Form No. 3382-241 Rev A Reelmaster® 6500-D and 6700-D 2-Wheel Drive Traction Unit Model No. 03806—Serial No. 314000001 and Up Model No. 03807—Serial No. 314000001 and Up Model No. 03808—Serial No. 314000001 and Up Model No. 03812—Serial No. 314000001 and Up Model No. 03813—Serial No. 314000001 and Up Register at 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 This product contains a chemical or chemicals known to the State of California to cause cancer, birth defects, or reproductive harm. 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 1.
Contents Optional Lighting...................................................45 Drive System Maintenance .........................................46 Checking the Torque of the Wheel Nuts or Bolts .................................................................46 Checking the Planetary Gear Drive Oil ......................46 Changing the Planetary Gear Drive Oil ......................46 Checking the Rear Axle Lubricant .............................47 Changing the Rear Axle Lubricant........................
Safe Handling of Fuels Safety • To avoid personal injury or property damage, use 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. extreme care in handling gasoline. Gasoline is extremely flammable and the vapors are explosive. • Extinguish all cigarettes, cigars, pipes, and other sources of ignition.
• • • • • • • • • Hauling before leaving the operator's position for any reason including emptying the grass baskets. Stop equipment and inspect the machine after striking objects or if an abnormal vibration 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.
Sound Power Level • The operator must be skilled and trained in how to drive on hillsides. Failure to use caution on slopes or hills may cause loss of control and cause the vehicle to tip or roll, possibly resulting in personal injury or death. Always use the seat belt and Roll Over Protection System (ROPS) together. Reelmaster 6500 This unit has a guaranteed sound power level of 101 dBA, which includes an Uncertainty Value (K) of 1 dBA.
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: 14/10 Figure 4 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. Mount the Cutting Units Cutting unit models 03860, 03861, and 03862 can be installed at any of the mounting locations on the traction unit.
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. available, as well as the amount of ground clearance in transport and turn around. 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. 11.
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 3. On lift arms #6 and #7, position the brackets and U-bolts 368 mm (14.5 inches) behind the center line of the pivot knuckle (Figure 11). Rotate the brackets 10 degrees to the outboard side of the machine.
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).
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: A. On cutting units #1, 4, 5, 6 and 7, only use 6 of the chain links. B. 1 On cutting units #2 and 3, use all 7 of the chain links. G003321 2 Figure 16 1. Plastic plug 2. Cap screw (2) 4. Install the counter weight to the right end of the cutting unit with the 2 screws previously removed. 5.
Figure 20 2. Tighten hex nuts on front end of spring rod until the compressed length (A) of spring is 159 mm (6.25 inches) (Figure 20). Figure 19 1. Reel drive motor 2. Capscrew Note: When operating on rough terrain, decrease the spring length by 13 mm (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 4 CE decals 2 CE certificate Procedure Procedure The factory sets the tractor appropriately for most fairway mowing applications.
Product Overview • An electrical malfunction has been detected (open or Controls • A hydraulic leak has been detected (Only if Turfdefender shorted output. leak detector is installed on machine) • A communications error has been detected (Only if Traction Pedal Turfdefender leak detector is installed on machine) The traction pedal (Figure 21) 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.
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.
To adjust for operators weight, turn spring tension knob; clockwise to increase tension, counterclockwise to decrease spring tension. 1 1 G019525 2 Figure 24 1. Hour meter G019451 Figure 26 1. Seat adjusting knob 2. Seat adjusting lever Backlap Knobs The backlap knobs (Figure 25) are used in conjunction with lower mow/raise control lever for backlapping operation. Refer to Backlapping in Cutting Unit Maintenance (page 53).
Attachments/Accessories • One of the outputs is open circuited. Using the diagnostic display, determine which output is malfunctioning, refer to Checking Interlock Switches. A selection of Toro approved attachments and accessories is available for use with the machine to enhance and expand its capabilities. Contact your Authorized Service Dealer or Distributor or go to www.Toro.com for a list of all approved attachments and accessories.
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 liters (7.5 quarts) with the filter. G019454 Figure 29 Use high-quality engine oil that meets the following specifications: 1.
1 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). 2. Check level of coolant in radiator and in expansion tank (Figure 31). G019456 Figure 32 Radiator should be filled to the top of the filler neck and the expansion tank filled to the Full mark.
Use of summer grade fuel above -7° C (20° F) will contribute toward longer fuel pump life and increased power compared to winter grade fuel. DANGER In certain conditions during fueling, static electricity can be released causing a spark which can ignite the fuel vapors. A fire or explosion from fuel can burn you and others and can damage property. Important: Do not use kerosene or gasoline instead of diesel fuel. Failure to observe this caution will damage the engine.
