Toro 6500-D - Manual

Rev. E Reelmaster 6500-D/6700-D Page 1 - 2 Safety 7. Remove all debris or other objects that might be picked up and thrown by the reels or fast moving compo- nents from other attached implements. Keep all by- standers away from operating area. 8. Since diesel fuel is highly flammable, handle it care...

Safety Rev. E Reelmaster 6500-D/6700-D Safety Page 1 -- 3 Maintenance and Service 1. Before servicing or making adjustments, stop engine and remove key from the switch. 2. When changing attachments, tires or performing oth- er service, use the correct blocks, hoists and jacks. Al- ways chock or bloc...

Product Records and M aintenance Rev. E Reelmaster 6500-D/6700-D Page 2 - 1 Product Records and Maintenance Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS 1 . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE 1 . . . . . . . . . . . . . . . . . . . . . . . . . ...

0.09375 Rev. E Reelmaster 6500-D/6700-D Page 2 - 2 Product Records and Maintenance Equivalents and Conversions

Product Records and M aintenance Rev. A Reelmaster 6500-D/6700-D Page 2 - 3 Product Records and Maintenance Torque Specifications Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is...

Rev. A Reelmaster 6500-D/6700-D Page 2 - 6 Product Records and Maintenance Other Torque Specifications SAE Grade 8 Steel Set Screws Thread Size Recommended Torque Thread Size Square Head Hex Socket 1/4 -- 20 UNC 140 + 20 in--lb 73 + 12 in--lb 5/16 -- 18 UNC 215 + 35 in--lb 145 + 20 in--lb 3/8 -- 16 ...

Kubota Diesel Engine Reelmaster 6500-D/6700-D Page 3 - 1 Kubota Diesel Engine Chapter 3 Kubota Diesel Engine Table of Contents INTRODUCTION 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 4 ....

Reelmaster 6500-D/6700-D Page 3 - 2 Kubota Diesel Engine Introduction This Chapter gives information about specifications, maintenance, troubleshooting, testing, and repair of the diesel engine used in the Reelmaster 6500-D and 6700-D. Most repairs and adjustments require tools which are commonly av...

Kubota Diesel Engine Reelmaster 6500-D/6700-D Page 3 - 3 Kubota Diesel Engine Specifications Item Description Make/Designation Kubota V1505--T (E), 4-Cycle, 4 Cylinder, Turbocharged, Vertical, Water Cooled, Diesel Engine Horse Power 42.5 HP @ 3000 RPM Bore 3.07 in. (78 mm) Stroke 3.09 in. (78 mm) To...

Reelmaster 6500-D/6700-D Page 3 - 4 Kubota Diesel Engine General Information Stopping The Engine IMPORTANT: Before stopping the engine after mowing or full load operation, cool the turbo-char- ger by allowing the engine to idle at low speed for 5 minutes. Failure to do so may lead to turbo-charger t...

Kubota Diesel Engine Reelmaster 6500-D/6700-D Page 3 - 5 Kubota Diesel Engine Fill Fuel Tank DANGER Under certain conditions, diesel fuel and fuel va- pors 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...

Rev. D Reelmaster 6500-D/6700-D Page 3 - 6 Kubota Diesel Engine Check Cooling System The cooling system is filled with a 50/50 solution of water and permanent ethylene glycol anti-freeze. Check level of coolant at the beginning of each day before starting the engine. System capacity is about 10 quar...

Kubota Diesel Engine Reelmaster 6500-D/6700-D Page 3 - 7 Kubota Diesel Engine Adjustments Adjust Throttle Cable 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Release hood latch and open hood. 3. Position thrott...

Reelmaster 6500-D/6700-D Page 3 - 8 Kubota Diesel Engine Adjust Alternator Belt The condition and tension of all belts should be checked periodically as recommended in the maintenance schedules in Chapter 2 - Product Records and Mainte- nance. 1. Park machine on a level surface, lower cutting units,...

Kubota Diesel Engine Reelmaster 6500-D/6700-D Page 3 - 9 Kubota Diesel Engine Service and Repairs Bleed Fuel System 1. Park machine on a level surface, lower cutting units, stop engine, and engage parking brake. Make sure fuel tank is at least half full. 2. Release hood latch and open hood. DANGER U...

Reelmaster 6500-D/6700-D Page 3 - 10 Kubota Diesel Engine Bleed Air from Fuel Injectors IMPORTANT: This procedure should be used only if the fuel system has been purged of air through nor- mal priming procedures (see Bleed Fuel System) and engine will not start. 1. Park machine on a level surface, l...

Kubota Diesel Engine Reelmaster 6500-D/6700-D Page 3 - 11 Kubota Diesel Engine Clean Radiator and Oil Cooler 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. 1. Park...

Reelmaster 6500-D/6700-D Page 3 - 12 Kubota Diesel Engine Fuel Filter/Water Separator DANGER Under certain conditions, diesel fuel and fuel va- pors 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 fu...

Kubota Diesel Engine Reelmaster 6500-D/6700-D Page 3 - 13 Kubota Diesel Engine 4. Place a suitable container under fuel/water separa- tor, and unscrew filter element and base from the filter head. 5. Unscrew filter element from base and discard ele- ment. 6. Lubricate gasket on new filter element an...

Reelmaster 6500-D/6700-D Page 3 - 14 Kubota Diesel Engine Fuel System Figure 19 1. Fuel Hose 2. Cable Tie 3. Spring Clamp 4. Round Head Screw 5. Lock Washer 6. Sending Unit 7. Gasket 8. Fuel Hose 9. Hose Clamp 10. Stand Pipe 11. Fuel Elbow Connector 12. Grommet 13. Tank Cap 14. Fuel Tank 15. Drain C...

Reelmaster 6500-D/6700-D Page 3 - 16 Kubota Diesel Engine Air Filter General Maintenance 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Release hood latch and open hood. 3. Check air cleaner, seals, and intake h...

Kubota Diesel Engine Reelmaster 6500-D/6700-D Page 3 - 17 Kubota Diesel Engine This page is intentionally left blank.

Reelmaster 6500-D/6700-D Page 3 - 18 Kubota Diesel Engine Radiator Figure 24 1. Fan Shroud RH 2. Screw 3. Hex Nut 4. Flat Washer 5. Hex Nut 6. Fan Shroud LH 7. Screw 8. Flat Washer 9. Radiator Support 10. Screw 11. Reservoir Bracket 12. Locknut 13. Overflow Hose (to ground) 14. Hose Clamp 15. Overfl...

Kubota Diesel Engine Reelmaster 6500-D/6700-D Page 3 - 19 Kubota Diesel Engine Removal (Fig. 24) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Unlatch and remove rear screen. 3. Unscrew knobs and pivot oil cool...

Reelmaster 6500-D/6700-D Page 3 - 20 Kubota Diesel Engine Engine Figure 25 1. Muffler 2. Hexnut 3. Lockwasher 4. Screw 5. Flat Washer 6. Muffler Support 7. Screw 8. Lockwasher 9. Locknut 10. Engine Bracket (front RH) 11. Fuel Hose 12. Hose Clamp 13. Locknut 14. Flat Washer 15. Fuel Pump 16. Fuel Hos...

Kubota Diesel Engine Reelmaster 6500-D/6700-D Page 3 - 23 Kubota Diesel Engine 10.Install radiator support and oil cooler. 11. Install radiator (see Radiator Installation in this sec- tion of this manual). 12.Connect air filter hose to the engine. 13.Install muffler assembly. 14.Connect both battery...

