking the Tire Pressure Bleeding the Fuel System Service Interval: Before each use or daily 1. Park the machine on a level surface. Make sure fuel tank is at least half full. 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. 2. Unlatch and raise hood. DANGER Important: Maintain even pressure in all tires to ensure a good quality-of-cut and proper machine performance.
1 Figure 37 1. Bypass valve g019459 Figure 36 1. Fuel injection pump bleed screw 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. 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. Tighten screw and turn key to Off.
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 Diagnostic ACE also has the ability to detect which output solenoids or relays are turned on. This is a quick way to determine if a machine malfunction is electrical or hydraulic. Figure 38 1.
required input switches are in the necessary positions to allow that function to occur. Verify correct switch function. 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. If the output LEDs are on as specified, but the machine does not function properly, this indicates a non-electrical problem. Repair as necessary. Clearing the Fault Memory (Diagnostic Tool not required) 7.
Solenoid SV 7 On. The machine should not be started until the glow plug cycle is complete. Function Right rear wing cutting unit Load Holding SV8 Mowing Start engine and move throttle to FAST so engine is running at maximum speed. Move the Enable/Disable switch to ENABLE and use the LOWER MOW/RAISE lever to control the cutting units (front cutting units are timed to lower before the rear cutting units). To move forward and cut grass, press traction pedal forward.
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.
Service Interval Chart g023347 Figure 40 36
Daily Maintenance Checklist Duplicate this page for routine use. Maintenance Check Item For the week of: Mon. Tues. Wed. Thurs. Fri. Sat. Check safety interlock operation. Check brake operation. Check engine oil and fuel level. Check cooling system fluid level. Drain the water/fuel separator. Check the air filter restriction indicator. Check the radiator and screen for debris. Check unusual engine noises.1 Check unusual operating noises. Check the transmission oil level.
Lubrication Greasing the Bearings and Bushings Service Interval: Every 50 hours 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.) (Figure 41). g019486 Figure 42 1.
• Rear lift cylinder pivot (2) (Figure 45). • Rear lift arm pivots (2) (Figure 48). g019492 g019489 Figure 45 Figure 48 • Lift arm pivot (3) (Figure 46). • Brake pedal shaft (1) (Figure 49). G019490 Figure 46 G019493 Figure 49 • Rear axle pivot (Figure 47).
Engine Maintenance This cleaning process prevents debris from migrating into the intake when the primary filter is removed. 3. Remove and replace the primary filter (Figure 52). Servicing the Air Cleaner Cleaning of the used element is not recommended due to the possibility of damage to the filter media. Inspect the new filter for shipping damage, checking the sealing end of the filter and the body. Do not use a damaged element.
Adjusting Throttle Servicing the Engine Oil and Filter 1. Position throttle lever forward so it stops against seat base slot. Service Interval: After the first 50 hours 2. Loosen the throttle cable connector on the lever arm at the injection pump (Figure 56). Every 150 hours Change oil and filter initially after the first 50 hours of operation, thereafter change oil and filter every 150 hours. 1 1. Remove drain plug (Figure 54) and let oil flow into drain pan. When oil stops, install drain plug.
Fuel Lines and Connections Fuel System Maintenance Service Interval: Every 400 hours Check lines and connections every 400 hours or yearly, whichever comes first. Inspect for deterioration, damage, or loose connections. Fuel Tank Service Interval: Every 2 years Fuel Filter/Water Separator 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.
Bleeding Air From Injectors Electrical System Maintenance Note: This procedure should be used only if fuel system has been purged of air through normal priming procedures and engine will not start; refer to Bleeding the Fuel System in Operation Section. Battery Care Service Interval: Every 50 hours 1. Loosen the pipe connection to the No. 1 nozzle and holder assembly.
Optional Lighting 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. Important: If optional lighting is be added to the traction unit, use the instructions, schematic (Figure 62), and part numbers listed below to prevent damage to the traction units electrical system.
Figure 62 Switch Relay Toro Part No. 75-1010 Toro Part No. 70-1480 Honeywell Part No. 1TL1-2 Hella Part No.
