Toro Reelmaster 6500–D Service Manual
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Toro Reelmaster 6500–D Service Manual

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Preface
The purpose of this publication is to provide the service
technician with information for troubleshooting, testing,
and repair of major systems and components on the
Reelmaster 6500–D and 6700–D.
REFER TO THE TRACTION UNIT AND CUTTING
UNIT OPERATOR'S MANUALS FOR OPERATING,
MAINTENANCE AND
TIONS. Space is provided in Chapter 2 of this book to
insert the Operator's Manuals and Parts Catalogs for
your machine. Replacement Operator's Manuals are
available by sending complete Model and Serial Num-
ber to:
The Toro Company
8111 Lyndale Avenue South
Minneapolis, MN 55420
The Toro Company reserves the right to change product
specifications or this publication without notice.
Reelmaster
ADJUSTMENT
INSTRUC-
E The Toro Company – 1996, 1998, 1999, 2002
R
6500–D/6700–D
This safety symbol means DANGER, WARN-
ING, or CAUTION, PERSONAL SAFETY
INSTRUCTION. When you see this symbol,
carefully read the instructions that follow.
Failure to obey the instructions may result in
personal injury.
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing or re-
pair of the machine.
IMPORTANT: The IMPORTANT notice will give im-
portant instructions which must be followed to pre-
vent damage to systems or components on the
machine.
PART NO. 95871SL Rev. D
Service Manual
(With Peugeot Engine)

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Summary of Contents for Toro Reelmaster 6500–D

  • Page 1 Minneapolis, MN 55420 portant instructions which must be followed to pre- vent damage to systems or components on the The Toro Company reserves the right to change product machine. specifications or this publication without notice. E The Toro Company – 1996, 1998, 1999, 2002...
  • Page 2 Reelmaster 6500–D/6700–D...

  • Page 3: Table Of Contents

    Table Of Contents Chapter 1 – Safety Chapter 6 – Axles, Planetaries and Brakes Safety Instructions ......1 –...
  • Page 4 Reelmaster 6500–D/6700–D...

  • Page 5: Safety And Instruction Decals

    ......Safety Instructions The REELMASTER 6500-D and 6700–D was tested and certified by TORO for compliance with the CAUTION B71.4-1990 specifications of the American National Standards Institute when ballast is added.
  • Page 6 7. Remove all debris or other objects that might be B. Do not remove fuel tank cap while engine is hot or picked up and thrown by the reels or fast moving compo- running. nents from other attached implements. Keep all by- C.
  • Page 7 Toro replacement parts and accessories. Replacement parts and accessories made 26. Before disconnecting or performing any work on the...
  • Page 8 Safety and Instruction Decals The following safety and instruction decals are affixed to the traction unit. If any decal becomes illegible or damaged, install a new decal. Part numbers are listed below and in your Parts Catalog. UNDER FLOOR PLATE (Part No.
  • Page 9 ON TOOL BOX (Part No. 93–1262) WARNING: Read Operating & Safety Instructions ON BACKLAP BRACKET (Part No. 93–1264) WARNING: Read Backlap, Operating & Safety Instructions ON LIFT ARMS (Part No. 93–6687) Do Not Step ON TOWER (Part No. 93–6699) Mowing Speed Control ON ROLL BAR ROOF ON CONSOLES (Part No.
  • Page 10 Safety Reelmaster 6500–D/6700–D Page 1 – 6...

  • Page 11: Product Records

    Chapter 2 Product Records and Manuals Table of Contents PRODUCT RECORDS ......Capscrew Markings and Torque Values – Metric EQUIVALENTS AND CONVERSIONS .

  • Page 12: Equivalents And Conversions

    Equivalents and Conversions Product Records and Manuals Reelmaster 6500–D/6700–D Page 2 – 2...

  • Page 13: Torque Specifications

    For critical applications, as determined reduced by 25% for lubricated fasteners to achieve by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may is unique to the application is clearly identified and spe- also have to be reduced when the fastener is threaded into aluminum or brass.

  • Page 14: Capscrew Markings And Torque Values - U.s

    Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Grade 1, 5, & SAE Grade 1 Bolts, Screws, Studs, & SAE Grade 5 Bolts, Screws, Studs, & SAE Grade 8 Bolts, Screws, Studs, & Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts...

  • Page 15: Capscrew Markings And Torque Values - Metric

    Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws, and Studs with Class 10.9 Bolts, Screws, and Studs with Thread Size Thread Size Reg lar Height N ts Regular Height Nuts Reg lar Height N ts Regular Height Nuts (Class 8 or Stronger Nuts) (Class 10 or Stronger Nuts)

  • Page 16: Other Torque Specifications

    Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque** Thread Size Thread Size Square Head Hex Socket 7/16 – 20 UNF 65 + 10 ft–lb 88 + 14 N–m Grade 5 1/4 –...

  • Page 17: Quick Reference Maintenance Aid

    Reelmaster 6500–D/6700–D Product Records and Manuals Page 2 – 7 Rev. C...

  • Page 18: Bearing And Bushing Lubrication

    Lubricating Bearings and Bushings CAUTION Before servicing or making adjustments to the machine, stop engine and remove key from the switch. The machine has grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease. If machine is operated under normal condi- tions, lubricate all bearings and bushings after every 50 Figure 3 hours of operation or immediately after every washing.
  • Page 19 Figure 7 Figure 8 Figure 9 Reelmaster 6500–D/6700–D Product Records and Manuals Page 2 – 9 Rev. C...
  • Page 20 Product Records and Manuals Reelmaster 6500–D/6700–D Page 2 – 10 Rev. C...

  • Page 21: Operation And Service History Report

    EQUIPMENT OPERATION AND SERVICE HISTORY REPORT REELMASTERR 6500–D AND 6700–D TORO Model and Serial Number: ______________–______________ Engine Numbers: _____________________________ Transmission Numbers: _____________________________ Drive Axle(s) Numbers: _____________________________ Date Purchased: _____________________________ Warranty Expires____________ Purchased From: _____________________________ _____________________________ _____________________________ Contacts: Parts _____________________________ Phone____________________...
  • Page 22 REELMASTER 6500–D/6700–D Maintenance Schedule Minimum Recommended Maintenance Intervals Maintenance Procedure Maintenance Interval & Service Every Every Every Every 400hrs 800hrs Lubricate All Grease Fittings Every 200hrs 100hrs 50hrs Inspect Air Filter, Dust Cup, and Baffle A Level Check Battery Level/Cable Connections Service } Change Engine Oil and Filter Inspect Cooling System Hoses...

  • Page 23: Specifications

    REELMASTER 6500–D/6700–D Daily Maintenance Check List Daily Maintenance: (duplicate this page for routine use) Check proper section of Operator’s Manual for fluid specifications Daily Maintenance Check For Week Of _________________ Maintenance Maintenance Check Item b TUES THURS Safety Interlock Operation Brake Operation Engine Oil &...
  • Page 24 Product Records and Manuals Reelmaster 6500–D/6700–D Page 2 – 14 Rev. C...

  • Page 25: Special Tools

    Chapter 3 Engine Table of Contents INTRODUCTION ......2 Injector Tests ......29 IDENTIFICATION AND SPECIFICATIONS .

  • Page 26: Introduction

    6500-D through TORO Distributors. Repair parts may be or- mower. dered by TORO Part Number. If no parts list is available be sure to provide your dealer or distributor with the Most repairs and adjustments require tools which are TORO Model Number and Serial Number.

  • Page 27: Identification And Specifications

    Identification and Specifications General Specifications Item Specification ___________________________________________________________________________________________ Engine Type Peugeot XUD9AI, 4 cycle, water cooled, 4 cylinder, vertical in-line cylinders, single overhead cam, indirect injection, naturally aspirated. ________________________________________________________________________________________________________________________________________________________ Compression ratio 23.5 : 1 ________________________________________________________________________________________________________________________________________________________ Governor: Mechanical centrifugal type integral with fuel injection pump. ________________________________________________________________________________________________________________________________________________________ 2500 ±...

  • Page 28: Repairs

    Cylinder Head Cylinder head height h is measured with the camshaft in place fitted with two bearing caps. h is measured on the oil seal lip contact diameter (the largest diameter). h nominal: 157.40 to 157.75 mm Maximum permissible bow on bottom of cylinder head: 0.07 mm (camshaft must turn freely).
  • Page 29 Camshaft Camshafts with 0.5 mm oversize bearings* are identi- fied by a yellow paint ring (d) between the cams of No. 1 cylinder. * NOTE: These camshafts are installed only on ex- change engines, and can be obtained on special order. Figure 4 Valves Units: mm...
  • Page 30 Valve Springs Units: mm Spring ød P1: daN 42.4 Figure 7 Valve Guides Units: mm øf øg øk ± 0.25 ± 0.50 Tolerance + 0.032 – 0.011 + 0.2 Production 14.02 13.981 14.13 14.051 Repair 1 14.29 14.211 52.00 36.50 8.02 Repair 2 14.59...
  • Page 31 Valve Seats Units: mm Intake øa øb ± 0.025 ± 0.15 Tolerance – 0.025 – 0.1 Production 40.161 6.25 8.267 40.361 40.2 6.45 8.467 Repair 1 40.461 40.3 6.45 8.467 Repair 2 40.661 40.5 6.45 8.467 Units: mm Exhaust øa øb ±...
  • Page 32 Cylinder / Piston Matching Units: mm Identification CYLINDER øa PISTON øb Tolerance: Tolerance: ± 0.009 + 0.018 – 0 Production None 82.93 83.03 82.96 Repair 1 83.20 83.13 Repair 2 83.50 83.43 Repair 3 83.80 83.73 NOTE: The piston øb must be measured at dimension c. 25.00 NOTE: The repair dimension (x) is stamped on the cylinder block and pistons.
  • Page 33 Crankshaft Units: mm Crank Pins and Journals øa øc ± 0.003 ± 0.003 Tolerance – 0 – 0 – 0.016 – 0.019 Production 50.00 1.827 60.00 1.842 Repair 1 49.70 1.977 59.70 1.992 NOTE: Repair 1 size connecting rod and main bearing shells can be identified by white paint (1) on the edge of the shell.
  • Page 34 Tightening Torques Part ft-lb __________________________________________________________________________________________ Connecting rod end caps ________________________________________________________________________________________________________________________________________________________ Camshaft bearing caps 17.5 ________________________________________________________________________________________________________________________________________________________ Camshaft gear ________________________________________________________________________________________________________________________________________________________ Coolant pump ________________________________________________________________________________________________________________________________________________________ * Crankshaft pulley 40 + 60° 4 + 60° 30 + 60° ________________________________________________________________________________________________________________________________________________________ Cylinder head bolts pre-tightening * tightening 70 +120°...

  • Page 35: Special Tools

    Special Tools NOTE: Order special tools from the TO R O S P E C IA L Reelmaster 6500-D Parts Catalog. Some tools may also TO O L S A N D A P P LIC AT IO N S G U ID E (C O M M E R C IA L be available from a local supplier.
  • Page 36 TOR2437T Dial Indicator This dial indicator may be used with TOR80110H, TOR80117AM and TOR80504A2 to accomplish any of the following tasks: for checking the protrusion of the swirl chambers, valve recess and measurement for cylinder head gasket selection, adjusting the timing of the injection pump and for checking the crankshaft and float.
  • Page 37 TOR70153C Rear Main Seal Installer Used with a small hammer to install new rear main oil seal. Figure 20 TOR70153D Front Cover Seal Installer Used with a small hammer to install new front crankshaft seal. Figure 21 TOR70153N Flywheel T.D.C. Locator Pin Used to set injection pump timing.
  • Page 38 TOR80110GY Extension Rod and Adapter Used with TOR 80504A1 and TOR80504A2 to check crankshaft end float. Figure 24 TOR80110H Indicator Holder Block used to hold dial indicator to check protrusion of swirl chambers, valve recess and measurement for cylinder head gasket selection. Figure 25 TOR80117AM Timing Tool Kit For Roto Diesel DPC Pump...
  • Page 39 TOR80149 Injector Socket Used to remove and install fuel injectors. Figure 28 TOR80504A1 Extension Used with TOR 80110GY and TOR 80504A2 to check crankshaft end float. Figure 29 TOR 80504A2 Indicator Holder Used with TOR80110GY and TOR 80504A1 to check crankshaft end float.
  • Page 40 .0149 - Cylinder Head Separating Levers (Make Locally) Used to remove cylinder head (qty. 2 required). Units: mm Figure 32 TOR70153H Injector Pump Gear Puller Loosen the nut on the injector pump gear, then use this TOR70153H tool to loosen the pulley from the tapered shaft on the injector pump.

