Form No. 3355-222 Rev A Reelmaster® 6500-D and 6700-D Traction Unit Model No. 03806—Serial No. 260000301 and Up Model No. 03807—Serial No. 260000301 and Up Model No. 03808—Serial No. 260000001 and Up Register your product at www.Toro.
Warning Model No. CALIFORNIA Proposition 65 Warning 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. Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Important: This engine is not equipped with a spark arrester muffler.
Starting and Stopping ........................ 25 Bleeding the Fuel System ................... 25 Pushing or Towing the Machine ............................ 26 Checking the Interlock Switches ............................ 27 Fault Memory and Retrieval ............... 28 Hydraulic Solenoid Valve Functions .......................... 29 Operating Tips .................................. 29 Maintenance...................................................... 31 Recommended Maintenance Schedule(s) ...................
Safety • Wear appropriate clothing including hard hat, safety glasses and ear protection. Long hair, loose clothing or jewelry may get tangled in moving parts. 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 13.
• • • • • • • occurs. Make necessary repairs before resuming operations. Keep hands and feet away from the cutting units. Look behind and down before backing up to be sure of a clear path. Never carry passengers and keep pets and bystanders away. 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.
• • • • • • it has stopped because these areas could be hot enough to cause burns. If a cutting unit strikes a solid object or vibrates abnormally, stop immediately, turn the engine off, wait for all motion to stop, and inspect the machine for damage. A damaged reel or bedknife must be repaired or replaced before operation is continued. Traverse slopes carefully. Do not start or stop suddenly when traveling uphill or downhill. The operator must be skilled and trained in how to drive on hillsides.
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. 93-6680 104-5229 1. Read the Operator’s Manual. 2. Fuse for starter 3. Fuse for headlights (optional) 93-6686 1. 2. Hydraulic oil Read the Operator’s Manual. 105-7506 1. Read the Operator’s Manual. 2. Engine—stop 3. On 4. Engine—preheat 5. Engine—start 93-6699 1. 2. Machine speed Slow 3. 4.
1 93-6696 2 1. Stored energy hazard—read the Operator’s Manual. 3 4 93-6687 1. Do not step here. 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. 93-6689 1. Warning—do not carry passengers. 93-6681 1. Cutting/dismemberment—hazard, fan-stay away from moving parts.
108-6708 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. 9 Reels disabled—lift and lower Headlights (optional) Headlights—On Headlights—Off Read the Operators Manual.
4-9296 Models 03806 and 03807 1. Throttle—slow 4. 2. Throttle—fast 5. Reels lowered and on when 7. Reels disabled—lift and lower10. enabled—forward and backlap Reels enabled 8. Headlights (optional) 11. 3. Reels raised and off 6. Reels disabled—lift only 9. Headlights—On Headlights—Off Read the Operator’s Manual for further instructions. 104-9294 1. Read the Operator’s Manual. 3. Warning—Read the Operator’s Manual. 2. Do not tow the machine.
104-9295 Replaces 104–9294 for CE 1. Read the Operator’s Manual. 3. Warning—Read the Operator’s Manual. 2. Do not tow the machine. Cutting hazard of hand or foot—stay away from moving parts. 4. 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 and do not before leaving the machine.
106-6754 1. Warning—do not touch the hot surface. 2. Cutting/dismemberment hazard, fan and entanglement hazard, belt—stay away from moving parts. 67-7960 105-9268 1. Reel—height of cut 2. Reel—mow and backlap 3. Read the Operator’s Manual. 4. 5. 6. Machine speed Rear reels circuit controls Front reels circuit controls Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 6. 2. No re, open ame, or smoking. 7. 3. Caustic liquid/chemical burn hazard 4.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Step 1 No parts required 2 Large O-ring Counter weight Steering locking pin 3 No parts required 4 5 6 Use Qty.
