Form No. 3361-445 Rev B Reelmaster® 6500-D and 6700-D Traction Unit Model No. 03806—Serial No. 290000001 and Up Model No. 03807—Serial No. 290000001 and Up Model No. 03808—Serial No. 290000001 and Up Model No. 03812—Serial No. 290000001 and Up Model No. 03813—Serial No. 290000001 and Up To register your product or download an Operator's Manual or Parts Catalog at no charge, go to www.Toro.com.
Warning Model No. CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Serial No. This manual identifies potential hazards and has safety messages identified by the safety alert symbol (Figure 2), which signals a hazard that may cause serious injury or death if you do not follow the recommended precautions.
Contents Fuel Filter/Water Separator ................................ 42 Bleeding Air From Injectors ............................... 42 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.
• Slow down and use caution when making turns and crossing roads and sidewalks. Stop reels if not mowing. • Do not operate the mower under the influence of alcohol or drugs. • Use care when loading or unloading the machine into a trailer or truck. • Use care when approaching blind corners, shrubs, trees, or other objects that may obscure vision. This product is capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death.
• When a person or pet appears unexpectedly in or near the mowing area, stop mowing. Careless operation, combined with terrain angles, ricochets, or improperly positioned guards can lead to thrown object injuries. Do not resume mowing until the area is cleared. on measurements of identical machines per ISO 11201 and EN 836. Sound Power Level Reelmaster 6500–D • Do not park on slopes unless the wheels are chocked or blocked.
Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. 93-6686 1. Hydraulic oil 2. Read the Operator’s Manual. 104-5229 1. Read the Operator’s Manual. 2. Fuse for starter 3. Fuse for headlights (optional) 93-6699 1. Machine speed 2. Slow 105-7506 1. Read the Operator’s Manual. 2. Engine—stop 3. On 3. Continuous variable setting 4. Fast 1 2 4. Engine—preheat 5.
93-6687 1. Do not step here. 104-9298 1. Read the Operator’s Manual. 93-6689 1. Warning—do not carry passengers. 93-6681 1. Cutting/dismemberment—hazard, fan-stay away from moving parts.. 93-1263 93-1263 1. Read the Operator’s Manual. 2. To engage the parking brake, connect the brake pedals with the locking pin, push down on both pedals, and pull the brake latch out. 3. To release the parking brake, press both pedals until the parking brake latch retracts. 4. Danger—reels enabled. 93-1265 1.
105-0123 Model 03808 and 03813 1. 2. 3. 4. 5. 6. Throttle—slow Throttle—fast Reels raised and off Reels lowered and on when enabled—forward and backlap Reels—enabled Reels disabled—lift only 7. 8. 9. 10. 11. Reels disabled—lift and lower Headlights (optional) Headlights—On Headlights—Off Read the Operators Manual. 104-9296 Models 03806, 03807 and 03812 1. Throttle—slow 2. Throttle—fast 4. Reels lowered and on when 7. Reels disabled—lift and enabled—forward and lower backlap 5. Reels enabled 8.
115-2046 1. 2. 3. 4. 5. 6. 7. 8. Warning—read the Operator’s Manual. Cutting hazard of hand or foot—stay away from moving parts; keep all guards in place. Warning—do not operate this machine unless you are trained. Tipping hazard—lower the cutting unit when driving down slopes; do not mow on slopes greater than 15 degrees. Warning—wear the seat belt when seated in the operator’s position. Warning—read the Operator’s Manual; do not tow the machine.
5-2045 (Affix over part no. 115–2046 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. 2. 3. 4. 5. 6. 7. 8. Warning—read the Operator’s Manual. Cutting hazard of hand or foot—stay away from moving parts; keep all guards in place.
115-2049 Models 03806, 03807 and 03812 1. Reel—height of cut 2. Reel—mow and backlap 3. Read the Operator’s Manual. 115-8000 Model 03808 and 03813 4. Machine speed 5. Rear reels circuit controls 6. Front reels circuit controls 1. Reel—height of cut 2. Reel—mow and backlap 3. Read the Operator’s Manual. 106-6754 4. Machine speed 5. Rear reels circuit controls 6. Front reels circuit controls Battery Symbols Some or all of these symbols are on your battery 1. Warning—do not touch the hot surface. 2.
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 2. Large o-ring 7/5 Counter weight 7/5 Steering locking pin 3. Counterweight 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. 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).
Figure 14 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). Figure 12 1. Lift chain 2. Chain bracket Adjust the Rear Shield Under most conditions, best dispersion is attained when the rear shield is closed (front discharge). When conditions are heavy or wet, rear shield may be opened.
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: A. On cutting units #1, 4, 5, 6 and 7, only use 6 of the chain links. B. On cutting units #2 and 3, use all 7 of the chain links. 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).
Adjusts the speed at which the cutting units lower. 7 • Adjusting the lifted height of the outer front cutting units Adjusts the turnaround height of the outer front cutting units to provide greater clearance on contoured fairways. Reading the Manuals and Storing Additional Parts • Adjusting the travel of the front three cutting units Parts needed for this procedure: Adjusts the downward travel of the front three cutting units to allow for highly contoured fairways.