  • Page 41: Adjustments

    Adjustments Valve Clearance Adjustment (See Valve Clearance Adjustment in the Engine Over- haul Section.) Engine Speed Adjustments Maximum fuel flow and speed adjustments are sealed and should only be unsealed by a CAV Lucas ROTO- DIESEL service dealer. Throttle Cable Adjustments The throttle control lever at the operator’s station must not touch the end of the slot during full range of motion from idle (SLOW) to full engine RPM (FAST).

  • Page 42: Troubleshooting

    Troubleshooting Alternator Problem Possible Causes Alternator is not charging. Alternator belt loose. Charging circuit defective. Energizing circuit defective. Brushes worn or seized. Rotor winding defective. Stator winding defective. Regulator defective. Output low or irregular. Alternator belt loose. Charging circuit defective. Energizing circuit defective.
  • Page 43 Fuel Injectors Problem Possible Cause Correction Bad spray pattern Carbon deposit around the orifice Clean Scored nozzle seat Replace injector Needle damaged Replace injector Leaking injector Foreign matter jammed between Clean nozzle seat and needle Nozzle seat out-of-true Replace injector Needle seized or showing seizing Water in fuel Drain water and flush fuel feed...
  • Page 44 Fuel Injection Pump Problem Possible Cause Correction Engine has no power Defective fuel supply Check filter cartridge and pipes Incorrect pump timing Correct timing Incorrect spray, or injector pressure Check, clean and adjust injectors out of adjustment Air intake restriction Check hoses and air cleaner Insufficient automatic advance Have pump repaired...
  • Page 45 Problem Possible Cause Correction Engine will not start No preheating Check glow plugs and relay No fuel supply Make sure tank is not empty Check filter element and pipes Check system bleeding Defective solenoid valve Check electric stop solenoid Seized pump plunger Have pump repaired Discharge valve blocked in “stop”...
  • Page 46 Low Power Problem Possible Causes Engine does not give full power Injection pump timing Seized piston rings Defective injector(s) Air intake restricted Valve leaks Clogged fuel filter Injection pipe restriction due to excessive tightening of unions Defective injection pump Irregular idling Defective injection pump Air getting into fuel system Idling stop out of adjustment...
  • Page 47 Noisy Engine Problem Possible Causes Knocking Loose main bearings Broken part Leakage return collector clogged Lifters out of adjustment Foreign matter in a cylinder Seized injector Injection pump timing Sheared glow plug Timing out of adjustment Whistling, blowing Leaking cylinder head gasket Leaky glow plug Valve seats Leaky injector...
  • Page 48 Pre-heating Problem Possible Causes Glow plug does not glow red hot Faulty glow plug Faulty glow plug relay Damaged wiring or connector All four glow plugs burnt out / ends melted – injection pump timing out of adjustment (engine overheating) See Chapter 5 - Electrical System Engine Page 3 - 24...
  • Page 49 Smoke During Operation Problem Possible Causes Black Defective injector Injection pump out of adjustment Injection pump timing Air intake restricted Inlet chambers clogged Not enough advance Grey Defective injector Injection pump timing Air intake restricted Not enough advance Blue-Grey Defective injector Injection pump timing Too much oil Blue...
  • Page 50 Starting Problems Problem Possible Causes Engine will not start and emits black smoke Air intake obstructed Defective injectors Lack of compression (seized rings, damaged or worn valve seats, or general wear) Injection pump timing Engine will not start and emits white smoke Leaking cylinder head gasket Engine will not start and does not emit any smoke Frozen fuel...

  • Page 51: Testing And Inspection

    Testing and Inspection Injection Pump Timing (See Timing of Injection Pump in the Engine Overhaul section.) Glow Plug Test CAUTION Be careful while handling or testing glow plugs. Glow plugs become extremely hot. Ac- cidental contact with the heated plug tip could cause personal injury.
  • Page 52 Compression Test Minimum cylinder compression is 20 bar (290 psi) at 200 rpm (normal cranking speed). The engine should be warm - coolant temperature of 50 C (120 IMPORTANT: DO NOT put oil into the combustion chamber before performing a compression test. Damage may result because of “hydraulic”...
  • Page 53 Injector Tests There are several tests to examine the condition of the sion stroke. The point at which this fuel injection occurs injection nozzles. These tests require the use of a is determined by the injection timing. If the nozzle is nozzle tester and nozzle tester adapter.
  • Page 54 Nozzle Leakage Test A nozzle that leaks fuel from the nozzle orifice must be replaced. 1. Securely fasten the nozzle to the adapter. 2. Wipe all fuel from the nozzle. Good 3. Operate the pump until the pressure is approximately 20 bar or kg/cm (280 psi) below opening pressure.
  • Page 55 Injection Pump Testing Calibration of fuel delivery volumes, pressure and dis- D. Put the throttle control in the FAST position. Turn tribution between pump barrels should be performed by the ignition key to the START position to crank the a professional diesel engine service shop. Special test engine.
  • Page 56 Thermostat Test If the engine overheats or runs too cool, and a faulty thermostat is suspected, the thermostat should be tested. 1. Remove the thermostat. 2. Put the thermostat in a container of water with a thermometer and heat the water. Starts to open at: 81 C (178 7 mm (0.28 in.) full open at 88...

  • Page 57: Fuel System Service

    Fuel System Service Priming Fuel System 1. Stop the engine. Unlatch and raise the hood 2. Fill the fuel tank. 3. Install a 3/16" hose over bleed screw. Put other end of hose into a container to catch fuel (Fig. 38). 4.
  • Page 58 Injector Service NOTE: If injectors need to be inspected or repaired it is recommended that it be done by an authorized CAV Lucas ROTO DIESEL service dealer - especially during the warranty period. Repairs by non-authorized dealers WILL void the warranty on the injectors. Removal 1.
  • Page 59 Assembly 1. Check all parts for condition and cleanliness. Oil parts before reassembly. 2. Secure the injector body in a “V” type injector holder. 3. Install the adjusting shims, spring, push rod, spacer and injector (Fig. 40, Items 2, 3, 4, 5, 6). 4.

  • Page 60: Timing Belt Replacement

    Timing Belt Replacement Timing Belt Removal IMPORTANT: Never install a used belt. When the timing belt is removed a NEW timing belt must be installed. SPECIAL TOOLS REQUIRED: Tune-Up Tool Set TOR 4035 1 ea. M8 x 125 x 40 Metric Bolt 2 ea.
  • Page 61 7. Loosen the nut (Fig. 45, Item 8) and the bolt (Item 9), securing the roller tensioner bracket (Item 10). 8. Rotate the roller tensioner bracket square (Item A) to compress the spring (Item 11). 9. Re-tighten the bolt (Item 9). 10.
  • Page 62 Timing Belt Installation IMPORTANT: Never install a used belt. When the timing belt is removed a NEW timing belt must be installed. 1. Install the new timing belt, with the runs taut, in the following order (Fig. 46): Crankshaft gear (Item 13) Fixed roller (Item 11) Injection pump gear (Item B) Camshaft gear (Item C)
  • Page 63 4. Remove the three gear locking bolts and TDC Lock Pin tool. 5. Turn the crankshaft two revolutions (clockwise). 6. Re-install the TDC Lock Pin tool TOR 70153 N and the three gear locking bolts. IMPORTANT: If you can not install any one of the locking devices, repeat the Timing Belt Installation procedures from the beginning.

  • Page 64: Injection Pump Timing

    Injection Pump Timing Timing of Injection Pump (Pump Mounted on Engine) The adjustment position for start of injection varies on each pump (manufacturing tolerances). The adjustment position is given by measurement “X.XX” in one of three places on the pump (Fig. 51): a.
  • Page 65 6. Clean the area around the pump timing plug (Fig. 54, Item d). Remove the pump timing plug. 7. Use Timing Tool Assembly TOR 80117 AM. Lubricate the timing rod (Fig. 55, Item 1) with Diesel fuel, then install the timing rod in the pump timing hole (Item d). Check to see that the rod moves freely in the bore.

  • Page 66: Preparation For Engine Repair

    Preparation For Engine Repair 1. Before cleaning and disassembly, carefully check for 4. Disassemble the engine in proper order, arranging problems that cannot be found after the engine has the parts the disassembled parts neatly. Apply clean been cleaned or disassembled (e.g. oil leaks from engine oil to all disassembled parts to prevent rust.

  • Page 67: Engine Removal And Installation

    Engine Removal and Installation Figure 57 Removing the Engine 1. Put machine on a level surface and engage parking brake. Turn engine OFF and remove key from ignition switch. Allow engine and radiator to cool. CAUTION 2. Drain oil from engine. DO NOT open radiator cap or drain coolant if engine or radiator is hot.
  • Page 68 Check for oil and coolant leaks and repair as necessary. Peugeot recommended Coolant/Antifreeze is available in 1 U.S. Gallon containers under Toro Part No. 93-7213. IMPORTANT: The anti-freeze should contain no Borate and have a Ph of 7 to 8.5.

  • Page 69: Engine Overhaul

    Engine Overhaul Disassembly of External Components 1. Remove TDC sensor and clutch housing center- ing pin. 2. Mount the engine on a stand. 3. Lock the flywheel with TOR FD86 tool. 4. Remove exhaust manifold and inlet manifold. 5. Remove the coolant manifold. 6.
  • Page 70 12. Remove the thermostat housing cover (Fig. 58, Item 17). TOR 80149 13. Remove the thermostat housing (Item 18). 14. Remove the injectors (Item 19) and retrieve the copper washer (Item 20), and flame trap washer (Item 21). 15. Remove the glow plugs (Item 22). Figure 58 Injection Pump Removal 1.
  • Page 71 Figure 60 4. Remove the pump (Fig. 61, Item 5) / drive chain / crankshaft sprocket (Item 7) assembly. NOTE: Item 6 - spacer is not used on engines used in TORO machines. Figure 61 Reelmaster 6500-D/6700-D Page 3 - 47...
  • Page 72 Crankshaft and Piston Removal 1. Remove flywheel locking tool. 2. Remove the connecting rod end caps (Fig. 62, Item 8), marking each cap for re-installation in the same location. NOTE: Connecting rods and end caps are not num- bered. Once they are removed there is no way of knowing the correct location for installation unless you mark them for re-installation.
  • Page 73 Cylinder Head Overhaul 1. Progressively slacken the camshaft bearing caps (Fig. 65, Item 1). 2. Remove the bearing caps (Item 1), oil seals (Item 2), camshaft (Item 3), tappets (Item 4) and adjustment shims (Item 5). Mark adjustment shims and tappets so they will be re-installed in the same location –...
  • Page 74 8. Check the protrusion of the swirl chambers (Fig. 68, A). Protrusion: 0 to 0.03 mm Achieve this dimension by machining faces (a) and (b). 9. Check the valve recess (B). Exhaust: 0.9 to 1.45 mm Inlet: 0.5 to 1.05 mm Achieve this dimension by machining the valve seats.
  • Page 75 Crankshaft Installation 1. Put thread lock Loctite on the oil gallery plugs and install them in the cylinder block. 2. Install the grooved main bearing shells. (See Crank- shaft in the Inspection and Specifications section for main bearing shell thickness.) Figure 71 3.
  • Page 76 7. Check crankshaft end float (Fig. 74): A . I n s t a l l t he dia l in dica to r, usin g t oo l s TOR 80110G1, TOR 80504 A1 and A2. TOR 80110G1 B. End float must be between 0.07 and 0.32 mm. NOTE: For choice of half-washer thickness see Crankshaft in the Identification and Specifications section.
  • Page 77 13. Tighten the bearing cap bolts to a torque of 70 Nm (52 ft-lb). 14. Using shim TOR 80110DZ, cut off the side seals so that they protrude 2 mm. 15. Check that the crankshaft rotates without tight spots. TOR 80110DZ Figure 76 Pistons and Connecting Rod Assembly 1.
  • Page 78 3. Oil the piston and tighten the piston ring clamp (Fig. 78, Item 4). 4. Remove the connecting rod end caps. 5. Install the pistons in the bores, matching the markings made when removed, and aligning the crown recess (Item a) on the oil filter side of the block. 6.
  • Page 79 3. Install the special shoulder bolt (Fig. 81, Item 1) to center the pump in the proper location. 4. Install the other bolts and tighten the bolts (Item 1, 2, 3) to a torque of 20 Nm (15 ft-lb). 5. Install the seal carrier plate and a new gasket (Item 4) and tighten the bolts to a torque of 15 Nm (11 ft-lb).
  • Page 80 Cylinder Head Gasket Selection 1. Install the dial indicator on support TOR 80110 H and zero it on a surface plate. 2. Turn the crankshaft and measure the protrusion of each piston at TDC. 3. Note the maximum protrusion (Fig. 82, Item d). TOR 80110H 4.
  • Page 81 Cylinder Head Tightening 1. Install new washers on the bolts. 2. Pre-tighten the bolts in the order shown (Fig. 84) to a torque of 30 Nm (22 ft-lb). 3. Tighten the bolts in the order shown to a torque of 70 Nm 52 ft-lb).
  • Page 82 3. Remove the camshaft gear (Fig. 86, Item 1). 4. Remove the camshaft bearing caps (Item 2). 5. Remove the camshaft (Item 3). 6. Remove the tappets (Item 4). 7. Remove the basic shims (Item 5). 8. Determine the shim thickness to be fitted for each valve.
  • Page 83 11. Apply a thin coat of Formetanch or Permatex No. 2 sealant to each end of the bearing housing at (Fig. 87, Item a). 12. Apply MOLYKOTE G RAPID to the bearing surfaces on the camshaft. 13. Install the camshaft (Item 3) with the DIST marking at the timing gear end.
  • Page 84 Assembly of External Components 1. Install new fire ring washers (Fig. 89, Item 1), convex surface facing up. 2. Install new copper washers (Item 2). 3. Install the injectors and tighten to a torque of 90 Nm (66 ft-lb). 4. Install the pre-heat plugs (Item 4) and tighten to a torque of 22 Nm (16 ft-lb).
  • Page 85 Break-in Engine After Overhaul After disassembling or overhauling the engine, install the a new oil filter. Replace this filter with a new filter after the first 20 to 50 hours of operation. Reelmaster 6500-D/6700-D Page 3 - 61 Engine...
  • Page 86 Engine Page 3 - 62 Reelmaster 6500-D/6700-D...