Hydraulic System Rev. F Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 1 Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 3 . . . . . . . . . . . . . . . . . . . . . Hydraulic Hoses 3 . . . . . . . . . . ....

Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 3 General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage condi- tions, or mishandling during o...

Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 4 SAE Straight Thread O-Ring Port - Non-adjustable 1. Make sure both threads and sealing surfaces are free of burrs, nicks, scratches, or any foreign material. 2. Always replace the O-ring seal when this type of fit- ting shows signs of leakage. 3. ...

Hydraulic System Rev. F Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 5 Pushing or Towing Traction Unit In an emergency, the machine can be moved by actuat- ing the bypass valve in the variable displacement hy- draulic pump and pushing or towing the machine. IMPORTANT: Do not push or tow the ma...

Rev. F Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 6 Hydraulic Schematics MOW C IRCUIT Hydraulic System Schematic Serial Numbers 210000101 To 210999999 All solenoids are shown as d e- energiz ed. V1 F R F R P4 R5 R3 R6 R6 RH LH IN OUT AUX M8 M9 G1 G2 C. U. 3 MD 2 MO W 2 BKL P2 BAC K LA P FC2 ...

Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 14 Hydraulic Flow Diagrams Tr action C ircuit (4WD Forward Direction S hown) High Pressure Low Pressure (Charge) Return or Suction Fl ow Reelmaster 6500-D/6700-D F R F R P4 CHARGE P RESSURE RELIEF M8 M9 T P2 12:1 P1 12:1 P3 R4 50 PSI P5 M10 R F 13.8...

Hydraulic System Rev. C Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 15 Traction Circuit The hydraulic pump assembly is driven by a coupling at- tached to the engine flywheel. The pump assembly con- sists of a three section gear pump, a gerotor charge pump, and a variable displacement piston p...

Hydraulic System Rev. F Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 17 Lower Cutting Units The hydraulic pump assembly is driven by a coupling at- tached to the engine flywheel. The pump assembly con- sists of a three section gear pump, a gerotor charge pump, and a variable displacement pisto...

Hydraulic System Rev. C Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 19 Raise Cutting Units The hydraulic pump assembly is driven by a coupling at- tached to the engine flywheel. The pump assembly con- sists of a three section gear pump, a gerotor charge pump, and a variable displacement pisto...

Hydraulic System Rev. C Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 21 Mow and Backlap Mow The reel manifold contains two independent control cir- cuits for the front and rear cutting units. Each circuit is supplied by its own gear pump section. Gear pump sec- tion (P1) supplies hydraulic pow...

Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 23 Right and Left Turns In addition to supplying hydraulic flow to the cutting unit lift circuits, gear pump section (P3) supplies hydraulic flow to the steering control valve for turning the rear wheels. With the the engine running...

Rev. E Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 24 Special Tools NOTE: Order special tools from your Toro Distributor. Some tools may also be available from a local supplier. Hydraulic Pressure Test Kit - TOR47009 Use to take various pressure readings for diagnostic tests. Quick disconnect...

Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 25 Hydraulic Tester - With Pressure and Flow Capabilities - TOR214678 Figure 12 You must have o-ring face seal (ORFS) adapter fittings for this tester to use it on the Reelmaster 6500--D and 6700--D. 1. INLET HOSE: Hose connected fr...

Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 26 Troubleshooting The cause of an improperly functioning hydraulic sys- tem is best diagnosed with the use of proper testing equipment and a thorough understanding of the com- plete hydraulic system. A hydraulic system with an excessive increase in...

Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 27 Transmission or Hydraulic System is Operating Hot Cause Correction Oil in reservoir is below level. Fill reservoir to proper level. Contaminated oil. Drain reservoir and refill with clean oil. Oil in system too light. Drain reser...

Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 28 Transmission Response Sluggish Cause Correction Charge pressure low. TEST NO. 1. Inspect charge relief valve R5. Repair or replace if defective. Servo control valve faulty. Inspect control valve for: Plugged control orifices. Damaged mounting gas...

Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 29 Transmission Will Not Operate in Either Direction (Continued) Cause Correction Wheel motor(s) worn or damaged. NOTE: If a motor has internal damage, it is likely that the pump and other motor are also damaged. Inspect wheel motor...

Hydraulic System Rev. E Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 31 Front (Rear) Reels Will Not Turn (Continued) Cause Correction Relief valve R1 (R2) by-passing oil. TEST NO. 3. Adjust relief valve R1 (R2) if necessary. Do cartridge valve service procedure for valve R1 (R2). Replace fault...

Hydraulic System Rev. E Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 33 Front (Rear) Reels Stop Under Load Cause Correction Relief valve R1 (R2) by-passing oil. TEST NO. 3. Adjust relief valve R1 (R2) if necessary. Do cartridge valve service procedure for valve R1 (R2). Replace faulty valve. G...

Hydraulic System Rev. E Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 35 Cutting Units Will Not Lower Cause Correction Solenoid Valve SV1 not shifting. Do electrical diagnostics to make sure that voltage is being applied to SV1 and that there is no electrical fault. See Chapter 5 - Electrical S...

Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 37 TEST NO. 1: Traction Circuit Charge Pressure 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. 2. Make sure machine is parked on a level surface with the cuttin...

Hydraulic System Rev. B Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 39 TEST NO. 3: Cutting Unit Drive Circuit Pressure Note: The front cutting unit drive circuit is protected by relief valve R1 and the rear circuit by relief valve R2. See Hydraulic Flow Diagrams at the beginning of this chap-...

Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 42 TEST NO. 6: Reel Drive Motor Cross-Over Relief Pressure Use a tee fitting to install pressure gauge in inlet line of motor being tested.NOTE: Inlet is front hose. High Pressure Low Pressure Flow Reel Manifold Block M4 R7 R7 M1 R7 R7 M5 R7 R7 Figu...

Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 47 Adjust Traction Drive for Neutral The machine must not creep when traction pedal is re- leased. If it does creep, an adjustment is required. 1. Park machine on a level surface, shut engine off and lower cutting units to the floor...

Rev. F Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 48 Adjust Cutting Unit Drop Rates (Serial Numbers Below 280000000) The cutting unit lift/lower circuit is equipped with adjust- able flow control valves to ensure the cutting units do not drop too quickly and damage the turf. Center (#1), Out...

Rev. F Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 50 Check Hydraulic Lines and Hoses WARNING Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not hands, to search for leaks. Hydraulic fluid escaping under pressure...

Hydraulic System Rev. F Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 51 Charge Hydraulic System Note: When initially starting the hydraulic system with new or rebuilt components such as motors, pumps, or lift cylinders, it is important that the hydraulic system be charged properly. Air must be...

Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 52 Change Hydraulic Fluid Change hydraulic fluid after every 800 operating hours, in normal conditions. If fluid becomes contaminated, contact your local TORO distributor because the system must be flushed. Contaminated fluid looks milky or black wh...

Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 53 Replace Hydraulic Oil Filter The hydraulic system filter head is equipped with a ser- vice indicator. With the engine running, view the indica- tor, it should be in the GREEN zone. When the indicator is in the RED zone, the filte...

Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 54 Piston Pump (Traction Pump) 31 32 33 34 35 36 37 38 40 41 42 43 44 45 1 2 3 4 5 6 7 8 9 10 16 17 19 20 21 22 23 24 25 26 27 28 29 30 11 12 13 14 15 23 23 10 44 5 3 15 47 38 48 41 17 Figure 28 1. Nut 2. Retaining Ring 3. Retaining Ring 4. Sealing ...

Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 58 Servo Control 1 2 3 4 5 4 6 7 8 9 16 17 18 19 20 21 22 23 24 10 12 13 14 15 11 Figure 33 1. Plug 2. O-ring 3. Retaining Ring 4. Spring Retainer 5. Spring 6. Spool Valve 7. Control Housing 8. Input Shaft 9. O-ring 10. Wiper Seal 11. O-ring 12. Ada...

Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 60 Gear Pump 1 2 3 4 5 6 7 8 9 10 16 17 18 19 20 21 22 23 24 25 27 26 28 29 11 12 13 14 15 30 Figure 35 1. O-ring 2. Front Body 3. Drive Gear Assembly 4. Wearplate 5. Balance Pressure Seal 6. Backup Gasket 7. Plug 8. Front Plate Assembly 9. Copper W...

Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 64 Wheel Motor 1 2 3 4 5 6 7 8 9 10 16 17 18 19 11 12 13 14 15 4 5 Figure 36 1. Retaining Ring 2. Shaft Seal 3. Washer 4. Retaining Ring 5. Thrust Race 6. Thrust Bearing 7. Splined Drive Shaft 8. Screw 9. Backplate Assembly 10. O-ring 11. Speed Pick...

Rev. E Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 66 4WD Rear Axle Motor 1 2 3 4 5 6 7 8 9 10 16 17 11 12 13 14 15 4 5 Figure 38 1. Retaining Ring 2. Spacer 3. Shaft 4. Retaining Ring 5. Thrust Race 6. Thrust Bearing 7. Screw 8. Backplate Assembly 9. O-ring 10. Dowel Pin 11. Dowel Pin 12. Ne...

Rev. E Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 68 Reel Motor (Barnes) 1 2 3 4 5 6 7 8 Use seal protector tool TOR4072 when inserting shaft through seal. NOTE: Seal protector tool is part of TOR4070 Cutting Unit Tool Kit shown in Chapter 7 - Cutting Units. Figure 40 1. Retaining Ring 2. Sh...

Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 72 Hydraulic Control Manifolds 1. Straight Hydraulic Fitting 2. O-ring 3. O-ring 4. Hydraulic Tube 5. 90 _ Hydraulic Fitting 6. O-ring 7. O-ring 8. Control Manifold 9. Flat Washer 10. Safety Switch 11. Test Port Fitting 12. O-ring 13. Test Port Cap ...

Rev. E Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 74 Hydraulic Control Manifold Service 1. Logic Cartridge 2. Seal Kit 3. Rotary Cartridge Valve (flow control) 4. Relief Cartridge Valve (3000 psi) 5. Seal Kit 6. Relief Cartridge Valve (2000 psi) 7. Rotary Cartridge Valve (4 way) 8. Seal Kit ...

Rev. F 76.1 Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 1. Lift manifold block 2. Nut 3. NWD--6 plug 4. Solenoid blocking valve (4 used) 5. Solenoid valve (S3) 6. Solenoid valve (S1) 7. Solenoid valve (S2) 8. Flow control valve (2 used) 9. Solenoid coil (6 used) 10. Solenoid ...

Rev. E Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 78 3. Make sure manifold is clean before removing the cartridge valve. Remove the valve and seal kit. 4. Visually inspect the manifold port and cartridge valve for damage to sealing surfaces, damaged threads, and contamination. A. Contaminati...

Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 80 Lift Cylinders Removal and Installation 1. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of this chapter. 2. Disconnect hydraulic hoses from lift cylinde...

Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 81 Rear (6700-D #6 or 7 Only) A. Remove both lock nuts and upper link plate. Re- move upper link and rollers from the lift arm and cylin- der clevis (Fig. 52). B. Remove retaining ring from the cylinder cap end pin. Remove cylinder ...

Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 82 Lift Cylinder Service 1. Barrel with Clevis 2. Nut 3. Uni-ring 4. Piston 5. O-ring 6. Rod Seal 7. O-ring 8. Back-up Ring 9. Head 10. Dust Seal 11. Collar 12. Shaft with Clevis 13. Grease Fitting Figure 53 FRONT LEFT AND FRONT RIGHT LIFT CYLINDER ...

Rev. E Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 88 Power Steering The Reelmaster R 6500-D/6700 is equipped with power steering. The power steering valve is enclosed in the steering tower at the front of the traction unit. As the steering wheel is turned, the steering valve meters hy- draul...

Hydraulic System Rev. E Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 89 Steering Valve Removal (Figs. 57 and 58) 1. Engage the parking brakes, lower the cutting units to the ground, turn the engine OFF and remove the key from the ignition switch. 2. Remove the front center cutting unit (see Ch...

Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 90 Steering Valve Service Figure 59 Disassembly Note: Cleanliness is extremely important when repairing steering control units. Work in a clean area. Before disconnecting the hydraulic lines, clean the port area of the steering control unit. Before ...

Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 94 Hydraulic Reservoir 1. Hydraulic Reservoir 2. Gasket 3. Tank Cover 4. Breather Adapter 5. Tank Breather 6. Capscrew 7. Reservoir Cap 8. O-ring 9. Dipstick 10. Filler Screen 11. O-ring 12. Hydraulic Tube 13. O-ring 14. Tee Hydraulic Fitting 15. Hy...

Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 96 Hydraulic Oil Cooler Removal (Fig. 66) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. CAUTION The radiator and oil cooler may be hot. To avoid possible burns, a...

Electrical System Reelmaster 6500-D/6700-D Page 5 - 1 Electrical System (Rev. C) Chapter 5 Electrical System Table of Contents ELECTRICAL SCHEMATICS, ELECTRICAL HARNESS, and CONNECTOR DRAWINGS See Chapter 8 . . . . . . . SPECIAL TOOLS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUB...

Rev. E Reelmaster 6500-D/6700-D Page 5 - 2 Electrical System (Rev. C) Special Tools Order special tools from your Toro Distributor. Some tools may be listed in the Parts Catalog for the Reelmas- ter 6500-D or 6700-D. Some tools may also be available from a local supplier. Digital Multimeter The mete...

Electrical System Reelmaster 6500-D/6700-D Page 5 - 3 Electrical System (Rev. C) Toro Automated Control Electronics t Diagnostic Tools Diagnostic ACE t Display The diagnostic display is connected to the wiring harness connector located inside the control console to help the user verfiy correct elect...

Electrical System Reelmaster 6500-D/6700-D Page 5 - 5 Electrical System (Rev. C) Fault Identification/Operator Warning: S Alerts operator to several potential problems with audible “beeps” and/or by cutting unit shut down. Diagnostics: S Do troubleshooting by connecting one of the follow- ing device...

Electrical System Reelmaster 6500-D/6700-D Page 5 - 9 Electrical System (Rev. C) Note: See Leak Detector Troubleshooting Guide in this section of this manual for additional information. 1. Park machine on a level surface and engage the parking brake. 2. Open control panel cover. Locate leak detector...

Electrical System Reelmaster 6500-D/6700-D Page 5 - 11 Electrical System (Rev. C) 1. Overlay decal (English shown)2. “Inputs Displayed” LED (Red)3. “Outputs Displayed” LED (Green)4. Toggle button 1 Diagnostic ACE Display Functions Figure 13 3 2 4 3 2 1 7 1. LED lit if oil level is too high2. LED lit...