Checking the Hydraulic Fluid 2. Clean area around filler neck and cap of hydraulic tank (Figure 34). Remove cap from filler neck. Service Interval: Before each use or daily 1 The machines reservoir is filled at the factory with approximately 32 liters (8.5 U.S. gallons) of high quality hydraulic fluid. Check the level of the hydraulic fluid before the engine is first started and daily thereafter. The recommended replacement fluid is as follows: Toro Premium All Season Hydraulic Fluid (Available in 18.
2. Turn ignition switch to On/Preheat position. An automatic timer will control preheat for approximately 6 seconds. After preheat, turn key to Start position. Crank the engine for no longer than 15 seconds. Release key when engine starts. If additional preheat is required, turn key to Off position then to On/Preheat position. Repeat process as required. 3. Run engine at idle speed or partial throttle until engine warms up. 4. To stop, move all controls to Neutral and set parking brake.
Pushing or Towing the Machine depressed with either the operator off the seat or the parking brake engaged. 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. To verify interlock switch function: Service Interval: Before each use or daily 1. Park machine on a level surface, lower the cutting units, stop the engine and engage the parking brake. Important: Do not push or tow the machine faster than 3-4.
switches are in the necessary positions to allow that function to occur. Verify correct switch function. Individually, change each of the switches from open to closed (i.e., sit on seat, engage traction 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.
The brakes can be used to assist in turning the machine. However, use them carefully, especially on soft or wet grass conditions because the turf may be torn accidentally. 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. 8.
machine on slopes. Drive slowly and avoid sharp turns on slopes to prevent roll overs. The cutting units should be lowered when going downhill for steering control.
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. 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 3. Remove and replace the primary filter (Figure 52). 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. Insert the new filter by applying pressure to the outer rim of the element to seat it in the canister. Do not apply pressure to the flexible center of the filter.
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 1. Loosen the pipe connection to the No. 1 nozzle and holder assembly.
cable connectors with Grafo 112X (skin-over) grease (Toro Part No. 505-47) or petroleum jelly to prevent corrosion. DANGER 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. • Fill the battery where clean water is always available for flushing the skin. Fuses There are 7 fuses in the machines electrical system.
Optional Lighting Note: Punch out in control panel provided for switch installation. 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. 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. Installation Instructions 5.
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).
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. Checking the Rear Axle Lubricant Figure 67 1. Drain plug location Service Interval: Every 400 hours The rear axle is shipped from the factory filled with SAE 85W-140 wt. gear lube. Check level before engine is first started and every 400 hours thereafter. Capacity is 2.3 liters (80 ounces).
Rear Wheel Toe-In 3. Start engine and allow run at low idle. Service Interval: Every 800 hours 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 69). After every 800 operating hours or annually, check the rear wheel toe-in. 1 2 1. Measure the center-to-center distance (at axle height) at the front and rear of the steering tires. The front measurement must be 3 mm (1/8 inches) less than the rear measurement.
Maintaining the Cooling System Cooling System Maintenance Service Interval: Every 100 hours Removing Debris Every 2 years Service Interval: Before each use or daily Capacity of the system is 9.4 liters (10 quarts). Always protect cooling system with a 50/50 solution of water and permanent ethylene glycol anti-freeze. Do not use water only in the cooling system. Remove debris from rear screen, oil cooler and radiator daily, clean more frequently in dirty conditions.
Brake Maintenance Belt Maintenance Adjusting the Service Brakes Checking the Alternator Belt Adjust the service brakes when there is more than 2.5 cm (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.
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 Use the Toro replacement filter (Part No. 94-2621). Service Interval: Every 800 hours Important: Use of any other filter may void the warranty on some components.
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.
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 80). Figure 79 1. Test port D (Charge pressure) 3. Test port F (Traction reverse pressure) 2. Test port E (Traction forward pressure) 4.
brake, and move the Enable/Disable switch to disable position. 9. If reels stall or become erratic while backlapping, stop backlapping by moving the Lower Mow/Lift control lever rearward. Once the reels have stopped, move the desired reel speed selector knob(s) one position closer to 13. Resume backlapping by moving the Lower Mow/Lift control lever forward. 2. Unlock and raise the seat to expose controls. 3. Locate the reel speed selector knobs and backlap knobs (Figure 81).
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.
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 liters (7.5 quarts) of SAE15W-40 CD, CE, CF, CF-4, or CG-4 motor oil. 2. Check the tire pressure. Inflate all tires to 103–137 kpa(15-20 psi). 4. Start the engine and run at idle speed for approximately two minutes. 3.
Notes: 58
Notes: 59
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).