  • Page 87: Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

    Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS ......Test No. 7: Reel Drive/Lift Pump Efficiency .

  • Page 88: Specifications

    NOTE: A red dye additive for the hydraulic oil is avail- able in 2/3 oz. bottles. One bottle is sufficient for 4 to 6 gallons of hydraulic oil. Order Part No. 44–2500 from your authorized Toro Distributor. Hydraulic System Reelmaster 6500–D/6700–D Page 4 –...

  • Page 89: General Information

    General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such WARNING as, pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage condi- Before disconnecting or performing any work tions or mishandling during operation or maintenance. on hydraulic system, all pressure in system These conditions can cause damage or premature dete- must be relieved by stopping the engine and...
  • Page 90 SAE Straight Thread O–Ring Port – Non–adjustable (Fig. 4) 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. O–Ring 3.

  • Page 91: Pushing Or Towing Traction Unit

    Pushing or Towing Traction Unit In an emergency, the Reelmaster 6500–D can be moved by actuating the by–pass valve in the variable displacement hydraulic pump and pushing or towing the machine. IMPORTANT: Do not push or tow the machine faster than 2–3 mph (3–4.8 km/hr) because internal trans- mission damage may occur.

  • Page 92: Hydraulic Schematics

    Hydraulic Schematics Hydraulic System Reelmaster 6500–D/6700–D Page 4 – 6 Rev. B...
  • Page 93 Reelmaster 6500–D/6700–D Hydraulic System Rev. B Page 4 – 7...
  • Page 94 Hydraulic System Reelmaster 6500–D/6700–D Page 4 – 8...
  • Page 95 Reelmaster 6500–D/6700–D Hydraulic System Page 4 – 9...
  • Page 96 Hydraulic System Reelmaster 6500–D/6700–D Page 4 – 10...
  • Page 97 Reelmaster 6500–D/6700–D Hydraulic System Page 4 – 11...
  • Page 98 Hydraulic System Reelmaster 6500–D/6700–D Page 4 – 12...
  • Page 99 Reelmaster 6500–D/6700–D Hydraulic System Page 4 – 13...
  • Page 100 Hydraulic System Reelmaster 6500–D/6700–D Page 4 – 14 Rev. B...
  • Page 101 Reelmaster 6500–D/6700–D Hydraulic System Page 4 – 15...
  • Page 102 Hydraulic System Reelmaster 6500–D/6700–D Page 4 – 16...
  • Page 103 Reelmaster 6500–D/6700–D Hydraulic System Page 4 – 17...

  • Page 104: Special Tools

    Special Tools NOTE: Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Some tools may also be available from a local supplier. Hydraulic Pressure Test Kit – TOR47009 Use to take various pressure readings for diagnostic tests.
  • Page 105 Hydraulic Tester – With Pressure and Flow Capabilities – TOR214678 Figure 11 You must have o–ring face seal (ORFS) adapter fittings 4. HIGH PRESSURE GAUGE: High range gauge to ac- for this tester to use it on the Workman vehicle. commodate pressure beyond the capacity of the low pressure gauge, 0 –...

  • Page 106: Troubleshooting

    Troubleshooting The cause of an improperly functioning hydraulic sys- Continued use of an improperly functioning hydraulic tem is best diagnosed with the use of proper testing system could lead to extensive internal component equipment and a thorough understanding of the com- damage.
  • Page 107 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 reservoir and refill with proper viscosity oil. Heat exchanger defective.
  • Page 108 Transmission Response Sluggish Cause Correction Charge pressure low. TEST NO. 1. Inspect charge relief valve. Repair or replace if defective. Servo control valve faulty. Inspect control valve for: Plugged control orifices. Damaged mounting gasket. Misadjusted or damaged neutral return spring. Broken control connector pin.
  • Page 109 Cause Correction Wheel motor(s) worn or damaged. Inspect wheel motors and repair or replace if worn or damaged. NOTE: If a motor has internal damage, it is likely that the pump and other motor are also damaged. Pump worn or damaged. Inspect pump and repair or replace if worn or damaged.
  • Page 110 Excessive Wheel Motor Case Drain Flow Cause Correction Excessive internal wear in wheel motor. Disassemble motor completely. Inspect parts and replace as necessary. Case drain flow should not exceed 7.6 L/m [2 gal/m] at full pressure. Noisy Gear Pump Caused by Cavitation Cause Correction Oil too heavy.
  • Page 111 Cause Correction VS1A not shifting. Do electrical diagnostics to make sure that voltage is NOTE: Lift function will also be affected. being applied to VS1A and that there is no electrical fault. See Chapter 5 – Electrical System. Do cartridge valve service procedure for valve VS1A. Interchange VS1A with VS1B and check operation.
  • Page 112 Front Reels Turn Too Fast Cause Correction VS1A not operating properly. Do electrical diagnostics to make sure that voltage is being applied to VS1A and that there is no electrical fault. See Chapter 5 – Electrical System. Do cartridge service procedure for VS1A. Interchange VS1A with VS1B and check operation.
  • Page 113 Front Reel Speed Erratic Cause Correction Reel bearing or bedknife to reel adjustment too tight. See Chapter 8 – Cutting Units. Electrical problem. See Chapter 5 – Electrical System. REAR Cutting Unit Problems Cause Correction For problems with rear cutting unit reel operation, refer Substitute R1A with R1B to the Correction recommended for the front cutting...
  • Page 114 Cutting Units Raise, But Will Not Stay Up NOTE: Lift cylinders and check valves cannot provide units in the lowered position. This also prevents acci- an absolutly perfect seal. The lift arms will eventually dental lowering of the cutting units if the lift lever (joy- lower if left in the raised position during storage.

  • Page 115: Testing

    Testing The most effective method for isolating problems in the 1. Thoroughly clean the machine before disconnecting hydraulic system is by using hydraulic test equipment or disassembling any hydraulic components. Always such as pressure gauges and flow meters in the circuits keep in mind the need for cleanliness when working on during various operational checks.

  • Page 116: Test No. 1: Traction Circuit Charge Pressure

    TEST NO. 1: Traction Circuit Charge Pressure 1. Make sure hydraulic oil is at normal operating temper- ature before doing test. 2. Park the machine on a level surface, engage the parking brake and stop the engine. 3. Connect a 1000 PSI gauge onto charge pressure test port.

  • Page 117: Test No. 2: Traction Circuit System Pressure

    TEST NO. 2: Traction Circuit System Pressure 1. Make sure hydraulic oil is at normal operating temper- ature before doing test. 2. Drive machine to an open area, lower cutting units, and shut off the engine. 3. Connect a 10,000 psi gauge to traction circuit test port for function to be checked.

  • Page 118: Test No. 3: Steering Circuit Pressure

    TEST NO. 3: Steering Circuit Pressure 1. Make sure hydraulic oil is at normal operating temper- ature before doing test. 2. Park the machine on a level surface, engage the parking brake and stop the engine. 3. Connect a 5000 PSI gauge onto steering pressure test port.

  • Page 119: Test No. 4: Lift Circuit Pressure

    TEST NO. 4: Lift Circuit Pressure 1. Make sure hydraulic oil is at normal operating temper- ature before doing test. 2. Lower cutting units, engage parking brake and stop the engine. 3. Raise seat to get access to hydraulic test fittings. Re- move access cover from in front of hydraulic valve block.

  • Page 120: Test No. 5: Front Mow Circuit Pressure

    TEST NO. 5: Front Mow Circuit Pressure 1. Make sure hydraulic oil is at normal operating temper- ature before doing test. 2. Lower cutting units, engage parking brake and stop the engine. Set HOC Selector Knob, located under the instrument panel, to position A (full speed). Make sure Backlap switch is OFF.

  • Page 121: Test No. 6: Rear Mow Circuit Pressure

    TEST NO. 6: Rear Mow Circuit Pressure 1. Make sure hydraulic oil is at normal operating temper- ature before doing test. 2. Lower cutting units, engage parking brake and stop the engine. Set HOC Selector Knob, located under the instrument panel, to position A (full speed). Make sure Backlap switch is OFF.

  • Page 122: Test No. 7: Reel Drive/Lift Pump Efficiency

    TEST NO. 7: Reel Drive/Lift Pump Efficiency (Using Tester with Pressure Gauges and Flow Meter) M5A D4 .060 PC1A S4A S5A .040 PC1B VS1A .040 Front VS1B Rear Valve Block Valve Block 12:1 12:1 High Pressure Low Pressure 14.4 Return or Suction Flow Pump Package...
  • Page 123 Reel Drive/Lift Pump Efficiency Test flow from the pump, through the tester and into the valve block. Over a period of time, the gears and wear plates in the pump can wear. A worn pump will by–pass oil and make IMPORTANT: The pump is a positive displacement the pump less efficient.

  • Page 124: Test No. 8: Reel Drive Motor Cross-Over Relief Pressure

    TEST NO. 8: Reel Drive Motor Cross Over Relief Pressure Test 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 Front Valve Block Figure 16.1 Hydraulic System Reelmaster 6500–D/6700–D Rev.
  • Page 125 1. Make sure hydraulic oil is at normal operating temper- 3. Lower cutting units, engage parking brake and stop ature before doing test. the engine. 4. Install a tee fitting between the motor inlet fitting and hose. Install a 5000 PSI pressure gauge on the tee fit- CAUTION ting.

  • Page 126: Test No. 9: Reel Drive Motor Efficiency

    TEST NO. 9: Reel Drive Motor Efficiency (Using Tester with Pressure Gauges and Flow Meter) Outlet hose Case drain hose Disconnect case drain hose (small diameter hose) at bulkhead fitting on frame. High Pressure Low Pressure Case Drain Flow Install tester in series between fitting and hose at motor outlet.

  • Page 127: Adjustments

    Over a period of time, the motor can wear internally. A flow from the motor, through the tester and into the worn motor will by–pass oil to the case drain line and next motor or the valve block. make the motor less efficient. Eventually, enough oil 7.

  • Page 128: Adjustments

    Adjustments Traction Drive Neutral Adjustment 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. Depress only the right brake pedal and engage the parking brake.

  • Page 129: Cutting Unit Lift Rate Adjustment

    Front Outer Cutting Unit Lift Rate Adjustment The #4 (left front) and #5 (right front) cutting unit lift cir- cuit is equipped with a adjustable valve to ensure the front cutting units lower evenly. Adjust cutting units as follows: 1. Locate valve under seat. 2.

  • Page 130: Repairs

    Repairs Removing Hydraulic System Components 1. Thoroughly clean the machine before disconnecting, 2. After repairs, check control linkage for proper adjust- removing or disassembling any hydraulic components. ment, binding or broken parts. Always keep in mind the need for cleanliness when 3.