Changing the Planetary Gear Drive Oil Drive System Maintenance Service Interval: After the first 200 hours Every 800 hours (Or yearly, whichever comes first) Checking the Torque of the Wheel Nuts or Bolts Change the oil initially after 200 hours operation. Thereafter, change the oil every 800 hours. Use high quality SAE 85W-140 wt. gear lube as replacement. 1. With machine on level surface, position a wheel so one of the check/drain plugs is at the lowest (6 o’clock) position (Figure 64).
Important: If the planetary fills before the 22 ounces (0.6 liter) of oil is added, wait one hour or install the plug and move the machine approximately ten feet to distribute the oil through the brake system. Then, remove the plug and add the remaining oil. 7. Re-install the plug. 8. Repeat the procedure on the opposite planetary/brake assembly. Figure 67 1. Drain plug location Checking the Rear Axle Lubricant 3. Remove the (3) oil level check plugs and main axle vent cap to ease in draining of the oil.
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. 1. Measure the center-to-center distance (at axle height) at the front and rear of the steering tires. The front measurement must be 1/8 in. (3 mm) less than the rear measurement. 2. To adjust, remove the cotter pin and nut from either tie rod ball joint.
Cooling System Maintenance 2 Removing Debris 1 Service Interval: Before each use or daily Remove debris from rear screen, oil cooler and radiator daily, clean more frequently in dirty conditions. g019479 Important: Never spray water onto a hot engine as damage to engine may occur. Figure 71 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.
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 73). Replace belt as required. Check the tension as follows: 1.
Replacing the Hydraulic Filter Hydraulic System Maintenance The hydraulic system filter head is equipped with a service interval indicator. With the engine running, view the indicator, it should be in the GREEN zone. When the indicator is in the RED zone, the filter element should be changed. Changing the Hydraulic Fluid Service Interval: Every 800 hours Use the Toro replacement filter (Part No. 94-2621). Change hydraulic fluid after every 800 operating hours, in normal conditions.
WARNING 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.
6. Test Port F is used to measure traction reverse pressure (Figure 79). Cutting Unit Maintenance 7. Test Port G is used to measure steering circuit pressure (Figure 79). 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 80).
brake, and move the Enable/Disable switch to disable position. 2. Unlock and raise the seat to expose controls. 3. Locate the reel speed selector knobs and backlap knobs (Figure 81). Rotate the desired backlap knob(s) to the backlap position and the desired reel speed selector knob(s) to position 1. 9. If reels stall or become erratic while backlapping, stop backlapping by moving the Lower Mow/Lift control lever rearward.
Lifted Height of Outer Front Cutting Units (Enable Position) The turnaround height of the front outer cutting units (#4 & #5) and rear (#6 & #7) cutting units may be increased to provide additional ground clearance on contoured fairways. Note: The RM CONFIG time delay should not be changed from the original setting of 0 when using this method to adjust turn around height.
Adjusting the Travel of the Front Three Cutting Units Additional downward travel of the front three cutting units may be desirable in highly contoured locations. If any of the front three cutting units lift off the ground when cresting a hill, the front carrier frame may be lowered by removing mounting bolts and repositioning frame in the bottom set of holes in the main frame (Figure 85). Contact your distributor for assistance.
Storage Engine Traction Unit 1. Drain the engine oil from the oil pan and replace the drain plug. 1. Thoroughly clean the traction unit, cutting units and the engine. 2. Remove and discard the oil filter. Install a new oil filter. 2. Check the tire pressure. Inflate all tires to 15-20 psi. 3. Refill oil pan with 7.5 qts. (7 l) of SAE15W-40 CD, CE, CF, CF-4, or CG-4 motor oil. 3. Check all fasteners for looseness; tighten as necessary. 4.
Schematics Electrical Schematic, All models (Rev.
Electrical Schematic, Model 03808 and 03813 only (Rev.
Hydraulic Schematic, Model 03806 (Rev.
Hydraulic Schematic, Model 03807 and 03812 (Rev.
Hydraulic Schematic, Model 03808 and 03813 (Rev.
Notes: 63
The Toro Total Coverage Guarantee A 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. This warranty is applicable to all products with the exception of Aerators (refer to separate warranty statements for these products).