Product Overview Figure 21 1. Steering wheel 3. Cutting unit 5. Manual tube 2. Brake pedals 4. Traction pedal 6. Hood 7. Roll over protection system (ROPS) Controls Traction Pedal The traction pedal (Figure 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. For no load, maximum ground speed, fully depress pedal while throttle is in FAST.
Forward Speed Limiter Lower Mow/Raise Control Lever (Joystick) Preset the forward speed limiter (Figure 22) to limit the amount the traction pedal can be depressed in the forward direction to maintain a constant mowing speed. The lever (Figure 23 and Figure 24) raises and lowers the cutting units and also starts and stops the reels. Red Diagnostic Light Fuel Gauge The red diagnostic light (Figure 22), located on steering tower, is used to convey several different messages.
Hour Meter The hour meter (Figure 25) shows total hours that machine has been operated. Figure 24 Models 03806, 03807 and 03812 1. Lower mow/raise control lever 2. Fuel gauge 3. Engine coolant temperature gauge 4. Engine oil pressure warning light 5. Engine coolant temperature warning light 6. Glow plug indicator light Figure 25 7. Charge indicator 8. Throttle control 1. Hour meter 9.
Using the diagnostic display, determine which output is malfunctioning, refer to Checking Interlock Switches. 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.
Attachments/Accessories Operation A selection of Toro approved attachments and accessories are 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. Note: Determine the left and right sides of the machine from the normal operating position.
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 32). 2. Check level of coolant in radiator and in expansion tank (Figure 32). Figure 30 1. Dipstick Radiator should be filled to the top of the filler neck and the expansion tank filled to the Full mark. 3.
No. 1-D/2-D blend) below that temperature. Use of winter grade fuel at lower temperatures provides lower flash point and cold flow characteristics which will ease starting and reduce fuel filter plugging. 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. Important: Do not use kerosene or gasoline instead of diesel fuel. Failure to observe this caution will damage the engine. Figure 33 4.
2. Using a clean rag, clean area around fuel tank cap. 3. Remove cap from the fuel tank (Figure 34). 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. • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any fuel that spills. • Never fill the fuel tank inside an enclosed trailer.
Checking the Tire Pressure 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. Service Interval: Before each use or daily The tires are over-inflated for shipping. Therefore, release some of the air to reduce the pressure.
Bleeding the Fuel System 1. Park the machine on a level surface. Make sure fuel tank is at least half full. 2. Unlatch and raise hood. 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. Figure 37 1. Fuel injection pump bleed screw • 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. 6.
Figure 39 Figure 38 1. Loop-back connector 1. Bypass valve 3. Connect the Diagnostic ACE display connector to the harness connector (Figure 40). Make sure correct overlay decal is positioned on Diagnostic ACE display. 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. Important: Running the engine with the bypass valve open will cause the transmission to overheat.
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. required input switches are in the necessary positions to allow that function to occur. Verify correct switch function.
Operating Tips Problem circuit will be flashing. Records will repeat until key is turned off. Unit will not start in this mode. Familiarization 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. 9. Turn the Reel Control Switch to Enable position. 10. Move the Joystick to the Raise position and hold. 11.
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. Maintain a speed which does not result in the Reel Control Light being illuminated. Gradually increase or decrease traction speed to ensure proper clip is maintained.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 8 hours • Check the torque of the wheel nuts or bolts (after the first 1–4 hours of operation and then after 10 hours of operation). After the first 50 hours • Change the engine oil and oil filter. After the first 200 hours • Change the planetary gear drive oil. • Change the rear axle lubricant.
If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the ignition and disconnect the wire from the spark plug before you do any maintenance. Set the wire aside so that it does not accidentally contact the spark plug.
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 42) Figure 43 1.
Figure 49 Figure 46 • Brake pedal shaft (1) (Figure 50) • Lift arm pivot (3) (Figure 47) Figure 50 Figure 47 • Rear axle pivot (Figure 48) Figure 48 • Rear lift arm pivots (2) (Figure 49) 39
Engine Maintenance which could force dirt through the filter into the intake tract. Servicing the Air Cleaner This cleaning process prevents debris from migrating into the intake when the primary filter is removed. Service Interval: Every 400 hours 3. Remove and replace the primary filter (Figure 53). 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.
5. Install the cover orienting the rubber outlet valve in a downward position—between approximately 5:00 to 7:00 when viewed from the end. 6. Reset the indicator (Figure 51) if it shows red. 2. Loosen the throttle cable connector on the lever arm at the injection pump (Figure 57). Servicing the Engine Oil and Filter Service Interval: After the first 50 hours Every 150 hours Change oil and filter initially after the first 50 hours of operation, thereafter change oil and filter every 150 hours. 1.
Fuel 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.
Electrical System Maintenance Battery Care Service Interval: Every 50 hours Warning Figure 60 1. Fuel injectors (4) CALIFORNIA Proposition 65 Warning 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. 2. Move throttle to Fast position. 3. Turn key in key switch to Run position and watch fuel flow around connector.