  • Page 131: Servo Controlled Piston Pump

    Servo Controlled Piston Pump (Traction Pump) 14 15 65 66 T–2120 Figure 22 1. Valve Plate 22. Roll Pin 47. Washer 2. Bearing 28. Nut 48. Seal Washer 3. Quad Ring 29. Control Arm 49. Seal 4. Retaining Ring 30. Cap Screw 50.
  • Page 132 Disassembly – Servo Controlled Piston Pump 7. Remove housing gasket (34) from housing (58) or backplate (8). The following instructions apply to a single servo con- trolled piston pump with or without a gerotor charge 8. With pump still in vise, remove the six cap screws (30) pump.
  • Page 133 Housing Inspection: 4. Screw the cover plate (43) onto the servo piston as- sembly (41). Install new cover plate gasket (42) in place  Check the bearing (57) (press fit) in housing (58). If on housing (58). Install servo piston assembly (41) and needles remain in cage, move freely, and setting at cover plate (43) into servo piston bore in right side of the dimension shown in figure 24, removal not re-...
  • Page 134 9. Install shaft assembly into front of housing. Seat seal 16. Apply a small amount of petroleum jelly to the steel (54) into position with seal driver and retain with interior side of valve plate (1) to hold in place for installation. retaining ring (55).

  • Page 135: Servo Control

    Servo Control T–2119 Figure 26 1. Plug 9. O–Ring 17. Set Screw 2. O–Ring 10. Wiper Seal 18. Set Screw 3. Retaining Ring 11. O–Ring 19. Pin 4. Spring Retainer 12. Adaptor 20. Retaining Ring 5. Spring 13. Ball 21. Link 6.
  • Page 136 5. Apply Loctite #242 or equivalent to set screw (18) and D. Leaving the control arm in the detent position, the install, retaining input shaft (8). Adjust set screw until it light will remain on. Screw in the switch until the light bottoms out on input shaft and back out one–quarter goes off.

  • Page 137: Wheel Motor

    Wheel Motor T–2117 Figure 28 1. Retaining Ring 8. HH Screw 15. Valve Plate 2. Shaft Seal 9. Backplate Assembly 16. Rotating Kit 3. Washer 10. O–Ring 17. Camplate Insert 4. Retaining Ring 11. Speed Pickup Sensor 18. Housing 5. Thrust Race 12.
  • Page 138 7. Remove retaining ring (4) from shaft and remove 4. Install shaft in housing. Install washer (3), new shaft thrust washers (5) and thrust bearing (6). seal (2), and retain with retaining ring (1). 8. Discard the shaft seals and o–ring, and replace with 5.

  • Page 139: 4Wd Rear Axle Motor

    4WD Rear Axle Motor T–2118 Figure 30 1. Retaining Ring 7. HH Screw 13. Valve Plate 2. Spacer 8. Backplate Assembly 14. Rotating Kit 3. Straight Drive Shaft 9. O–Ring 15. Camplate Insert 4. Retaining Ring 10. Dowel Pin 16. Housing 5.
  • Page 140 8. Remove retaining ring (4) from shaft and remove 4. Install shaft in housing. Install new spacer (2), and re- thrust washers (5) and thrust bearing (6). tain with retaining ring (1). 9. Discard the shaft seals and o–ring, and replace with 5.

  • Page 141: Gear Pump

    Gear Pump T–2138 Figure 32 1. O–Ring 11. Shaft seal 21. Rear adapter plate 2. Front body 12. Washer 22. O–Ring 3. Drive gear assembly 13. Idler gear assembly 23. Plug 4. Wear plate 14. Key 24. Idler gear 5. Balance pressure seal 15.
  • Page 142 Repair Information 14. Remove o–rings (1) from front plate (8), adapter plates (20, 21), and backplate (30). Work in a clean area, cleanliness is extremely important when repairing hydraulic pumps. Before disconnecting 15. Remove backup gaskets (6) and balance pressure the lines, clean port area of pump.
  • Page 143 Front Plate, Backplate NOTE: The small half moon port cavity must be on the and Adapter Plates Inspection pressure side of pump. 1. Oil groove in bushings in front plate, backplate and 7. Place wear plate (4) on top of backup gasket (6) with bronze face up.

  • Page 144: Valve Blocks

    Valve Blocks Solenoid Wire Identification Torque to Solenoid Power Wire Color Function 15 in–lb VS1A Orange/Black Front Reel Speed, Front Lift Speed Black/Red Front Reels On/Off, Front Lift Violet/Red Front Reels/Lift Selector Blue/White Front Reels Mow/Backlap Selector Orange/Blue Lift All Apply VS1A Brown/White...
  • Page 145 Solenoid Wire Identification Torque to Solenoid Power Wire Color Function 15 in–lb VS1B Yellow/Blue Rear Reel Speed, Rear Lift Speed Orange/Red Rear Reels On/Off Orange/White Rear Reels/Lift Selector White/Orange Rear Reels Mow/Backlap Selector Pink/Blue Lift/Lower #2, #3 Apply Loctite 242 VS1B to threads Torque to...
  • Page 146 Torque to Solenoid Wire Identification 15 in–lb Solenoid Power Wire Color Function Apply VS1B Yellow/Blue Rear Reel Speed, Rear Lift Speed Loctite 242 Orange/Red Rear Reels On/Off Orange/White Rear Reels/Lift Selector to threads White/Orange Rear Reels Mow/Backlap Selector Pink/Blue Lift/Lower #2, #3 Black/Red Lift/Lower Selector #6, #7 Violet/Red...

  • Page 147: Cartridge Valves

    Cartridge Valves 1. Clean valve block to prevent contamination when Cartridge Installation valve cartridge is removed. 1. Lubricate all o–rings with clean hydraulic oil. 2. Remove cartridge valve: 2. Carefully thread cartridge into the port by hand. Valve cartridge should go in easily without binding. A.

  • Page 148: Reel Motor

    Reel Motor 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. T–2091 Figure 37 1. Retaining Ring 4. E–Seal 7. Valve Block 2.
  • Page 149 6. Remove valve block (7). O–ring Replacement 7. Remove gear housing. Make sure rear bearing block 1. Remove dowel pins (6) and O–rings (5) from gear remains on drive and idler gear shafts. housing. Clean O–ring grooves. 8. Remove rear bearing block from drive and idler gear 2.

  • Page 150: Steering Cylinder (2Wd)

    Steering Cylinder (2WD) Figure 38 1. Butt & Tube Assembly 5. Teflon Seal 9. Piston Rod 2. Lock Nut 6. O–Ring 10. U–cup 3. Piston 7. Gland 11. O–Ring 4. O–Ring 8. Wiper IMPORTANT: To prevent damage when clamping 7. Remove all seals and O–rings. cylinder barrel or rod in a vise, clamp only on pivotal 8.

  • Page 151: Steering Cylinder (4Wd)

    Steering Cylinder (4WD) Figure 39 1. Butt & Tube Assembly 5. O–Ring 9. Piston Rod Assembly 2. Teflon Seal 6. U–cup 10. O–Ring 3. O–Ring 7. Gland 11. Lock Nut 4. Piston 8. Wiper IMPORTANT: To prevent damage when clamping 6.

  • Page 152: Front Lift Cylinders

    Front Lift Cylinders Figure 40 1. Grease Fitting 6. Special Seal 11. Dust Seal 2. Barrel Assembly 7. O–Ring 12. Shaft w/Clevis 3. Locknut 8. Backup 13. Collar 4. Piston 9. Rod Seal 5. O–Ring 10. Head IMPORTANT: To prevent damage when clamping 5.

  • Page 153: Rear Lift Cylinders

    Rear Lift Cylinders Figure 41 1. Grease Fitting 6. O–Ring 11. Head 2. Barrel Assembly 7. Shaft w/Clevis 12. Dust Seal 3. Nut 8. Rod Seal 13. Collar 4. Uni–Ring 9. O–Ring 5. Piston 10. Backup IMPORTANT: To prevent damage when clamping 7.

  • Page 154: And #7 Lift Cylinders (Rm6700-D)

    #6 and #7 Lift Cylinders (RM6700–D) Figure 42 1. Grease Fitting 6. Special Seal 11. Dust Seal 2. Barrel Assembly 7. O–Ring 12. Shaft w/Clevis 3. Locknut 8. Backup 13. Collar 4. Piston 9. Rod Seal 5. O–Ring 10. Head IMPORTANT: To prevent damage when clamping 6.

  • Page 155: Steering Valve (75-0600 Or 92-7544)

    Steering Valve (75–0600 or 92–7544) 21 22 16 17 92–7546 T–2062 Figure 41 1. Seal Ring 15. Stator 29. Bushing 2. Valve Ring 16. Rotor 30. Thrust Bearing Spacer 3. Valve Plate 17. Link Drive Spacer 31. Seal Spacer 4. Spring 18.
  • Page 156 Steering Valve Service Before Disassembly When disassembling any of the parts, use a clean work bench. Wash all parts in solvent and dry them with com- pressed air. DO NOT wipe them dry with a cloth of paper as lint and dirt may remain. Keep each part separate to prevent nicks and burrs.
  • Page 157 Disassembly of Steering Valve 1. To avoid distorting or damaging the steering valve, do not clamp it directly into a vise. Clamp a service assem- bly fixture securely in a vise (Fig. 43). Put the steering valve, input shaft first, into the service assembly fixture. Attache the steering valve to the fixture with four (4) 5/16–24 UNF nuts (Fig.
  • Page 158 4. Grasp the port cover assembly (four plates bonded together) and lift it from the unit. Remove and discard the four o–rings and seal ring (Fig. 47). Figure 47 5. Remove the loosened plug and o–ring assembly from the port cover. Be ready to catch the steel check ball as it falls from its cavity (Fig.
  • Page 159 11. Remove the valve ring (Fig. 50). Remove and dis- card the two seal rings (Fig. 51). The valve ring should be free of nicks and scoring. Figure 50 Figure 51 12. Remove the valve plate by lifting it from the isolation manifold (Fig.
  • Page 160 14. Remove three springs from the isolation manifold pockets (Fig. 53). NOTE: The unit has two different length spring sets. the set you have just removed from the isolation manifold is 1/2 in. (13 mm) long. Keep this spring set separate from the set removed from the port manifold.
  • Page 161 18. Remove the two alignment pins that align the port manifold, valve ring and isolation manifold (Fig. 56). Figure 56 19. Remove the isolation manifold (four plates bonded together) (Fig. 57). 20. Inspect the ground surfaces of the isolation man- ifold.
  • Page 162 22. Remove the drive link from the unit (Fig. 59). 23. Inspect each end of the drive link. the four crowned contact surfaces should not be worn or scored. Replace if wear or scoring is evident. Figure 59 24. Remove the metering ring and discard the two seal rings (Fig.
  • Page 163 26. Remove and discard the commutator seal from the commutator cover (Fig. 62). Figure 62 27. Remove the eleven hex socket head screws, that hold the metering package together (Fig. 63). Use a 3/32 in. Allen wrench. Inspect the screws for thread and socket damage and replace as necessary.
  • Page 164 30. Remove the commutator ring (Fig. 65). Inspect for cracks, burrs and scoring. IMPORTANT: Handle the commutator ring with care, as it is easily broken. Figure 65 31. Remove the commutator from the rotor (Fig. 66). IMPORTANT: To prevent damage, DO NOT use a screwdriver to remove the commutator.
  • Page 165 34. Remove the drive link spacer (Fig. 68). Replace it if it grooved or worn. 35. With the rotor set lying on the drive plate, the rotor should rotate and orbit freely within the stator. The com- mutator side of the stator face must be free of grooves or scoring.
  • Page 166 39. Inspect the thrust bearing side of the drive plate (Fig. 71) for brinelling (dents) or spalling (flaking). The flat sides of the input shaft engagement hole should not be grooved or worn. If any of these conditions in steps 38 and 39 are present, the drive plate must be replaced.
  • Page 167 43. Remove the upper cover plate (four plates bonded together) (Fig. 74). Inspect the upper cover plate. You should notice some polishing due to the action of the seal. The plate should be free of brinelling (dents) or spalling (flaking). If it is damaged, the upper cover plate must be replaced.
  • Page 168 47. Remove the washer and upper cover & jacket (Fig. 77). NOTE: The retaining plate and upper cover & jacket are a matched set. If either part is worn or damaged, both must be replaced. Figure 77 48. Inspect the bushing at the top of the cover & jacket for wear or damage.
  • Page 169 50. Remove the nuts holding the four bolts to the fixture, and remove the bolts (Fig. 80). Check the bolt threads for wear or damage. Figure 80 Reelmaster 6500–D/6700–D Hydraulic System Page 4 – 81...
  • Page 170 Assembly of Steering Valve Replace all seals and o–rings with new ones. Make sure the seals and o–rings remain seated correctly when components are assembled. Before assembling the steering valve, wash all parts in clean solvent. Dry the parts with compressed air. DO NOT wipe them dry with a cloth or paper as lint and dirt may remain.
  • Page 171 3. Put the upper cover and jacket on the four bolts with the jacket tube pointing down through the hole in fixture (Fig. 84). Make sure the square shoulder of the bolts en- gage the square holes in the upper cover. 4.
  • Page 172 8. Apply clean multi–purpose grease to the face of the upper cover plate, input shaft and face seal (Fig. 88). Figure 88 9. Assemble the seal backup ring and face seal onto the seal spacer (Fig. 89). Figure 89 10. Install the face seal, backup ring and spacer assem- bly over the end of the input shaft and onto the upper cover plate (Fig.
  • Page 173 11. Put the drive plate on a clean lint–free surface with the eleven tapped holes facing up. Put the rotor set on top of the drive plate with the five pin holes facing up. Ro- tate the stator until the eleven hex socket head screw re- lief slots are aligned with the tapped holes in the drive plate (Fig.
  • Page 174 14. Align the five holes and press the five alignment pins in place (Fig. 94). IMPORTANT: Make sure the five alignment pins are pressed below the surface of the commutator. Figure 94 15. Put a few drops of oil into each recess in the commu- tator (Fig.
  • Page 175 17. Put the commutator cover on top of the commutator ring with the flat surface towards the commutator (Fig. 97). Align the screw holes in the cover, with the screw holes in the drive plate. Figure 97 18. Screw the eleven hex socket head cap screws loosely into the metering package (Fig.
  • Page 176 20. Put another piece of the 0.007 in. (0.18 mm) shim stock between the drive plate and each of the three pieces of shim stock already in place. Lift the metering ring and metering package and remove the wood block. Push the metering package and shims into the metering ring until the drive plate and shims are at least flush with the metering ring (Fig.
  • Page 177 22. Insert the LARGE tang of the drive link into the slot in the rotor (Fig. 103). IMPORTANT: An incorrect (reversed) assembly of the drive link will prevent the assembly of the hex drive. Figure 103 23. Grasp the drive link and rotate the metering package by hand to make sure the parts do not bind (Fig.
  • Page 178 25. Put the bearing spacer onto the face of the upper cover plate (Fig. 106). Figure 106 26. Lightly grease the roller thrust bearing and put it on the upper cover plate, inside the bearing spacer (Fig. 107). Figure 107 27.
  • Page 179 28. Put the metering package, drive plate side first, into the metering ring (Fig. 109). Revolve the input shaft or metering package until the hole in the drive plate en- gages the end of the input shaft and the drive plate is seated on the thrust bearing.
  • Page 180 31. Put two alignment pins into the metering ring (Fig. 112). Figure 112 32. Stack the isolation manifold (4 plates bonded to- gether) onto the metering ring, aligning the grooves on the side of the manifold with the grooves on the side of the upper cover plate (Fig.
  • Page 181 34. Put the three 1/2 in. (13 mm) springs into the spring pockets of the isolation manifold (Fig. 115). NOTE: Two different length springs are used in the unit. Be sure to use the 1/2 in. (13 mm) length springs during this part of the assembly.
  • Page 182 37. To install the valve plate correctly, first carefully study Figures 93 and 94 for positioning of the valve plate spring slots and other cavities in relation to the spring and spring recesses on the isolation manifold. Be sure to use the alignment grooves on the side of the isolation manifold for orientation.
  • Page 183 39. Put the port manifold (three plates bonded togeth- er), valve side up, in a clean surface. Install three 3/4 in. springs into the spring pockets (Fig. 121). Figure 121 40. Apply a few drops of oil to the valve plate. Align the grooves on the side of the port manifold with the grooves on the side of the isolation manifold and assemble the port manifold with the springs toward the valve plate...
  • Page 184 42. Apply clean multi–purpose grease to the four o– rings and seal ring. Put the new o–rings and seal ring into their proper location in the port cover (Fig. 124). Figure 124 43. Align a groove on the side of the port cover with the grooves on the side of the port manifold and put the port cover into position (Fig.
  • Page 185 44. Install the lock nuts onto the bolts. Tighten each nut gradually until resistance is felt (Fig. 126). Tighten to a torque of 20 – 24 ft–lb (27 – 33 Nm) in the sequence shown (Fig. 127). Figure 126 Figure 127 45.
  • Page 186 46. Apply a small amount of clean multi–purpose grease on the lip of the seal. Install the seal onto the jacket tube and input shaft (Fig. 129). 47. Make a final inspection of the relative groove posi- tions on the side of the unit (Fig. 42). Components of the steering valve with alignment grooves, must be as- sembled so that their alignment grooves are positioned as illustrated for the valve to function correctly (Fig.