Step 3. Lubricate and install a large O-ring into bearing housing groove on each end of cutting unit (Figure 4 & Figure 7). 2 Installing the Cutting Units Parts needed for this step: 14/10 7/5 7/5 Large O-ring Counter weight Steering locking pin Procedure Figure 4 1. Bearing housing 2. Large o-ring 3. Counterweight Cutting unit models 03860, 03861, and 03862 can be installed at any of the mounting locations on the traction unit.
7. Insert the horizontal shaft of the pivot knuckle into the mounting tube of the carrier frame (Figure 5). 8. Secure pivot knuckle to carrier frame with a thrust washer, flat washer and a flange head capscrew (Figure 5). 9. Insert a thrust washer onto vertical shaft of pivot knuckle (Figure 5). 10. If removed, insert the vertical shaft of the pivot knuckle into lift arm pivot hub (Figure 5).
Step • Adjusting the lifted height of the outer front cutting units 5 Adjusts the turnaround height of the outer front cutting units to provide greater clearance on contoured fairways. Installing CE Decals • Adjusting the travel of the front three cutting units Parts needed for this step: Adjusts the downward travel of the front three cutting units to allow for highly contoured fairways.
Product Overview Figure 8 1. Steering wheel 3. Cutting unit 5. Manual tube 2. Brake pedals 4. Traction pedal 6. Hood Controls Traction Pedal The traction pedal (Figure 9) 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.
Speedometer The speedometer (Figure 9) indicates ground speed at which machine is traveling. Brake Pedals Two brake pedals (Figure 9) operate individual wheel brakes for turning assistance, parking, and to aid in obtaining better sidehill traction. Locking pin connects the pedals for parking brake operation and transport. Parking Brake Latch Figure 9 1. 2. 3. 4. 5. Traction pedal Forward speed limiter Red diagnostic light Speedometer Brake pedals 6. 7. 8. 9.
Engine Oil Pressure Warning Light This light (Figure 10 and Figure 11) indicates dangerously low engine oil pressure. Throttle Control Move the control (Figure 10 and Figure 11) forward to increase engine speed, rearward to decrease speed. Engine Coolant Temperature Warning Light Figure 10 Model 03808 1. Lower mow/raise control 7. lever 2. Fuel gauge 8. 3. Engine coolant 9. temperature gauge 4. Engine oil pressure warning 10. light 5. Engine coolant 11. temperature warning light 6.
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. Figure 12 1. Hour meter Backlap Knobs Figure 14 1. Seat adjusting lever The backlap knobs (Figure 13) are used in conjunction with lower mow/raise control lever for backlapping operation. Refer to Backlapping in Cutting Unit Maintenance, page 48. 2.
• One of the outputs has been shorted. Height With ROPS installed • One of the outputs is open circuited. Weight*, model 03806 3200 lb (1451 kg) Weight*, model 03807 3300 lb (1496 kg) Weight*, model 03808 3950 lb (1792 kg) Using the diagnostic display, determine which output is malfunctioning, refer to Checking Interlock Switches in Operation, page 22.
Operation Note: Determine the left and right sides of the machine from the normal operating position. Checking the Engine Oil 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. Figure 17 Use high-quality engine oil that meets the following specifications: 1. Dipstick • API Classification Level Required: CH-4, CI-4 or higher. 3.
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 19). 2. Check level of coolant in radiator and in expansion tank (Figure 19). Figure 20 1. Radiator should be filled to the top of the filler neck and the expansion tank filled to the Full mark. Vent plug 4.
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.
Note: We recommend that anytime the machine is parked (short or long term) the cutting units should be lowered to the ground. This relieves pressure from the lift circuit and eliminates the risk of the cutting units accidentally lowering to the ground. 4. If level is low, add appropriate fluid to raise level to full mark. 5. Install dipstick and cap onto filler neck. Checking the Tire Pressure The tires are over-inflated for shipping. Therefore, release some of the air to reduce the pressure.
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. Important: Do not push or tow the machine faster than 2-3 mph (3-4.8 km/h) because internal transmission damage may occur. The bypass valve must be open whenever the machine is pushed or towed. Figure 23 1. Fuel lter/water separator 2. 1. The bypass valve is located on top of variable displacement pump (Figure 25).