Reelmaster 6500-D/6700-D Page 5 - 12 Electrical System (Rev. C) Leak Detector Troubleshooting Guide The following is a quick guide to the most common problems likely to be encountered. The hand-held DiagnosticACE is helpful for identifying specific problems 4-Beep Faults are Occurring Oil level is i...

Electrical System Reelmaster 6500-D/6700-D Page 5 - 13 Electrical System (Rev. C) Starting Problems Problem Possible Causes All electrical power is dead, including gauges. The battery charge is low. The ignition switch or circuit wiring is faulty. The fusible link from the battery is faulty. The 20 ...

Reelmaster 6500-D/6700-D Page 5 - 14 Electrical System (Rev. C) General Run and Transport Problems Problem Possible Causes Engine continues to run, but should not, when the ignition switch is turned off. The engine run (ETR) solenoid is stuck open. Ignition switch or circuit wiring is faulty. Engine...

Electrical System Reelmaster 6500-D/6700-D Page 5 - 15 Electrical System (Rev. C) Cutting Unit Operating Problems Problem Possible Causes The cutting units remain engaged, but should not, with no operator in the seat. The seat sensor or circuit wiring is faulty. Cutting units run, but should not, wh...

Reelmaster 6500-D/6700-D Page 5 - 16 Electrical System (Rev. C) Cutting Unit Operating Problems (Continued) Problem Possible Causes None of the cutting units will raise. Raise switch on joystick or circuit wiring is faulty. Solenoid SV1 or circuit wiring is faulty. Solenoid SV2 or circuit wiring is ...

Electrical System Reelmaster 6500-D/6700-D Page 5 - 17 Electrical System (Rev. C) Electrical System Quick Checks Battery Test (Open Circuit Test) This is a simple test used to determine the condition of the battery at rest. Tool required: Digital Multimeter - DC volts setting. Test instructions: Set...

Electrical System Reelmaster 6500-D/6700-D Page 5 - 19 Electrical System (Rev. C) Component Testing For accurate resistance and/or continuity checks, elec- trically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before doing a continuity check). NOT...

Reelmaster 6500-D/6700-D Page 5 - 20 Electrical System (Rev. C) Glow and Start Relays The glow relay and the start relay are mounted to the right side frame member below the operator’s seat. Note: Prior to taking small resistance readings with a digital multi meter, short the test leads together. Th...

Electrical System Reelmaster 6500-D/6700-D Page 5 - 21 Electrical System (Rev. C) Fuses The fuse blocks are located under the control panel and inside the control console. Identification, Function, and Wiring The fuses are held in two fuse blocks. Use Figure 20 to identify each individual fuse and i...

Reelmaster 6500-D/6700-D Page 5 - 22 Electrical System (Rev. C) Hydraulic Valve Solenoids These solenoids can be tested using the “Output Checks” feature of the ACE Diagnostic tool. The solenoids can also be tested manually. Note: Prior to taking small resistance readings with a digital multimeter, ...

Electrical System Reelmaster 6500-D/6700-D Page 5 - 23 Electrical System (Rev. C) High Temperature Warning and Shutdown Switch The high temperature warning and shut down switch is located on the right side of the water flange that is at- tached to the front of the engine cylinder head. There is a gr...

Reelmaster 6500-D/6700-D Page 5 - 24 Electrical System (Rev. C) Warning Light Cluster Note: Individual light bulbs can be tested by removing them from the lighting cluster and applying 14 VDC to their wiring terminals. Testing Cluster Removed from Connector. 1. Apply 14 VDC to pin D. 2. Ground pins ...

Electrical System Reelmaster 6500-D/6700-D Page 5 - 27 Electrical System (Rev. C) Fuel Gauge Sender The sender is located on top of the fuel tank under the right, front fender. 1. Remove blue/green wire and black ground wire from the sender. 2. Remove round head screws and lock washers from the send...

Electrical System Reelmaster 6500-D/6700-D Page 5 - 29 Electrical System (Rev. C) Temperature Sender The sender is located on the left side of the water flange that is attached to the front of the engine cylinder head. There is a blue/white wire attached to the terminal of the switch (Fig. 35). 1. L...

Electrical System Reelmaster 6500-D/6700-D Page 5 - 31 Electrical System (Rev. C) Hour Meter The meter is either located on the control panel or under the control panel inside the control console. 1. Connect the positive (+) terminal of a 12 VDC source to the positive terminal of the hour meter. 2. ...

Reelmaster 6500-D/6700-D Page 5 - 32 Electrical System (Rev. C) Engine Low Oil Pressure Switch The switch is normally closed (NC) and opens with pres- sure. The switch opens at approximately 8 psi. 1. Turn ignition key switch ON. Oil pressure lamp should be on. If lamp is not on: 1. Disconnect wire ...

Electrical System Reelmaster 6500-D/6700-D Page 5 - 33 Electrical System (Rev. C) Speedometer The speedometer can be tested using a DC pulse gen- erator. CAUTION Make sure the voltage source is turned OFF be- fore connecting it to the electrical circuit to avoid electrical shock and prevent damaging...

Rev. E Reelmaster 6500-D/6700-D Page 5 - 34 Electrical System (Rev. C) Reel Backlap Switches The front and rear backlap switches are attached to the reel hydraulic manifold block (Fig. 45). When the back- lap control valve (MD1 or MD2) is in the Backlap posi- tion, the switch contacts close. This fe...

Electrical System Rev. E Reelmaster 6500-D/6700-D Page 5 - 35 Electrical System (Rev. C) Seat Sensor The sensor consists of two parts. The reed switch is lo- cated on the lower bracket of the seat suspension mech- anism and has a normally open contact. The switch actuator is located on the upper pla...

Reelmaster 6500-D/6700-D Page 5 - 36 Electrical System (Rev. C) Cutting Unit Down Sensor(s) The cutting unit down switch is a normally open (NO) reed switch located on the left front lift arm that closes when the lift arm is in the lowered position. As the lift arm is lowered, a bracket on the lift ...

Electrical System Rev. E Reelmaster 6500-D/6700-D Page 5 - 37 Electrical System (Rev. C) Service and Repairs NOTE: For more component repair information, see the Kubota Workshop Manual, Diesel Engine, 05 Series at the end of Chapter 3 - Kubota Diesel Engines. Battery Storage If the machine will be s...

Electrical System Rev. F Reelmaster 6500-D/6700-D Page 5 - 41 Electrical System (Rev. C) Speedometer Sensor Replacement 1. Thread locknut onto speed sensor to allow full expo- sure of sensor threads. 2. Center a motor piston with the center of the sensor port (see Sensor Port View in Figure 52 below...

Reelmaster 6500-D/6700-D Page 5 - 42 Electrical System (Rev. C) Installing Optional Lighting (customer supplied) IMPORTANT: If optional lighting is to be added to the traction unit, use the following schematic and part numbers to prevent damage to the traction unit’s electrical system. Installation ...

Axles. Planetaries and Brakes Reelmaster 6500-D/6700-D Page 6 - 1 Axles, Planetaries and Brakes (Rev. C) Chapter 6 Axles, Planetaries and Brakes Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE 3 . . . . . . . . . . . . . . . . . . . . . . . . ...