  • Page 187: Hydraulic Reservoir

    Hydraulic Reservoir 30–60 in–lb Figure 131 1. Hydraulic Tank 14. Elbow 90_ Fitting 27. Flat Washer 2. Flange Gasket 15. O–Ring 28. Hex Hd. Flange Screw 3. Tank Cover 16. Filter Hose 29. Grommet 4. Air Breather 17. Screw 30. RH Motor Tube 5.

  • Page 188: Flushing The Hydraulic System

    Flushing the Hydraulic System IMPORTANT: Flush the hydraulic system any time 13. Shut off engine and check for hydraulic oil leaks. there is a severe component failure or the system is Check oil level in hydraulic reservoir and add correct oil contaminated (oil appears milky or black or con- if necessary.

  • Page 189: Steering Valve (93-5165 Or 94-9950)

    Steering Valve (93–5165 or 94–9950) Figure 134 Before Disassembly then plug the ports and thoroughly clean the exterior. During repairs, always protect machined surfaces. Cleanliness is extremely important when repairing steering control units. Work in a clean area. Before dis- 1.
  • Page 190 Figure 135 3. Slide the spool and sleeve from the housing (Fig. 135). 4. Remove the trust bearing and bearing races. 5. Remove the quad seal. 6. Use a small blade screwdriver to carefully pry the dust seal from the housing. Be careful to not damage the dust seal seat.
  • Page 191 Reassembly Check all mating surfaces. Replace any parts with scratches or burrs that could cause leakage. Wash all metal parts in clean solvent. Blow them dry with pressur- ized air. Do not wipe parts dry with paper towels or cloth. Lint in a hydraulic system will cause damage.
  • Page 192 10. Clamp the housing in a vise (Fig. 138). Use just enough clamping force to hold the housing securely. 11. Lubricate and install a new o–ring seal in the groove in the housing. 12. Install the wear plate and align the holes in the wear plate with threaded holes in the housing.

  • Page 193: Wiring Schematics (S/N 50001 – 59999)

    Chapter 5 Electrical System Table of Contents WIRING SCHEMATICS ..ELECTRICAL SYSTEM QUICK CHECKS ..(S/N 50001 – 59999) Reelmaster 6500–D ......Battery .
  • Page 194 Wiring Schematics (S/N 50001 – 59999) Electrical System Reelmaster 6500–D/6700–D Page 5 – 2...
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  • Page 200: Wiring Schematics (S/N 60001 & Up)

    Wiring Schematics (S/N 60001 & Up) Electrical System Reelmaster 6500–D/6700–D Page 5 – 8 Rev. C...
  • Page 201 Reelmaster 6500–D/6700–D Electrical System Page 5 – 8.1 Rev. C...
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  • Page 212: Main Wire Harness Connector Diagram

    Main Wire Harness Connector Diagram INPUTS 92–5720 SOLID STATE CONTROLLER GROUND BATTERY POWER OUTPUTS Pin Labeling on Controller Connector PIN NO’S HARNESS NOTE: The smaller connector is phyisically labeled A–F, but the controller diagram refers to these connections as L–S. Electrical System Reelmaster 6500–D/6700–D Page 5 –...

  • Page 213: Special Tools

    The meter can test electrical components and circuits for current, resistance, or voltage drop. NOTE: Toro recommends the use of a DIGITAL mutli- meter when testing electrical circuits. The high imped- ance (internal resistance) of a digital meter will ensure that excess current is not allowed through the meter.
  • Page 214 The data log system controller is connected to the wiring harness connector near the electronic control unit (ECU). This device can record machine data while it is in operation to help your Toro Distributor diagnose intermittent problems. Figure 4 Electrical System Reelmaster 6500–D/6700–D...

  • Page 215: Troubleshooting

    Troubleshooting For all electrical problems, use of the Quick Refer- If the machine has any interlock switches by–passed, ence Troubleshooting guide is recommended. Us- they must be reconnected for proper troubleshooting ing the Diagnostic ACE Display allows you to and safety. quickly find the source of the electrical problem.
  • Page 216 To verify interlock switch function: toggle button, on Diagnostic ACE, to change LED to “in- puts displayed”. Do not hold button down. 1. Park machine on a level surface, lower the cutting units, stop the engine and engage the parking brake. 6.
  • Page 217 ECU problem. If this oc- If no output LED’s are blinking, but the correct output curs, contact your Toro Distributor for assistance. LED’s do not illuminate, verify that the required input switches are in the necessary positions to allow that IMPORTANT: The Diagnostic ACE display must not function to occur.

  • Page 218: Quick Reference Troubleshooting Guide (Reelmaster 6700-D)

    Quick Reference Troubleshooting Guide (Reelmaster 6700–D) Diagnostic Lights If the diagnostic light is not illuminated when the key switch is in the ON position, this indicates that the elec- The RM 6700–D is equipped with two diagnostic lights tronic controller is not operating. Possible causes are: which indicate if the electronic controllers are function- ing correctly.
  • Page 219 Checking Interlock Switches Note: The red text on the overlay decal refers to input switches and the green text refers to outputs. The purpose of the interlock switches are to prevent the engine from cranking or starting unless the traction ped- al is in NEUTRAL, the Enable/ Disable switches are in DISABLE and the Lower Mow/Raise control is in the neutral position.

  • Page 220: Fault Memory And Retrieval

    ECU problem. If this oc- function of the machine. The appropriate output LED’s curs, contact your Toro Distributor for assistance. should illuminate to indicate that the ECU is turning on that function. (Refer to the list on page 21 to be certain IMPORTANT: The Diagnostic ACE displays must not of the specified output LED’s.

  • Page 221: Leak Detector Operation

    Leak Detector Operation The TurfDefendert is an electronic hydraulic fluid leak Note: The low or high oil level 4 beep signal may oc- detection device that fits inside the hydraulic tank of your cur if machine is started on a slope. Move machine to machine.
  • Page 222 Float position (1 or 2 LED’s on left row) and “Oil level held Diagnostic ACE. A leak down test is required to OK” LED – should be displayed. identify small air leaks. Consult your Authorized Toro 2. Press toggle button until green “Outputs displayed” Distributor for assistance.
  • Page 223 3. Air leak in system. Check to make sure cap is se- potential false alarms. If “false leak detects” are sus- curely on tank. Contact your local authorized Toro Dis- pected, your Toro Distributor can adjust the calibration tributor for further assistance with air leak problem.
  • Page 224 Diagnostic ACE Display Functions 1. Overlay decal (English shown) 2. “Inputs Displayed” LED (Red) 3. “Outputs Displayed” LED (Green) 4. Toggle button Figure 11c Using “Inputs Displayed” (Red Text) 1. LED lit if oil level is too high 2. LED lit if oil level is OK 3.
  • Page 225 Turf Defender Troubleshooting Guide The following is a quick guide to the most common problems likely to be encountered. The hand–held Diagnostic ACE is helpful for identifying specific problems 4–beep faults are occurring: Oil level is incorrect Check tank dipstick on a level surface Machine started on a slope (oil level error) Try again on a level surface, add oil as required...
  • Page 226 This page is blank. Electrical System Reelmaster 6500–D/6700–D Page 5 – 26.6 Rev. B...

  • Page 227: Understanding The Controllers

    Understanding the Controllers Controller #1 (Primary) Functions: S Main controller for both the RM6500 and RM6700. S Contains primary logic program. S Manages all functions of machine safety, sequenc- ing of cutting units and clip control. Loopback S “Supervisor” for the RM6700 controller #2. connector S Connected to other controller and/or leak detector Controller #1...

  • Page 228: Understanding The Diagnostic Lamps

    Understanding the Diagnostic Lamps Controller #1 (Primary) Fault Identification / Operator Warning The reel control lamp (red) on the steering tower will stay ON with no flashing if: 1. The glow plugs are on. 2. Operator mowing too slow or too fast for proper ClipAce control.

  • Page 229: Starting Problems

    Starting Problems All Electrical and Gauges Are Dead Cause Correction Low battery charge. Charge battery. Replace battery if it will not hold a charge. Thermal circuit breaker No. 1 open. Find cause for open circuit breaker and correct. Circuit breaker will reset automatically after it has cooled. Key switch fuse open.
  • Page 230 Engine Starts, But Dies When Ignition Switch Is Released From Start Position Cause Correction Run solenoid faulty. Replace run solenoid. Run solenoid wiring faulty. Repair wiring. Faulty high engine water temperature shut–down Check switch and wiring and replace or repair if switch (engine not overheated) or wiring.