Note: Check battery condition weekly or after every 50 hours of operation. Keep terminals and entire battery case clean because a dirty battery will discharge slowly. To clean the battery, wash the entire case with solution of baking soda and water. Rinse with clear water. Coat the battery posts and cable connectors with Grafo 112X (skin-over) grease (Toro Part No. 505-47) or petroleum jelly to prevent corrosion.
Figure 63 Switch Relay Toro Part No. 75-1010 Toro Part No. 70-1480 Honeywell Part No. 1TL1-2 Hella Part No.
Drive System Maintenance Checking the Torque of the Wheel Nuts or Bolts Service Interval: After the first 8 hours Every 200 hours Figure 65 1. Brake housing Failure to maintain proper torque of the wheel nuts could result in personal injury. 2. Check plug location 3. Add gear oil to the hole in the planetary, if necessary, to bring the oil up to the proper level. Install the plug. 4. Repeat steps 1 through3 on the opposite gear assembly. Torque the front wheel nuts and rear wheel bolts to 85-100 ft.-lb.
Figure 68 2. Fill plug 1. Check plug Figure 67 1. Drain plug location 2. Check plug location Changing the Rear Axle Lubricant 4. When all of the oil has drained, install the bottom plug in the brake housing. Service Interval: After the first 200 hours 5. Position the wheel so that the plug hole is at the ten or two o’clock position on the planetary. Every 800 hours Change the oil initially after the first 200 hours of operation and every 800 hours of operation thereafter. 6.
Rear Wheel Toe-In Note: On 4 wheel drive models, left rear tire must also be off the shop floor. Service Interval: Every 800 hours 3. Start engine and allow run at low idle. After every 800 operating hours or annually, check the rear wheel toe-in. 4. Adjust jam nuts on pump rod end to move pump control tube forward to eliminate forward creep or rearward to eliminate rearward creep (Figure 71). 1. Measure the center-to-center distance (at axle height) at the front and rear of the steering tires.
Cooling System Maintenance Removing Debris Service Interval: Before each use or daily Remove debris from rear screen, oil cooler and radiator daily, clean more frequently in dirty conditions. Important: Never spray water onto a hot engine as damage to engine may occur. Figure 73 1. Oil cooler 1. Turn engine off, release hood latch and raise hood. Clean engine area thoroughly of all debris. Close hood. 2. Radiator Maintaining the Cooling System 2. Unlatch and remove rear screen (Figure 72).
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 75). Replace belt as required. Check the tension as follows: 1.
Hydraulic System Maintenance 1. Position machine on a level surface, lower the cutting units, stop the engine, engage the parking brakes and remove key from ignition switch. 2. Clean area around filter mounting area. Place drain pan under filter and remove filter (Figure 77). Changing the Hydraulic Fluid Service Interval: Every 800 hours Change hydraulic fluid after every 800 operating hours, in normal conditions.
Hydraulic fluid escaping under pressure can penetrate skin and cause injury. • Make sure all hydraulic fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to the hydraulic system. • Keep your body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid. • Use cardboard or paper to find hydraulic leaks.
Cutting Unit Maintenance Cutting Unit Kickstand Models 03863 and 03864 Whenever the cutting unit has to be tipped to expose the bedknife/reel, prop up the rear of the cutting unit with the kickstand (supplied with the traction unit) to make sure the nuts on the back end of the bedbar adjusting screws are not resting on the work surface (Figure 82). Figure 81 1. Test port D (Charge pressure) 2. Test port E (Traction forward pressure) 3. Test port F (Traction reverse pressure) 4.
1. Position the machine on a level surface, lower the cutting units, stop the engine, engage the parking brake, and move the Enable/Disable switch to disable position. 7. Move Enable/Disable switch to Enable position. Move Lower Mow/Lift control forward to start backlapping operation on designated reels. 8. Apply lapping compound with a long handle brush (Toro Part No. 29-9100). Never use a short handled brush (Figure 84). 2. Unlock and raise the seat to expose controls. 3.
Valve Cutting Unit Affected FC1 #1 (Front Center) FC4 #4 & #5 (Front Wings) FC5 #2 & #3 (Rear) FC6 #6 (Rear Left) FC7 #7 (Rear Right) Figure 86 Model 03808 and 03813 Figure 85 1. Adjustment valve for #1 (Front Center) cutting unit 2. Adjustment valve for #4 & #5 (Front Wings) cutting units 3. Adjustment valves for #2 & #3 (Rear) cutting units 12. Repeat procedure for all cutting units to be backlapped.
3. Using a Allen Head wrench, rotate the appropriate valve clockwise to slow down drop rate of cutting units. Adjusting the Travel of the Front Three Cutting Units 4. Verify the lift rate adjustment by raising and lowering cutting units several times. Readjust as required. Additional downward travel of the front three cutting units may be desirable in highly contoured locations.
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
Toro General Commercial Products Warranty A Two-Year Limited Warranty Conditions and Products Covered The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your Toro Commercial Product (“Product”) to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first. This warranty is applicable to all products with the exception of Aerators (refer to separate warranty statements for these products).