Axles. Planetaries and Brakes Reelmaster 6500-D/6700-D Page 6 - 3 Axles, Planetaries and Brakes (Rev. C) Maintenance Changing Planetary Gear Drive Lubricant Planetary gear drive lubricant should be changed every 800 hours of operation. There are 2 separate oil reser- voirs (one for each front wheel)...

Reelmaster 6500-D/6700-D Page 6 - 4 Axles, Planetaries and Brakes (Rev. C) Changing Rear Axle Lubricant Rear axle lubricant should be changed every 800 hours of operation. Rear axle lubricant should be SAE 85W-140 gear lube. 1. Position machine on a level surface. 2. Clean area around the check plug...

Axles. Planetaries and Brakes Reelmaster 6500-D/6700-D Page 6 - 5 Axles, Planetaries and Brakes (Rev. C) Adjustments Service Brake Adjustment 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 d...

Reelmaster 6500-D/6700-D Page 6 - 6 Axles, Planetaries and Brakes (Rev. C) Rear Wheel Toe-in Adjustment After every 800 operating hours or annually, check rear wheel toe-in. To check toe-in, rotate the steering wheel so the rear wheels point straight ahead. Measure the center-to- center distance, at...

Axles. Planetaries and Brakes Rev. E Reelmaster 6500-D/6700-D Page 6 - 7 Axles, Planetaries and Brakes (Rev. C) Repairs Planetary Wheel Drive Service 1 2b 3 4 5 6 7 8 9 10 16 17 18 22 21 19 20 23 24 25 11 12 13 14 15 2d 2c 2a Figure 9 1. Spindle 2. Seal Kit 3. Bearing Cone 4. Bearing Cup 5. Wheel St...

Axles. Planetaries and Brakes Rev. E Reelmaster 6500-D/6700-D Page 6 - 9 Axles, Planetaries and Brakes (Rev. C) Brake Service 1 2 5 6 9 4 8 7 10 75 to 85 ft-lbs 3 Figure 11 1. Capscrew 2. Wheel Motor 3. O-ring 4. Brake Cable 5. Flange Head Screw 6. Brake Assembly 7. Splined Shaft 8. Retaining Ring 9...

Reelmaster 6500-D/6700-D Page 6 - 10 Axles, Planetaries and Brakes (Rev. C) 1 2 3 4 5 6 7 8 9 10 11 12 13 Figure 12 1. Brake Housing - LH 2. Seal 3. Pull Rod 4. Clevis Pin 5. Link 6. Cotter Hair Pin 7. Stationary Disc 8. Rotating Disc 9. Retaining Ring 10. Gasket 11. Actuator 12. Extension Spring 13...

Reelmaster 6500-D/6700-D Page 6 - 16 Axles, Planetaries and Brakes (Rev. C) Bevel Gear Case and Axle Case The following procedures assume the rear axle assem- bly has been removed from the machine. Removal 1. Remove the mounting screws, nuts, and lock wash- ers. Remove the bevel gear case/axle case ...

Reelmaster 6500-D/6700-D Page 6 - 18 Axles, Planetaries and Brakes (Rev. C) Installation 1. Coat new shaft seal with grease and install in axle case as shown (Fig. 22). 1. Axle case 2. Bevel gear case 3. Shaft seal Figure 22 1 2 3 2. Install the lower bevel gear, and bevel gear shaft in the axle cas...

Reelmaster 6500-D/6700-D Page 6 - 20 Axles, Planetaries and Brakes (Rev. C) 9. Remove the bevel gear case/axle case assembly from the axle support. Coat a new O-ring with grease and temporarily install the axle cover assembly. Position a dial indicator at the tooths center. Prevent the axle from tur...

Axles. Planetaries and Brakes Reelmaster 6500-D/6700-D Page 6 - 21 Axles, Planetaries and Brakes (Rev. C) Axle Shafts The following procedures assume the rear axle assem- bly has been removed from the machine. Removal 1. Remove the axle cover mounting screws. Remove the axle cover from the axle case...

Reelmaster 6500-D/6700-D Page 6 - 22 Axles, Planetaries and Brakes (Rev. C) Input Shaft/Pinion Gear Figure 32 1 1. Nut 2. Lockwasher 3. Stud 4. Locknut 5. Stake washer 6. Oil Seal 7. O-ring 8. Seal Collar 9. Inner Bearing 10. O-ring 11. Outer Bearing 12. Input Shaft/Pinion Gear 13. Bearing Case 14. ...

Reelmaster 6500-D/6700-D Page 6 - 24 Axles, Planetaries and Brakes (Rev. C) Differential Gear The following procedures assume the rear axle assem- bly has been removed from the machine. Removal 1. Remove bevel gear case/axle case assemblies (see Bevel Gear Case/Axle Case Assembly in this section of ...

Axles. Planetaries and Brakes Reelmaster 6500-D/6700-D Page 6 - 25 Axles, Planetaries and Brakes (Rev. C) Inspection 1. Measure the differential side gear O.D. and the dif- ferential case I.D. to determine the side gear to case clearance (Fig. 39). Replace components as necessary. SIDE GEAR TO CASE ...

Axles. Planetaries and Brakes Rev. E Reelmaster 6500-D/6700-D Page 6 - 27 Axles, Planetaries and Brakes (Rev. C) Pinion Gear to Ring Gear Engagement The final position of the pinion gear is verified by using the gear contact pattern method as described in the fol- lowing procedure. GEAR TOOTH DEFINI...

Rev. E Reelmaster 6500-D/6700-D Page 6 - 28 Axles, Planetaries and Brakes (Rev. C) Gear Pattern Movement Summary Every gear has a characteristic pattern. The illustrations show typical patterns only and explain how patterns shift as gear location is changed. 1. If contact is toward the heel or base ...

Cutting Units Reelmaster 6500-D/6700-D Page 7 - 1 Cutting Units Chapter 7 Cutting Units Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 5 . . . . . . . . . . . . . ....

Reelmaster 6500-D/6700-D Page 7 - 2 Cutting Units Specifications Figure 1 REEL CONSTRUCTION: Fairway reels. All welded. 5, 7 or 11 blades. HEIGHT OF CUT RANGE: 5 Blade - 1” to 1-3/4” (25-44 mm) 7 Blade - 1/2” to 1” (13-25 mm) 11 Blade - 3/8” to 3/4” (10-19 mm) Note: Use bedknife Part No. 93-9774 for...

Cutting Units Rev. E Reelmaster 6500-D/6700-D Page 7 - 3 Cutting Units Special Tools Order special tools from your Toro distributor. Some tools may have been supplied with your machine or available as TORO parts. Some tools may also be avail- able from a local supplier. Gauge Bar Assembly Use gauge ...

Reelmaster 6500-D/6700-D Page 7 - 4 Cutting Units Bedknife Screw Tool - TOR510880 This screwdriver-type bit is made to fit Toro bedknife at- taching screws. Use this bit with a torque wrench to se- cure the bedknife to the bedbar. Make sure bedbar threads are clean and use new screws. Tighten screws...

Cutting Units Reelmaster 6500-D/6700-D Page 7 - 5 Cutting Units Troubleshooting There are a number of factors that can contribute to un- satisfactory quality of cut, some of which may be turf conditions. Turf conditions such as excessive thatch, “sponginess” or attempting to cut off too much grass h...

Cutting Units Reelmaster 6500-D/6700-D Page 7 - 7 Cutting Units Set-up and Adjustments IMPORTANT : Toro strongly recommends the use of a leveling plate when setting-up or adjusting any reel type cutting unit. The leveling plate will help to ensure accu- rate and consistent adjustments. Note: Right a...