  • Page 231: General Run And Transport Problems

    General Run and Transport Problems Engine Continues To Run, But Should Not, When Ignition Key Is Off Cause Correction Engine fuel lever or run solenoid stuck in “on” position. Check operation of run solenoid and adjust or replace if necessary. Make sure fuel stop lever moves without sticking and repair if necessary.

  • Page 232: Cutting Unit Operation Problems

    Engine Kills When Traction Pedal Is Depressed Cause Correction Seat lifting off seat switch. Instruct operator to sit back in seat during operation. Check seat plate hinges and seat support pin and repair if faulty Seat switch circuit open. Test seat switch and replace if faulty. Check seat switch wiring and repair if faulty.

  • Page 233: Electrical System Quick Checks

    Electrical System Quick Checks Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the Voltage Measured Battery Charge battery terminals. 12.6 V (or higher) Fully charged (100%) Set the multimeter to the DC Volts setting. The battery 12.4 V 75% charged should be at a temperature of 60_ to 100_ F.

  • Page 234: Glow Plug System Test

    Glow system. Adjust Meter Remember – there are 2 types of Glow Plug systems to read zero (if applicable). Cycle the Glow Plug system that Toro uses: at least two times (per instructions in Operator’s Manu- al) and record the final results.

  • Page 235: Component Identification And Testing

    Component Identification and Testing For all electrical problems, use of the Quick Refer- ence Troubleshooting guide is recommended. Us- CAUTION ing the Diagnostic ACE Display allows you to quickly find the source of the electrical problem. When testing electrical components for conti- This section will define given components, and the tests nuity with a volt–ohm meter or continuity tes- that can be performed on those components, when...

  • Page 236: Electronic Control Unit (Ecu)

    Electronic Control Unit (ECU) The Toro electronic control unit (ECU) senses the condi- tion of various switches, such as the seat switch, cutting unit down switches, traction neutral switch, etc., and di- rects power output to allow certain machine functions, such as engine run, cutting units engage, etc.

  • Page 237: Traction Neutral Switch

    Traction Neutral Switch The traction switch is normally closed and opens when traction pedal is depressed in either direction. The switch is located on the right side of the hydrostatic transmission. Test the switch by disconnecting the wires from the switch terminals and connecting a continuity tester across the two terminals that had wires connected to them.

  • Page 238: Lower/Mow/Raise Switches (Joystick)

    Lower–Mow/Raise Switches (Joystick) Each switch is normally open and closes when the joys- tick is moved. Test each switch by disconnecting the wiring connector from the switch and connecting a continuity tester across the two terminals of the switch being tested. Testing With the engine turned off, move the joystick, then allow it to return to neutral while watching the continuity tester.

  • Page 239: Backlap Switch

    Backlap Switch The Backlap switch is a three–way switch. Test the switch by disconnecting the wires and connecting a con- tinuity tester across terminals of switch. With the switch OFF, the tester should show no continu- ity across terminals 4 – 5 or 5 – 6. With the switch in the FRONT position (toward keyway), tester should show continuity across terminals 4 and 5.

  • Page 240: Glow Relay

    Glow Relay and Glow Plugs 1. Attach an amp meter to glow plug circuit. Turn ignition switch to ON. Meter may have an initial reading as high as 100 amps. A. If amp meter shows a reading for 5 to 12 se- conds, the glow relay is operating.

  • Page 241: Fuel Stop (Etr) Solenoid

    Fuel Stop (ETR) Solenoid This engine has an energize-to-run (ETR) fuel stop sole- noid. The solenoid will stop injector pump fuel delivery with any electrical failure in the RUN circuit. 1. Disconnect the wire from the solenoid. 2. Remove the solenoid from the injector pump. 3.

  • Page 242: Indicator Lights And Gauges

    Indicator Lights and Gauges Reel Control and Diagnostic Lamps Glow Light The glow light should be on when the ignition switch is See Quick Reference Troubleshooting Guide in Troubleshooting section for explanation of diagnostic in the ON position. The glow system runs off of a timer functions.

  • Page 243: Fuel Gauge Sender

    Fuel Gauge Sender Disconnect wire and remove the fuel gauge sender from the fuel tank. Install an ohm meter between the terminal and base. With arm completely down (empty position), resistance should be 240–260 ohms. With arm completely up (full position), resistance should be 29–34 ohms.

  • Page 244: Valve Block Solenoids

    Valve Block Solenoids 1. Disconnect the wire connector. 2. Connect a 12 volt battery so the positive (+) battery terminal is connected to colored solenoid lead. Connect the negative (–) battery terminal to black lead. The valve spool should retract completely as 12 V.D.C. is applied between leads.
  • Page 245 Solenoid Wire Identification Torque to Solenoid Power Wire Color Function 15 in–lb VS1A Orange/Black Front Reel Speed, Front Lift Speed Black/Red Front Reels On/Off, Front Lift Violet/Red Front Reels/Lift Selector Blue/White Front Reels Mow/Backlap Selector Apply Orange/Blue Lift All VS1A Brown/White Lower All Loctite 242...
  • Page 246 Solenoid Wire Identification Torque to Solenoid Power Wire Color Function 15 in–lb VS1B Yellow/Blue Rear Reel Speed, Rear Lift Speed Orange/Red Rear Reels On/Off Orange/White Rear Reels/Lift Selector White/Orange Rear Reels Mow/Backlap Selector Pink/Blue Lift/Lower #2, #3 Apply Loctite 242 VS1B to threads Torque to...
  • Page 247 Torque to Solenoid Wire Identification 15 in–lb Solenoid Power Wire Color Function Apply VS1B Yellow/Blue Rear Reel Speed, Rear Lift Speed Loctite 242 Orange/Red Rear Reels On/Off Orange/White Rear Reels/Lift Selector to threads White/Orange Rear Reels Mow/Backlap Selector Pink/Blue Lift/Lower #2, #3 Black/Red Lift/Lower Selector #6, #7 Violet/Red...

  • Page 248: And #7 Reel On/Off Solenoids

    3. Remove overlay decal from Diagnostic ACE Display from the desired setting. This calibration must be done tool so numbers 0 to 17 next to lamps are visible. by your Toro distributor. 4. Raise seat and set Backlap switch to FRONT backlap position.

  • Page 249: Repairs

    Repairs Battery Service IMPORTANT: To prevent damage to the electrical Electrolyte Specific Gravity components, do not operate the engine with the bat- Fully charged: 1.250 – 1.280 tery cables disconnected. Discharged: less than 1.240 Keep the terminals and entire battery case clean. To Battery Specifications clean the battery, wash the entire case with a solution of BCI Group 24 Battery:...

  • Page 250: Fuses

    Fuses Fuses are located below the control panel. NOTE: It is not always possible to see if a fuse is faulty. It is recommended that you check for faulty fuses with a continuity tester; not visually. Figure 36 1. Fuses Reelmaster 6500–D Reelmaster 6500–D/6700–D (S/N 50001 –...

  • Page 251: Installing Optional Lighting

    Orange Switch Relay Switch* Relay Toro Part No. 75–1010 Toro Part No. 70–1480 Honeywell Part No. 1TL1–2 Bosch Part No. 0–332–204 Black, red and orange wires are located in control console. Add 10 Amp fuse to fuse block at location shown * Punch out in control panel provided for switch installation Reelmaster 6500–D/6700–D...

  • Page 252: Hydraulic Valve Block Solenoid Coil Replacement

    Hydraulic Valve Block Solenoid Coil Replacement 1. Remove solenoid coil: A. Remove nut from solenoid. B. Remove solenoid coil and o–ring at each end of solenoid coil. NOTE: There are two different solenoid coils used on the hydraulic valve blocks. Cartridge valves VS1A and VS1B use 28 Watt coils.

  • Page 253: Speedometer Sensor Installation

    Speedometer Sensor Installation NOTE: It is recommended that this procedure be done with the motor removed from the machine. 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 below).

  • Page 254: Reel Speed Sensor Installation

    Reel Speed Sensor Installation See Cutting Unit Installation in Repairs section of Chap- ter 7 – Cutting Units. Figure 42 1. Reel speed sensor Traction Neutral Switch Installation See Servo Control in Repairs section of Chapter 4 – Hy- draulic System. Figure 43 1.

  • Page 255: Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

    Chapter 6 Axles, Planetaries and Brakes Table of Contents SPECIFICATIONS ......REPAIRS ........SPECIAL TOOLS .

  • Page 256: Specifications

    Specifications Item Specification Front wheel lug nut torque 45–55 ft–lb Rear wheel lug nut torque 85–100 ft–lb Steering cylinder bolt torque 100–125 ft–lb Rear wheel toe–in .25” Tire pressure 15–20 psi, front and rear Brake pedal free travel .12” Planetary brake housing, and wheel motor mounting cap screw torque 75–85 ft–lb Planetary gear drive oil...

  • Page 257: Special Tools

    Special Tools Order special tools from the TORO SPECIALS TOOLS APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Rear 4WD Axle Tools TOR4038 – Differential Case Gauge Used to determine the number of shims required be- tween the 4WD rear axle differential housing. Figure 3 TOR4039 –...
  • Page 258 TOR4041 – Bevel Gear Remover Used to separate the bevel gears from their shafts in the ends of the 4WD rear axle. Figure 6 TOR4042 – Pinion Gauge Used to determine the number of shims required to properly position the 4WD rear axle pinion. Figure 7 TOR4043 –...

  • Page 259: Adjustments

    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 distance the brake pedal moves before braking resistance is felt. 1.

  • Page 260: Repairs

    Repairs Rear Wheel Bearing Service (2WD) 24 25 42 43 44 T–2078 T.1–813.92–7400.16 Figure 11 1. Cap Hex Hd. Screw 24. Bearing Cup 43. Hydraulic 90_ Fitting 6. Cotter Pin 25. Hub Assembly 44. O–Ring 7. Hose Assembly 26. Bearing Cup 45.
  • Page 261 Disassemble, clean, repack and adjust the rear wheel 10. Adjust preload on the wheel bearings. bearings after each 800 hours of operation. Use No. 2 A. Tighten the jam nut to 75 – 80 in–lb (86 – 270 Kg– general purpose lithium base grease containing E.P. ad- cm) while turning the hub to seat the bearings and ditive.

  • Page 262: Planetary Wheel Drive Service

    Planetary Wheel Drive Service T–2070 92–7415 Figure 13 1. Spindle 9. Thrust washer 17. Thrust washer 2. Seal kit 10. Retaining ring 18. Ring gear 3. Bearing cone 11. Secondary carrier assembly 19. Retaining ring 4. Bearing cup 12. Primary carrier assembly 20.
  • Page 263 10. Use a puller to remove spindle (1) from housing (6). 6. Press bearing cone (8) onto spindle and secure with Remove bearing cone (8). thrust washer (9) and retaining ring (10). 11. Remove and discard all seals. 7. Install seal (2c), then assemble ring gear (18) to hous- ing (6) with capscrews (25).

  • Page 264: Brake Service

    Brake Service 75 – 85 ft–lb 75 – 85 ft–lb 75 – 85 ft–lb Figure 14 1. Capscrew 5. Flange head capscrew 9. Planetary wheel drive 2. Wheel motor 6. Brake assembly 10. Flange head capscrew 3. O–ring 7. Splined shaft 4.
  • Page 265 T–2071 92–7417 Figure 15 1. LH Brake Housing 6. Hair Cotter Pin 11. Actuator 2. Seal 7. Stationary Disc 12. Extension Spring 3. Pull Rod 8. Rotating Disc 13. Ball 4. Clevis Pin 9. Retaining Ring 5. Link 10. Gasket Brake Inspection and Repair (Fig.