Checking the Interlock Switches sure correct overlay decal is positioned on Diagnostic ACE display. If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. • Do not tamper with the interlock switches. • Check the operation of the interlock switches daily and replace any damaged switches before operating the machine. • Replace switches every two years regardless of whether they are operating properly or not. Figure 27 1.
To verify output function: 1. Park machine on a level surface, lower the cutting units, stop the engine and engage the parking brake. 2. Open control panel cover. Locate wire harness and connectors near controller. Carefully unplug loopback connector from harness connector. 3. Connect the Diagnostic ACE connector to the harness connector. Make sure correct overlay decal is positioned on Diagnostic ACE. 4. Turn the key switch to the On position, but do not start machine.
Important: The display will show eight (8) individual records with the fault displayed on 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 MSV2 Clearing the Fault Memory (Diagnostic Tool not required) 7. Rotate ignition key to Off position. 8. Turn Backlap Switch to the Front or Rear Backlap position.
Important: Before mowing grass, practice operating the machine in turns. Turf damage in turns may occur especially under soft or wet grass conditions if the turn is completed at a high speed or at a small turning radius. Maintain a speed below 3 mph during a turn and a turning radius greater than 8 feet to minimize turf damage from tires or cutting units.
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 rst 8 operating hours • Check the torque of the wheel nuts or bolts (after the rst 1–4 hours of operation and then after 10 hours of operation). After the rst 50 operating hours • Change the engine oil and oil lter. After the rst 200 operating hours • Change the planetary gear drive oil.
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. Maintenance Check Item For the week of: Mon. Tues. Wed. Thurs. Fri. Check safety interlock operation. Check brake operation. Check engine oil and fuel level. Check cooling system uid level. Drain the water/fuel separator. Check the air lter restriction indicator. Check the radiator and screen for debris. Check unusual engine noises.1 Check unusual operating noises. Check the transmission oil level. Check the hydraulic system oil level.
Figure 31 Figure 29 • Rear axle tie rod (2) (Figure 30) • Steering cylinder ball joints (2) (Figure 30) • King pin bushings (2) (Figure 30). The top fitting on the king pin should only be lubricated annually (2 pumps). Figure 32 • Rear lift cylinder pivot (2) (Figure 33) Figure 33 Figure 30 • Lift arm pivot (3) (Figure 34) 1.
Figure 34 Figure 37 • Rear axle pivot (Figure 35) Engine Maintenance Servicing the Air Cleaner 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. Service the air cleaner filter only when the service indicator (Figure 38) requires it. Changing the air filter before it is necessary only increases the chance of dirt entering the engine when the filter is removed.
Figure 39 1. Air cleaner latch 2. Figure 40 Air cleaner cover 1. Air cleaner primary lter 2. Remove the cover from the air cleaner body. Before removing the filter, use low pressure air (40 psi, clean and dry) to help remove large accumulations of debris packed between outside of primary filter and the canister. Avoid using high pressure air which could force dirt through the filter into the intake tract. Important: Never attempt to clean the safety filter (Figure 41).
Servicing the Engine Oil and Filter Change oil and filter initially after the first 50 hours of operation, thereafter change oil and filter every 150 hours. 1. Remove drain plug (Figure 42) and let oil flow into drain pan. When oil stops, install drain plug. Figure 44 1. Injection pump lever arm 2. Connector 3. Hold the injection pump lever arm against the high idle stop and tighten the cable connector. Note: When tightened, the cable connector must be free to swivel. 4.
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 1/4 to 1/2 in. (6 to 13 mm) below the bottom of the filler neck. This empty space in the tank allows the fuel to expand.
Note: Do not use water to clean engine, as damage may occur. Electrical System Maintenance Battery Care Warning Figure 47 1. Fuel pre-lter CALIFORNIA Proposition 65 Warning Note: Bleeding fuel system is required after replacing the fuel filter/water separator filter or the fuel filter. Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.