Reelmaster 6500-D/6700-D Page 7 - 8 Cutting Units Bedknife to Reel Adjustment IMPORTANT: The reel and bedknife must be parallel to insure the cutting unit cuts grass across the bedknife, and the reel and bedknife wear evenly. Note: Toro recommends light contact between the reel and bedknife. However...

Cutting Units Reelmaster 6500-D/6700-D Page 7 - 9 Cutting Units C. Recheck reel to bedknife contact on both ends of the bedknife. If necessary, repeat step B. Note: Reel to bedknife contact may become too tight or too loose after previous adjustment; therefore, turn bedknife adjustment knob, accordi...

Rev. E Reelmaster 6500-D/6700-D Page 7 - 12 Cutting Units Final Height of Cut Adjustment 1. Rotate the cutting unit vertical and place the gauge bar across front and rear rollers (Fig. 18). 2. Adjust rear roller until it contacts the gauge bar on both sides. Note: Make sure gauge bar is in contact w...

Cutting Units Reelmaster 6500-D/6700-D Page 7 - 13 Cutting Units Rear Shield Adjustment Under most conditions, best dispersion is attained when rear shield is closed (front discharge). When conditions are heavy or wet, rear shield may be opened. 1. To open rear shield, loosen flange head capscrews s...

Rev. E Reelmaster 6500-D/6700-D Page 7 - 14 Cutting Units Daily Adjustments Prior to each day’s mowing, or as required, each cutting unit must be checked to verify proper bedknife--to--reel contact. This must be performed even though quali- ty of cut is acceptable. 1. Lower cutting units onto a hard...

Reelmaster 6500-D/6700-D Page 7 - 16 Cutting Units Bedbar Removal and Installation 24 25 1 28 29 30 31 32 1 2 3 4 5 6 7 8 9 14 15 16 17 18 20 21 23 22 12 13 1 4 15 32 31 33 34 35 36 37 38 39 10 10 11 19 26 27 27 1. Screw 2. Washer 3. Quad Ring 4. Locknut 5. Pivot Hub - RH 6. Sideplate - RH 7. Reel F...

Rev. E Reelmaster 6500-D/6700-D Page 7 - 18 Cutting Units Bedknife Replacement and Regrinding 1. Remove bedbar from cutting unit. 2. Use bedknife screw tool TOR510880 to remove bed- knife screws. Remove bedknife (Fig. 27). 3. Remove all rust, scale and corrosion from bedbar sur- face before installi...

Cutting Units Reelmaster 6500-D/6700-D Page 7 - 19 Cutting Units Preparing Reel for Regrinding 1. Check to make sure reel bearings are in good condi- tion and properly adjusted before regrinding the reel. Make sure the cutting unit frame and roller brackets are true and not bent or damaged from impa...

Rev. E Reelmaster 6500-D/6700-D Page 7 - 20 Cutting Units Reel and Reel Bearings 1 2 3 4 4 6 3 5 8 7 12 11 9 10 18 15 16 14 15 17 17 19 Use tool TOR4064 Pack bearings with No. 2 general purpose grease Apply anti--seize lubricant to internal Use tool TOR4074 to install threaded spline insert. Apply L...

Cutting Units Rev. E Reelmaster 6500-D/6700-D Page 7 - 21 Cutting Units Reel Bearing Adjustment To insure long life of the reel bearings, periodically check if reel end play exists. The reel bearings can be checked and adjusted as follows: Note: Bearing and bearing housing were preset at factory as ...

Cutting Units Reelmaster 6500-D/6700-D Page 7 - 23 Cutting Units Roller and Frame Service 13 -- 17 ft--lb 13 -- 17 ft--lb 13 -- 17 ft--lb 75 -- 85 ft--lb (1.8 -- 2.4 KgM) (1.8 -- 2.4 KgM) (10.4 -- 11.8 KgM) (1.8 -- 2.4 KgM) 1 2 3 4 5 6 7 8 17 18 19 20 21 22 23 24 25 26 27 9 10 11 12 13 20 22 16 15 1...

Reelmaster 6500-D/6700-D Page 7 - 24 Cutting Units Roller Bearing and Seal Replacement 3 8 6 5 2 7 9 Sharp edge out Lip of sealfacing in 2 3 5 6 7 8 9 4 1 4 1 1. Roller 2. Inner Oil Seal 3. Bearing 4. Roller Shaft 5. Inner Seal 6. Outer Seal 7. Retaining Ring 8. Outer Oil Seal 9. Washer Figure 37 No...

Cutting Units Reelmaster 6500-D/6700-D Page 7 - 25 Cutting Units Cutting Unit Installation Cutting unit models 03860, 03861, and 03862 can be installed at any of the mounting locations on the traction unit. Figure 1 shows the orientation of the hydraulic drive motor for each of the five locations. F...

Reelmaster 6500-D/6700-D Page 7 - 26 Cutting Units 12. Insert steering pin into the pivot knuckle if you wish to keep cutting units locked in a straight line during op- eration. If no steering pin is used, the cutting units will steer themselves as the traction unit turns (Fig. 40). 13. Hook spring ...

Cutting Units Rev. E Reelmaster 6500-D/6700-D Page 7 - 27 Cutting Units Lubrication Each cutting unit has seven grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease (Fig. 42). IMPORTANT: Lubricating cutting units immediately af- ter washing helps purge wat...

Groomer Reelmaster 6500--D/6700--D Groomer (Rev. C) Page 7.1 -- 1 Chapter 7.1 Groomer Table of Contents TROUBLESHOOTING 2 . . . . . . . . . . . . . . . . . . . . . . . . . Factors Affecting Grooming 2 . . . . . . . . . . . . . . . . . . . Groomer Reel Mechanical Problems 3 . . . . . . . . . . . ADJU...

Reelmaster 6500--D/6700--D Groomer (Rev. C) Page 7.1 -- 2 Troubleshooting Factors Affecting Grooming There are a number of factors that can affect the perfor- mance of grooming. These factors vary for different golf courses and from fairway to fairway. It is important to in- spect the turf frequentl...

Groomer Reelmaster 6500--D/6700--D Groomer (Rev. C) Page 7.1 -- 3 Groomer Reel Mechanical Problems Problem Possible Causes Correction No rotation of the groomer reel. Seized groomer reel or idler bear- ing(s) in groomer side plate(s). Broken or damaged idler spring. The groomer belt is worn, broken ...

Reelmaster 6500--D/6700--D Groomer (Rev. C) Page 7.1 -- 4 Adjustments CAUTION Never work on the groomer with the engine running. Always stop the engine and remove the key from the ignition switch before working on the groomer. Groomer Height/Depth Adjustment Note: Grooming is performed above the soi...

Groomer Reelmaster 6500--D/6700--D Groomer (Rev. C) Page 7.1 -- 5 Service and Repairs Groomer Belt Replacement The groomer drive belt should be inspected/replaced annually or after 750 hours of operation. 1. Park machine on a clean and level surface, lower cutting units completely to the ground, sto...

Reelmaster 6500--D/6700--D Groomer (Rev. C) Page 7.1 -- 6 Groomer Reel Figure 4 1. Groomer reel assembly 2. Square key 3. Cap screw 4. Flat washer 5. Groomer plate 6. Retaining plate 7. Idler arm spacer 8. Torsion spring 9. Idler assembly 10. Flange nut (3 used) 11. Drive pulley 12. Flange head scre...