  • Page 266: Rear 4Wd Axle Service

    Rear 4WD Axle Service T–1111 Figure 16 T–1110 Figure 17 Axles, Planetaries and Brakes Reelmaster 6500–D/6700–D Page 6 – 12...
  • Page 267 Disassembly The two gear cases, right and left can be removed from the housing without requiring the entire axle to be disas- sembled. 1. Remove tie rod by disconnecting rod end ball joint on each end. Disconnect hydraulic cylinder rod end from drag link arm.
  • Page 268 Instal seal so garter spring faces hydraulic motor Figure 22 1. Bearing 6. Oil Seal 11. Bearing 2. O–Ring 7. Bushing 12. Adapter 3. Shim 8. Washer 13. Nut 4. Sleeve 9. Locknut 14. Stud Bolt 5. Bolt 10. O–Ring 15.
  • Page 269 Inspection Clean the disassembled parts by washing in cleaning solvent. Inspect gears and pinions to be sure their teeth are in good condition. Check to be sure that each bear- ing rotates smoothly. Examine housings for cracks. Reassembly Replace damaged or worn parts as necessary. Oil or grease the surfaces of rotating or sliding parts before as- sembling.
  • Page 270 Adjusting Pinion Shaft Cone Center “Cone Center” is the distance from the mating face of axle housing to end face of pinion. This distance can be increased or decreased by installing removing shims. 43 ± 0.05mm Cone center specification (1.69 ± 0.002 in.) Shim stock for this adjustment is available in the follow- ing thicknesses: Thickness...
  • Page 271 Adjusting Backlash Backlash specification 0.25 ~ 0.35 mm (0.010 ~ 0.014 in.) Adjust shim thickness (between bearing housing of axle housing (A) and bearing) to get specified backlash. Shim stock for this adjustment is available in these thick- nesses: Thickness Part No.
  • Page 272 Assembling Axle Housing 1. Coat mating faces of two housings (A) and (B) with sealant and attach selected shim to face of housing (B). Put the two housings together and fasten them by tight- ening bolts to following torque value: Torque specification 2.5 ~ 3.0 kg–m (18 ~ 22 ft-lb)
  • Page 273 Installing Drag Link and Tie Rod Arm 1. Carefully insert bushing into arm. 2. Put arm into position over holder, fitting it to final case and secure to case with bolts. 3. Check thrust clearance. Proper thrust clearance is 0 to 0.2 mm (0.008in.).
  • Page 274 4. After obtaining proper pinion backlash, grease o–ring and fit it to mating face of axle housing. Secure gear case to housing by tightening bolts to the following torque value: Torque specification 5.0 ~ 6.0 kg–m (36 ~ 43 ft-lb) Reassembling Wheel Shaft 1.
  • Page 275 Installing Axle on Machine 1. Support axle under machine with a jack. 2. Install axle pivot pin to secure axle to frame. Make sure to install thrust washers between axle pivot and frame. 3. Install hydraulic motor to adaptor housing. 4.
  • Page 276 Axles, Planetaries and Brakes Reelmaster 6500–D/6700–D Page 6 – 22...
  • Page 277 Chapter 7 Model 03853 Model 03854 Cutting Units Model 03856 Table of Contents SPECIFICATIONS ......Bedbar Removal and Installation .

  • Page 278: Specifications

    HEIGHT–OF–CUT & ROLLER ADJUSTMENT: single lip seals and a Toro labyrinth seal to provide four Height–of–cut adjustment is made at the rear roller with sealing surfaces to protect the bearings. quick locating pin and/or threaded micro–adjustment. Front roller position is adjustable to 3 locations to set cut- ROLLER SCRAPER KITS: ting unit attitude.

  • Page 279: Special Tools

    Order special tools from the TORO SPECIAL TOOLS Some tools may have been supplied with your machine AND APPLICATIONS GUIDE (COMMERCIAL PROD- or available as TORO parts. Some tools may also be UCTS). available from a local supplier. Gauge Bar Assembly Use gauge bar to verify height of cut.
  • Page 280 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 to a torque of 250 –...

  • Page 281: Troubleshooting

    Troubleshooting There are a number of factors that can contribute to un- Remember that the “effective” or actual height of cut de- satisfactory quality of cut, some of which may be turf pends on cutting unit weight and turf conditions. Effec- conditions.
  • Page 282 Factor Possible Problem/Correction 5. Bedknife to reel adjustment. Check bedknife to reel contact daily. Bedknife must have light contact all across reel. No contact will cause cutting edges to become dull. Excessive contact accelerates wear; quality of cut may be adversely affected.

  • Page 283: Set-Up And Adjustments

    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- RIGHT rate and consistent adjustments. Note: Right and left ends of cutting unit is determined by standing in the operator’s position (Fig.

  • Page 284: Bedknife To Reel Adjustment

    Bedknife to Reel Adjustment 1. A 19 mm (3/4 inch) wrench will be needed to rotate bedknife adjustment knob. Each notch on the knob will move the bedknife .0005 inches (.013 mm) (Fig. 6). 2. On either end of reel, insert a long strip of dry newspa- per between reel and bedknife.

  • Page 285: Front Roller Adjustment And Leveling

    Front Roller Adjustment and Leveling Note: Cutting units are shipped from the factory with the front roller mounted in the “C” position. The best cutting unit attitude is dependent on turf conditions and desired results. Experience in your conditions will determine the best setting to use.
  • Page 286 Height of Cut The Height–of–Cut adjustment is made by moving the rear roller up or down, after adjusting and leveling the front roller. This can be done by using the adjusting screw or quick height–of–cut locating pin (Fig. 13 & 13). Note: To ensure accuracy, initial rear roller set–up should be performed on a leveling plate .

  • Page 287: Verify Height Of Cut

    Verify Height of Cut 1. On gauge bar, set head of screw to desired Height– of–Cut. This measurement is from bar face to underside of screw head. 2. Place the bar across the front and rear rollers and ad- just the rear roller up or down until the underside of screw head engages the bedknife edge.

  • Page 288: Service And Repairs

    Note: Additional instructions and procedures on 1. Position machine on a clean, level surface, lower the Backlapping are available in the TORO Sharpening cutting units, stop the engine, engage the parking Reel & Rotary Mowers Manual Form No. 80–300PT.

  • Page 289: Bedbar Removal And Installation

    Bedbar Removal and Installation Figure 18 Reelmaster 6500–D/6700–D Page 7 – 13 Rev. B Cutting Units Model 03853 Model 03854 Model 03855...
  • Page 290 Remove Bedbar 1. Loosen bedknife adjusting knob to loosen bedknife to reel contact. 2. Loosen locknut on bedknife adjuster assembly and disengaging adjuster from bedbar. NOTE: On early pro- duction cutting units there is no slot in bedbar for disen- gaging bedknife adjuster from the bedbar;...

  • Page 291: Bedknife Replacement And Grinding

    Bedknife Replacement and Grinding 1. Remove bedbar from cutting unit. Use a torque 2. Remove bedknife screws and remove bedknife. wrench and bedknife screw tool 3. Remove all rust, scale and corrosion from bedbar sur- face before installing new bedknife. 4.

  • Page 292: Preparing Reel For Grinding

    Preparing Reel for Grinding 1. Check to make sure reel bearings are in good condi- Note: When grinding, be careful to not overheat the reel tion and properly adjusted before grinding the reel. blades. Remove small amounts of material with each Make sure the cutting unit frame and roller brackets are pass of the grinder.

  • Page 293: Reel Removal And Bearing Replacement

    Reel Removal and Bearing Replacement NOTE: Early production units have pressed in spline inserts. Use tool TOR4074 to install threaded spline insert. Apply Locite 242 to threads Tighten to 75 – 85 ft–lb (10.4 – 11.8 KgM) Apply anti–sieze lubricant to splines 9 10 Pack bearings with No.
  • Page 294 bearing race. Remove the seals. NOTE: If bearing is Remove Reel removed, the seal should be replaced. 1. Remove weight from cutting unit. If equipped with a B. Install new seals on the reel shaft. Make sure speed sensor, remove shaft magnet after removing seals are installed square to shaft.

  • Page 295: Roller And Frame Service

    Roller and Frame Service 13 – 17 ft–lb (1.8 – 2.4 KgM) 11 12 20 – 30 in–lb 14 15 (23 – 35 KgCm) 20 – 30 in–lb (23 – 35 KgCm) * Early production 13 – 17 ft–lb units only (1.8 –...

  • Page 296: Roller Bearing And Seal Replacement

    Roller Bearing and Seal Replacement Sharp edge out Lip of seal facing in Figure 26 1. Roller 4. Roller shaft 7. Retaining ring 2. Inner oil seal 5. Inner seal 8. Outer oil seal 3. Bearing 6. Outer seal 9. Washer NOTE: Bearing and seal configurations are the same for B.

  • Page 297: Cutting Unit Installation

    Cutting Unit Installation Cutting unit models 03854 and 03856 can be installed at any of the five mounting locations on the traction unit. Figure 17 shows the orientation of the hydraulic drive motor for each of the five locations. For any of the loca- tions requiring the motor to be mounted on the right end of the cutting unit, install a counter weight on the left end of the cutting unit.
  • Page 298 7. Mount the motor to the drive end of the cutting unit and secure with two capscrews provided (Fig. 30). 8. On front center and left rear cutting units, plug speed sensor wire harness connector into traction unit wire harness connector. Figure 30 1.
  • Page 299 Greasing Bearings, Bushings and Pivot Points Each cutting unit has (6) grease fittings (Fig. 32) that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease. The grease fitting locations and quantities are: reel bearings (2) and front and rear rollers (2 ea.) IMPORTANT: Lubricating cutting units immediately after washing helps purge water out of bearings and increases bearing life.
  • Page 300 Cutting Units Page 7 – 24 Rev. B Reelmaster 6500–D/6700–D Model 03853 Model 03854 Model 03855...

  • Page 301: Model 03857, S/N

    Chapter 8 Model 03857, S/N 80001–80301 Model 03858, S/N 80001–81418 Model 03859, S/N 80001–81992 Cutting Units Table of Contents SPECIFICATIONS ......SERVICE AND REPAIRS .

  • Page 302: Specifications

    POWER: Reel motors feature quick disconnect for re- same heavy duty ball bearings with two conventional moval or installation onto cutting unit. Cutting units can single lip seals and a Toro labyrinth seal to provide four be driven from either end. sealing surfaces to protect the bearings.

  • Page 303: Special Tools

    Order special tools from the TORO SPECIAL TOOLS Some tools may have been supplied with your machine AND APPLICATIONS GUIDE (COMMERCIAL PROD- or available as TORO parts. Some tools may also be UCTS). available from a local supplier. Gauge Bar Assembly Use gauge bar to verify height of cut and bedknife atti- tude.
  • Page 304 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 to a torque of 250 –...

  • Page 305: Troubleshooting

    Troubleshooting There are a number of factors that can contribute to un- Remember that the “effective” or actual height of cut de- satisfactory quality of cut, some of which may be turf pends on cutting unit weight and turf conditions. Effec- conditions.
  • Page 306 Factor Possible Problem/Correction 5. Bedknife to reel adjustment. Check bedknife to reel contact daily. Bedknife must have light contact all across reel. No contact will cause cutting edges to become dull. Excessive contact accelerates wear; quality of cut may be adversely affected.

  • Page 307: Set-Up And Adjustments

    Set–up and Adjustments IMPORTANT: Toro strongly recommends the use of a leveling plate when setting–up or adjusting any reel type RIGHT cutting unit. The leveling plate will help to ensure accu- rate and consistent adjustments. Note: Right and left ends of cutting unit is determined by standing in the operator’s position (Fig.

  • Page 308: Bedknife To Reel Adjustment

    Bedknife to Reel Adjustment 1. A 19 mm (3/4 inch) wrench will be needed to rotate bedknife adjustment knob. Each notch on the knob will move the bedknife .0005 inches (.013 mm) (Fig. 8). 2. Tip cutting unit rearward to gain access to reel and bedknife (Fig.

  • Page 309: Cutting Unit Set-Up Guide

    Cutting Unit Set–up Guide Adjustable front and rear brackets allow infinite adjust- ting unit on the turf will determine the best setting to use. ment of cuffing unit ”attitude”. Attitude refers to the angle Wear of the bedknife and reel will result in changes to of the knife relative to the ground.

  • Page 310: Preliminary Height Of Cut And Front Roller Adjustment

    Preliminary Height of Cut and Front Roller Adjustment When setting–up a cutting unit, or if repositioning or installing a front or rear roller to the cutting unit, proceed CONTACT ALONG FULL LENGTH as follows: AT “A” AND “B” LEVELS FRONT ROLLER TO REEL 1.

  • Page 311: Final Height Of Cut Adjustment

    Final Height of Cut Adjustment 1. Using a gauge bar, Toro part no. 98–1852 or equiva- lent (Fig. 15), set head of screw to desired Height–of– FINAL HOC SETTING Cut. This measurement is from bar face to underside of FRONT ROLLER screw head.

  • Page 312: Grass Shield And Fin Adjustment

    Grass Shield and Fin Adjustment Adjust grass shield and/or shield fin angle for desired grass clippings dispersion. For best dispersion under most conditions 1. Position cutting unit on a flat level surface. 2. To adjust fins, unhook and move front mounting tab to the straight ahead or angled position slot.

  • Page 313: Cutting Unit Attitude Adjustment

    (2 Screw Gauge Bar) The cutting unit attitude may be adjusted or verified ADJUST FOR FINAL HOC SETTING using a gauge bar, Toro part no. 98–1852. which has “B” two screws and three hole locations. The second screw is used in the inner hole to set or verify cutting attitude.

  • Page 314: Alternate Adjustments

    Alternate Adjustments Tractors are setup at the factory appropriately for most fairway mowing applications. The following adjustments are available for fine–tuning of the machine to the application: Adjusting Cutting Unit Stop Chains The lift chain of the cuttings units may be lengthened or shortened to adjust for either ground following or ground clearance of the cutting units.