Incorrect battery cable routing could damage the tractor and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. • Always connect the positive (red) battery cable before connecting the negative (black) cable. Figure 49 1. Fuses Note: Check battery condition weekly or after every 50 hours of operation.
5. Secure ground wires from lights to the engine block ground. 6. Install a 10 amp. fuse to fuse block at location shown on fuse block decal. Do not exceed fuse rating. Figure 51 Switch Relay Toro Part No. 75-1010 Toro Part No. 70-1480 Honeywell Part No. 1TL1-2 Hella Part No. 87411 B Drive System Maintenance Checking the Torque of the Wheel Nuts or Bolts Figure 52 1. Failure to maintain proper torque of the wheel nuts could result in personal injury. Check/drain plug 2.
Figure 53 1. Brake housing 2. Figure 55 Check plug location 1. Drain 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. 2. Check plug location 4. When all of the oil has drained, install the bottom plug in the brake housing. 5. Position the wheel so that the plug hole is at the ten or two o’clock position on the planetary. 6. Slowly add approximately 16 oz. (0.
Rear Wheel Toe-In 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. Remove tie rod ball joint from axle case support (Figure 58). Figure 56 1. Check plug 2. Fill plug 3.
only the right brake pedal and engage the parking brake. 2. Jack up left side of machine until front tire is off the shop floor. Support machine with jack stands to prevent it from falling accidentally. Note: On 4 wheel drive models, left rear tire must also be off the shop floor. 3. Start engine and allow run at low idle. 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 59). Figure 60 1. Rear screen 3.
Brake Maintenance 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. Disengage locking pin from brake pedals so both pedals work independently of each other. Figure 63 2. To reduce free travel of brake pedals, tighten the brakes by loosening the front nut on the threaded end of the brake cable (Figure 62).
Figure 64 Figure 65 1. Hydraulic reservoir 1. Hydraulic lter 3. Fill reservoir with approximately 8.5 gallons of hydraulic fluid; refer to Checking the Hydraulic Fluid in Operation, page 22. 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. Then tighten filter 1/2 turn. Important: Use only hydraulic fluids specified.
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. Figure 67 • Use cardboard or paper to find hydraulic leaks. Models 03806 and 03807 1.
6. Test Port F is used to measure traction reverse pressure (Figure 69). 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. Test Port G is used to measure steering circuit pressure (Figure 69). 2. Unlock and raise the seat to expose controls. 3. Locate the reel speed selector knobs and backlap knobs (Figure 70).
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 71). Figure 71 1. Long handled brush 9. If reels stall or become erratic while backlapping, stop backlapping by moving the Lower Mow/Lift control lever rearward.
Adjusting the Cutting Unit Lowering Rate The Turf Compensation Spring also transfers weight from the front to rear roller. This helps to reduce a wave pattern in the turf, also known as bobbing. The cutting unit lift circuits are equipped with adjustable valves to ensure the cutting units lower at the desired rate. Adjust as follows: Important: Make spring adjustments with cutting unit mounted to traction unit and lowered to shop floor. Refer to Setup, page 13, for mounting instructions.
as required. Tighten set screw securing adjustment. may be increased to provide additional ground clearance on contoured fairways. Rear Cutting Unit 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. 5. Locate valve in front of rear axle for rear cutting units (Figure 76).
Note: Moving the carrier frame down will decrease the amount of clearance between the cutting units and the ground in turnaround and transport positions and may require adjusting the lift chain length on the cutting unit. Figure 78 1.
Storage 6. Flush the fuel tank with fresh, clean diesel fuel. 7. Secure all fuel system fittings. Traction Unit 8. Thoroughly clean and service the air cleaner assembly. 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. Wipe up any excess lubricant. 5.
Schematics Electrical Schematic (Rev.
Hydraulic Schematic, Model 03806 (Rev.
Hydraulic Schematic, Model 03807 (Rev.
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 afliate, 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 rst.