Reelmaster 6500--D/6700--D Groomer (Rev. C) Page 7.1 -- 8 Groomer Reel Service Inspect groomer reel blades frequently for damage and wear. Straighten bent blades with a pliers. Either replace worn blades or reverse the blades to put the sharpest blade edge forward (Fig. 7). Blades that are rounded t...

Groomer Reelmaster 6500--D/6700--D Groomer (Rev. C) Page 7.1 -- 9 Idler Assembly The drive side plate assembly groomer kit incorporates the idler system for tensioning the groomer drive belt. A torsion spring is used to maintain proper belt tension. Removal (Fig. 10) 1. Remove groomer belt cover and...

Reelmaster 6500--D/6700--D Groomer (Rev. C) Page 7.1 -- 10 Groomer Drive Figure 12 1. Flange nut 2. Groomer belt cover 3. Groomer drive belt 4. Flange head screw (3 used) 5. Drive pulley 6. Idler assembly 7. Torsion spring 8. Idler arm spacer 9. Retaining plate 10. Retaining plate spacer (2 used) 11...

Reelmaster 6500--D/6700--D Groomer (Rev. C) Page 7.1 -- 12 Groomer Height of Cut Assembly Figure 15 1. Groomer reel assembly 2. Grease seal 3. Bearing 4. Height of Cut screw 5. Washer 6. Lock nut 7. Grease fitting 8. Bearing housing 9. Grease seal 10. Adjustment bracket 11. Height of Cut bracket 12....

Units DP A Cutting Rev. E Reelmaster 6500--D/6700--D DPA Cutting Units Page 7.2 -- 1 Chapter 7.2 DPA Cutting Units Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 3 . . . . . . . . . . . . . . . . . . . . . Cutting Unit Operator’s Manu...

Rev. E Reelmaster 6500--D/6700--D DPA Cutting Units Page 7.2 -- 2 Specifications Figure 1 Frame Construction: Precision machined die cast alu- minum cross member with two (2) bolt--on cast ductile iron side plates. Reel Construction: Reels are 22 inches (55.9 cm.) in length and 7 inch (17.8 cm) in d...

Units DP A Cutting Rev. E Reelmaster 6500--D/6700--D DPA Cutting Units Page 7.2 -- 3 General Information Cutting Unit Operator’s Manual The Cutting Unit Operator’s Manual provides informa- tion regarding the operation, general maintenance and maintenance intervals for the DPA cutting units on your R...

Rev. E Reelmaster 6500--D/6700--D DPA Cutting Units Page 7.2 -- 4 Special Tools Special tools for servicing Toro Commercial Products are available from your Toro Distributor. Some tools may have been supplied with your machine or are available as TORO parts. Gauge Bar Assembly Toro Part Number: 108-...

Units DP A Cutting Rev. E Reelmaster 6500--D/6700--D DPA Cutting Units Page 7.2 -- 5 Plastic Plug Toro Part Number: 94--2703 This plug is used for placement into the side plate bear- ing housing when the hydraulic reel motor is removed. It prevents dirt and debris from entering the cutting reel bear...

Rev. E Reelmaster 6500--D/6700--D DPA Cutting Units Page 7.2 -- 6 Cutting Unit Tool Kit Toro Part Number: TOR4070 This tool kit includes special tools required for rebuilding the cutting unit and cutting unit drive motor on the Reelmaster 6500--D/6700--D series of machines. TOR4064 Spanner Wrench (n...

Rev. E Reelmaster 6500--D/6700--D DPA Cutting Units Page 7.2 -- 8 Factors That Can Affect Cutting Performance There are a number of factors that can contribute to un- satisfactory quality of cut, some of which may be turf conditions. Turf conditions such as excessive thatch, “sponginess” or attempti...

Units DP A Cutting Rev. E Reelmaster 6500--D/6700--D DPA Cutting Units Page 7.2 -- 11 Set Up and Adjustments Characteristics CAUTION Never install or work on the cutting units or lift arms with the engine running. Always stop en- gine and remove key first. The dual knob bedknife--to--reel adjustment...

Rev. E Reelmaster 6500--D/6700--D DPA Cutting Units Page 7.2 -- 12 Reel Bearing Adjustment To insure cut quality and long life of the cutting reel bear- ings, periodically check reel bearing adjustment. Check Reel Bearing Adjustment 1. Remove hydraulic reel motor from cutting unit (see Hydraulic Ree...

Units DP A Cutting Rev. E Reelmaster 6500--D/6700--D DPA Cutting Units Page 7.2 -- 13 Leveling Rear Roller The precision machined components of the cutting unit frame keep the rear roller and cutting reel in alignment (parallel). If the side plates are disassembled or as the cutting reel wears, a li...

Units DP A Cutting Rev. E Reelmaster 6500--D/6700--D DPA Cutting Units Page 7.2 -- 15 Service and Repairs Hydraulic Reel Motor IMPORTANT: When performing maintenance pro- cedures on the cutting units, carefully position the cutting unit reel motors to prevent damage to the motors or hydraulic hoses....

Rev. E Reelmaster 6500--D/6700--D DPA Cutting Units Page 7.2 -- 18 Bedbar Assembly 1. Bedbar 2. Bedknife 3. Screw (8 used) 4. Bedbar adjuster shaft (2 used) 5. Flange bushing (4 used) 6. Cap screw (2 used) 7. Detent (2 used) 8. Wave washer (2 used) 9. Retaining ring (2 used) 10. Bedbar adjuster scre...

Rev. E Reelmaster 6500--D/6700--D DPA Cutting Units Page 7.2 -- 20 Bedbar Adjuster Service Figure 21 1. Bedbar assembly 2. Compression spring 3. Lock nut 4. Bedbar adjuster shaft 5. Flange bushing 6. Cap screw 7. Detent 8. Wave washer 9. Retaining ring 10. Bedbar adjuster screw 11. Washer 14 to 16 f...

Units DP A Cutting Rev. F Reelmaster 6500--D/6700--D DPA Cutting Units Page 7.2 -- 21 Bedknife Replacement and Grinding Bedknife Removal 1. Remove bedbar from cutting unit (see Bedbar Re- moval in this section). 2. Remove screws from bedbar using a socket wrench and bedknife screw tool (see Special ...

Rev. E Reelmaster 6500--D/6700--D DPA Cutting Units Page 7.2 -- 22 Reel Assembly Removal and Installation 1. Bedbar assembly 2. Rubber bushing (2 used) 3. Flange bushing (2 used) 4. Plastic washer (4 used) 5. Metal washer (2 used) 6. Bedbar pivot bolt (2 used) 7. Lock nut (2 used) 8. Shoulder bolt (...

Rev. E Reelmaster 6500--D/6700--D DPA Cutting Units Page 7.2 -- 26 Reel Assembly Service 1. Cutting reel 2. Threaded insert (RH thread) 3. Retaining ring 4. Grease seal 5. Bearing 6. Threaded insert (LH thread) 7. Retaining ring groove 8. Groove indicating LH threads 9. Bearing shoulder 10. Reel spi...

Rev. E Reelmaster 6500--D/6700--D DPA Cutting Units Page 7.2 -- 28 Preparing Reel for Grinding Note: Before grinding a cutting reel, make sure that all cutting unit components are in good condition. Depend- ing on type of grinder used, faulty cutting unit compo- nents can affect grinding results. No...

Rev. E Reelmaster 6500--D/6700--D DPA Cutting Units Page 7.2 -- 30 Front Roller Removal (Fig. 29) 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and re- move key from the ignition switch. 2. Remove the cutting unit from the machine and place ...

Units DP A Cutting Rev. E Reelmaster 6500--D/6700--D DPA Cutting Units Page 7.2 -- 31 Rear Roller Removal (Fig. 30) 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and re- move key from the ignition switch. 2. Remove the cutting unit from the ...

Rev. E Reelmaster 6500--D/6700--D DPA Cutting Units Page 7.2 -- 32 Roller Service (Greasable Bearings with Retaining Ring) 1. Roller tube (front Wiehle shown) 2. Roller shaft 3. Inner oil seal 4. Grease fitting 5. Ball bearing 6. Inner seal 7. Outer seal 8. Retaining ring 9. Outer oil seal 10. Rolle...

Rev. E Reelmaster 6500--D/6700--D DPA Cutting Units Page 7.2 -- 34 Roller Service (Greasable Bearings with Bearing Nut) Disassembly (Fig. 33) 1. Remove bearing lock nut from each end of roller shaft. 2. Loosely secure roller assembly in bench vise and lightly tap one end of roller shaft until outer ...

Units DP A Cutting Rev. E Reelmaster 6500--D/6700--D DPA Cutting Units Page 7.2 -- 39 5. Check that roller brush has light contact with rear roll- er (Fig. 46). If contact is incorrect, brush operation will be adversely affected. Also make sure that brush shaft is parallel with rear roller. 6. Lubri...

Rev. E Reelmaster 6500--D/6700--D DPA Groomer Page 7.3 -- 1 Chapter 7.3 DPA Groomer Table of Contents GROOMING PERFORMANCE 2 . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 3 . . . . . . . . . . . . . . . . . . . . . . . . . Groomer Reel Mechanical Problems 3 . . . . . . . . . . . ADJUSTMENTS 4 ...

Rev. E Reelmaster 6500--D/6700--D DPA Groomer Page 7.3 -- 2 Grooming Performance There are a number of factors that can affect the perfor- mance of grooming. These factors vary for different golf courses and from fairway to fairway. It is important to in- spect the turf frequently and vary the groom...

Rev. E Reelmaster 6500--D/6700--D DPA Groomer Page 7.3 -- 5 Service and Repairs CAUTION Never work on the groomer with the engine running. Always stop the engine, remove the key from the ignition switch and wait for all machine movement to stop before working on the groomer. NOTE: The Groomer Instal...

Rev. E Reelmaster 6500--D/6700--D DPA Groomer Page 7.3 -- 6 Groomer Plate Assembly Figure 4 1. Groomer reel 2. Pulley spacer 3. Washer (as required) 4. Square key 5. Driven pulley 6. Flange nut 7. Socket head screw 8. Idler plate 9. Idler pulley assembly 10. Lock nut 11. Flange head screw 12. Drive ...

Rev. E Reelmaster 6500--D/6700--D DPA Groomer Page 7.3 -- 13 6. Place excluder seals on groomer shaft. 7. Install o--ring on non--drive end of groomer shaft. 8. Install groomer reel back on cutting unit (see Groom- er Reel Installation in this section). 1. Groomer shaft 2. Broomer strap Figure 13 1 ...

Rev. E Reelmaster 6500--D/6700--D DPA Groomer Page 7.3 -- 14 Groomer Pivot Hub Figure 14 1. Groomer drive shaft 2. Ball bearing 3. Grease seal 4. Retaining ring 5. Pivot hub 6. Retaining ring 7. Extension spring 8. Retaining ring 9. Idler plate 10. O--ring (7” cutting unit only) 4 3 1 2 9 10 8 5 6 7...

Rev. E Reelmaster 6500--D/6700--D DPA Groomer Page 7.3 -- 16 Height Adjuster Assembly Figure 16 1. Groomer plate (LH drive shown) 2. Shoulder bolt 3. Ball joint rod 4. Jam nut 5. Compression spring 6. Flange head screw 7. Lower ramp 8. External snap ring 9. Upper ramp 10. Bushing 11. Flat washer 12....

Electrical Diagrams Reelmaster 6500-D/6700-D Page 8 - 1 Electrical Diagrams Chapter 8 Electrical Diagrams Table of Contents ELECTRICAL SCHEMATICS Reelmaster 6500-D Model 03806 & 03807 Serial No. 210000001 - 210999999 Electrical Schematic 3 . . . . . . . . . . . . . . . . . . . . . . . . . Reelma...

Rev. E Electrical Schematic Reelmaster 6500-D Model 03806 & 03807 All relays and solenoids are shown as de-energized.All ground wires are black. Serial Numbers 210000001 -- 210999999 START RELAY 2A RUN (ETR) SOLENOID OUTPUTS INPUTS B A I Y X RUN START S 3C 2B 3M ENG INE W AT E R T EMP SENSO R ST...

Rev. E HIGH TEMPSHUTDOWN SWITCH IF EQU IPPED Accessory Power and Controller #2 Reelmaster 6500--D/6700--D Logic Circuit (7.5 Amp Fuse) Page 1 of 2 Reelmaster 6500-D/6700-D Page 8 - 12 Electrical Diagrams

Rev. E HIGH TEMPSHUTDOWN SWITCH IF EQU IPPED Starter, Glow Plugs, and Alternator Circuits Reelmaster 6500--D/6700--D (Fusible Links) Reelmaster 6500-D/6700-D Page 8 - 14 Electrical Diagrams

Rev. E Optional TurfDefender Leak Detector Reelmaster 6500-D/6700-D TURF DEFENDER LEAK DETECTOR 2D 1B 3B 2C 1E 2E 1C 3C 2A 2F 1F 3F A B C D A A B B C C E E ELECTRIC SOLENOID VALVE RED/WHITE BLACK/WHITE TO LEAK DETECTOR CONNECTOR OF MAIN HARNESS RED/YELLOW BLACK/YELLOW + -- (RED) ALARM TURF DEFENDER ...

Wire Harnesses Reelmaster 6500-D/6700-D P5 P3 P4 P45 J24 J25 J23 P12 P7 & P8 P29 P6 P37 P14 P15 P13 J5 P10 J6 P11 J4 J2 J3 Console Harness Neutral Switch Harness P41 J22 J21 Engine Harness Main Harness P24 J15 J16 J18 J19 J20 P39 P38 P27 P22 P23 J8 J9 P16 J17 J10 J11 J1 J14 J13 P42 P21 P43 P20 P...

Reelmaster 6500-D/6700-D Page 8 - 18 Electrical Diagrams Electrical Connector Drawing Reelmaster 6500-D/6700-D P19 MSV1 Solenoid Located on reel manifold Cavity Wire A Ye llow/White B Black P20 Front Lift Arm Located on left hand front lift arm Cavity Wire A Black/White B Black P11 Warning light clu...

Reelmaster 6500-D/6700-D Page 8 - 20 Electrical Diagrams Secondary (#2) Electronic Controller Harness and Reelmaster 6700-D SV6 Solenoid Located on lift manifold Cavity Wire A Brown/White B Black #6 Lift Arm Located on right side rear lift arm Cavity Wire A Red/Yellow B Black 1 2 3 Joystick Located ...