  • Page 315: Service And Repairs

    H.O.C. KNOB ONE POSITION TOWARD ”A”. 8. Apply lapping compound with a long handle brush Note: When backlapping, the front units all operate (Toro Part No. 29–9100). Never use a short handled together, and the rear units operate together. brush.

  • Page 316: Bedbar Removal And Installation

    Bedbar Removal and Installation Figure 21 1. Screw 16. Lock nut 32. Flange nut 2. Washer 17. Washer 33. L.H. pivot hub 3. Quad ring 18. Compression spring 34. Screw 4. Lock nut 19. Spring arm 35. L.H. side plate 5.
  • Page 317 Remove Bedbar 1. Loosen bedknife adjusting knob to loosen bedknife to reel contact. 2. Loosen locknut on bedknife adjuster assembly and disengaging adjuster from bedbar. 3. Remove bedbar leveling screw from L.H. side of cut- ting unit. 4. Remove fasteners securing L.H. and R.H. bedbar pivot hubs to frame.

  • Page 318: Bedknife Replacement And Grinding

    Bedknife Replacement and Grinding 1. Remove bedbar from cutting unit. Use a torque 2. Remove bedknife screws and remove bedknife. wrench and bedknife screw tool 3. Remove all rust, scale and corrosion from bedbar sur- face before installing new bedknife. 4.

  • Page 319: Preparing Reel For Grinding

    Preparing Reel for Grinding 1. Check to make sure reel bearings are in good condi- Note: When grinding, be careful to not overheat the reel tion and properly adjusted before grinding the reel. blades. Remove small amounts of material with each Make sure the cutting unit frame and roller brackets are pass of the grinder.

  • Page 320: Reel Removal And Bearing Replacement

    Reel Removal and Bearing Replacement Use tool TOR4074 to install threaded spline insert. Apply Locite 242 to threads Tighten to 75 – 85 ft–lb (10.4 – 11.8 KgM) Apply anti–sieze lubricant to splines 9 10 Pack bearings with No. 2 general purpose grease Use tool TOR4064 Tighten set–screw...
  • Page 321 Remove Reel 4. Inspect bearings and seals. To replace seals and bearings: 1. Remove weight from cutting unit. If equipped with a speed sensor, remove shaft magnet after removing A. Use a bearing puller tool to remove the bearings. weight and sensor. To prevent damage to bearings, pull on the inner bearing race.

  • Page 322: Roller And Frame Service

    Roller and Frame Service 13 – 17 ft–lb 11 12 (1.8 – 2.4 KgM) 13 – 17 ft–lb (1.8 – 2.4 KgM) 13 – 17 ft–lb (1.8 – 2.4 KgM) 13 – 17 ft–lb (1.8 – 2.4 KgM) 75 – 85 ft–lb (10.4 –...

  • Page 323: Roller Bearing And Seal Replacement

    Roller Bearing and Seal Replacement Sharp edge out Lip of seal facing in Figure 29 1. Roller 4. Roller shaft 7. Retaining ring 2. Inner oil seal 5. Inner seal 8. Outer oil seal 3. Bearing 6. Outer seal 9. Washer NOTE: Bearing and seal configurations are the same for B.

  • Page 324: Cutting Unit Installation

    Cutting Unit Installation Cutting unit models 03857, 03858, and 03859 can be Motor Weight Weight* Motor Weight Motor installed at any of the five mounting locations on the trac- tion unit. Figure 1 shows the orientation of the hydraulic drive motor for each of the five locations. For any of the locations requiring the motor to be mounted on the right Motor Weight*...
  • Page 325 6. Insert a thrust washer onto horizontal shaft of pivot knuckle as shown in figure 32. 7. Insert the horizontal shaft of the pivot knuckle into the mounting tube of the carrier frame (Fig. 32). 8. Secure pivot knuckle to carrier frame with a thrust washer, flat washer and a flange head capscrew (Fig.
  • Page 326 Greasing Bearings, Bushings and Pivot Points IMPORTANT: Lubricating cutting units immediately after washing helps purge water out of bearings and increases bearing life. Each cutting unit has (6) grease fittings (Fig. 34) that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease.
  • Page 327 Chapter 8.1 Model 03857, S/N 80302 & Up Model 03858, S/N 81419 & Up Model 03859, S/N 81993 & Up Cutting Units Table of Contents SPECIFICATIONS ......SPA (Single Point Adjustment) Spring .

  • Page 328: Specifications

    Both rollers use the same heavy duty ball bear- pin and/or threaded micro–adjustment. Front roller posi- ings with two conventional single lip seals and a Toro tion is adjustable to set cutting unit attitude. labyrinth seal to provide four sealing surfaces to protect Bedknife And Bedbar Adjustment: Single point ad- the bearings.

  • Page 329: Special Tools

    Order special tools from the TORO SPECIAL TOOLS Some tools may have been supplied with your machine AND APPLICATIONS GUIDE (COMMERCIAL PROD- or available as TORO parts. Some tools may also be UCTS). available from a local supplier. Gauge Bar Assembly Use gauge bar to verify height of cut and cutting unit atti- tude.
  • Page 330 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 to a torque of 250 –...

  • Page 331: Troubleshooting

    Troubleshooting There are a number of factors that can contribute to un- Remember that the “effective” or actual height of cut de- satisfactory quality of cut, some of which may be turf pends on cutting unit weight and turf conditions. Effec- conditions.
  • Page 332 Factor Possible Problem/Correction 5. Bedknife to reel adjustment. Check bedknife to reel contact daily. Bedknife must have light contact all across reel. No contact will cause cutting edges to become dull. Excessive contact accelerates wear; quality of cut may be adversely affected.

  • Page 333: Set-Up And Adjustments

    Set–up and Adjustments IMPORTANT: To insure proper setting of height–of–cut, NOTE: Right and left ends of cutting unit is determined these procedures must be followed in this order: by standing with the rear roller in front of you (Fig. 8). A.

  • Page 334: Adjusting (Parallel) Bedknife To Reel

    NOTE: If reel makes contact on both sides of bedknife but still does not cut paper, cutting unit may need to be backlapped (refer to Backlapping) and/or reel and bed- knife may need to be reground (refer to Toro manual for LEFT Sharpening Reel and Rotary Mowers, Form No.

  • Page 335: Setting Cutting Unit Attitude - New Cutting Units

    Therefore, after ini- tial set up use Checking and Adjusting Attitude for Used Cutting Unit procedure. 1. Using a two–screw gauge bar, Toro part no. “B” 98–1852, set first screw to desired Height–of–Cut. This setting is from the bar face to the underside of the screw head (Fig.
  • Page 336 1.756 44.6 * Optional Low Cut Bedknife, Toro part no. 93–9774, is required for height–of–cut below 0.500” (13 mm). NOTE: For front roller distances (“B”) greater than 1.5” (38 mm) switch long and short adjusting nut locations for better support (Fig. 14).
  • Page 337 3. Set the rear support bracket and side plate using the approximate dimensions given by Table 1. The rear support bracket is either in the top or bottom location, and the side plate location can be in holes 1 thru 4, with 1 being the top hole (Fig.

  • Page 338: Checking Or Adjusting Attitude - Used Cutting Units

    FIRST METHOD (Angle Indicator): 1. Rotate cutting unit backwards to gain access to reel and bedknife. 2. Place an angle indicator, Toro part no. 99–3503, on the bedknife and record the bedknife angle (Fig. 18). Figure 19 1. 1st screw 2.
  • Page 339 SECOND METHOD (Screw Height Difference) : 1. Rotate cutting unit backwards to gain access to reel and bedknife. 2. Using a two–screw gauge bar, Toro part no. 98–1852, set first screw to desired Height–of–Cut. 3. Place the gauge bar across front and rear rollers.

  • Page 340: Leveling Front Roller

    5.80 remaining cutting units on the machine. C. Leveling Front Roller IMPORTANT: Toro strongly recommends the use of a CONTACT ALONG FULL LENGTH OF FRONT ROLLER AND REEL BLADE LEVELS FRONT ROLLER TO REEL leveling plate when setting–up or adjusting any reel type cutting unit.

  • Page 341: Finalizing Height-Of-Cut

    1. Using a two–screw gauge bar, Toro part no. 98–1852, set first screw to desired Height–of–Cut. This setting is from the bar face to the underside of the screw head (Fig.

  • Page 342: Front Shield And Fins Adjustment

    Front Shield and Fins Adjustment Adjust front shield and/or shield fin angle for desired grass clippings dispersion. 1. Position cutting unit on a flat level surface. 2. To adjust fins (Fig. 28), unhook and move front mounting tab to the straight ahead or angled position slot.

  • Page 343: Turf Compensation Spring Adjustment

    Turf Compensation Spring Adjustment The Turf Compensation Spring (Fig. 30), connecting “B” carrier frame to cutting unit, controls the amount of fore– Ç Ç Ç Ç Ç Ç Ç aft rotation available, as well as the amount of ground “C” “A”...

  • Page 344: Reel Bearing Adjustment

    Reel Bearing Adjustment To insure long life of the reel bearings, periodically check if reel end play exits. The reel bearings can be checked and adjusted as follows: 1. Loosen reel to bedknife contact by turning the bed- knife adjusting knob counter–clockwise until no contact exists.

  • Page 345: Spa (Single Point Adjustment) Spring

    SPA (Single Point Adjustment) Spring If single point adjustment assembly (Fig. 41) is removed for servicing, make sure spring is compressed to a 1.25” length of 1.25” (32 mm). This adjustment is attained by (32mm) tightening nut on SPA knob shaft. Figure 34 1.

  • Page 346: Lifted Height Of Outer Front Cutting Units

    Lifted Height of Outer Front Cutting Units (Enable Position) The turnaround height of the front outer cutting units (#4 & #5) may be increased to provide additional ground clearance on contoured fairways. Contact your distribu- tor for assistance. Travel of Front Three Cutting Units Additional downward travel of the front three cutting units may be desirable in highly contoured locations.

  • Page 347: Service And Repairs

    Move Lower Mow / Lift control forward to start back–lap- ping operation on designated reels. 8. Apply lapping compound with a long handle brush (Toro Part No. 29–9100). Never use a short handled brush (Fig. 38). Figure 38 1. Long handle brush Reelmaster 6500–D/6700–D...

  • Page 348: Bedbar Removal And Installation

    Bedbar Removal and Installation Figure 39 1. Screw 16. Lock nut 32. Flange nut 2. Washer 17. Washer 33. L.H. pivot hub 3. Quad ring 18. Compression spring 34. Screw 4. Lock nut 19. Spring arm 35. L.H. side plate 5.
  • Page 349 Remove Bedbar 3. Loosen bedknife adjusting knob to loosen bedknife to reel contact. 4. Loosen locknut on bedknife adjuster assembly and disengaging adjuster from bedbar. 5. Remove bedbar leveling screw from L.H. side of cut- ting unit. 6. Remove fasteners securing L.H. and R.H. bedbar pivot hubs to frame.

  • Page 350: Bedknife Replacement And Grinding

    Bedknife Replacement and Grinding 1. Remove bedbar from cutting unit. Use a torque 2. Remove bedknife screws and remove bedknife. wrench and bedknife screw tool 3. Remove all rust, scale and corrosion from bedbar sur- face before installing new bedknife. 4.

  • Page 351: Preparing Reel For Grinding

    Preparing Reel for Grinding 1. Check to make sure reel bearings are in good condi- Note: When grinding, be careful to not overheat the reel tion and properly adjusted before grinding the reel. blades. Remove small amounts of material with each Make sure the cutting unit frame and roller brackets are pass of the grinder.

  • Page 352: Reel Removal And Bearing Replacement

    Reel Removal and Bearing Replacement Use tool TOR4074 to install threaded spline insert. Apply Locite 242 to threads Tighten to 75 – 85 ft–lb (10.4 – 11.8 KgM) Apply anti–sieze lubricant to splines 9 10 Pack bearings with No. 2 general purpose grease Use tool TOR4064 Tighten set–screw...
  • Page 353 Remove Reel 4. Inspect bearings and seals. To replace seals and bearings: 1. Remove weight from cutting unit. If equipped with a speed sensor, remove shaft magnet after removing A. Use a bearing puller tool to remove the bearings. weight and sensor. To prevent damage to bearings, pull on the inner bearing race.

  • Page 354: Roller And Frame Service

    Roller and Frame Service 13 – 17 ft–lb 11 12 (1.8 – 2.4 KgM) 13 – 17 ft–lb (1.8 – 2.4 KgM) 13 – 17 ft–lb (1.8 – 2.4 KgM) 13 – 17 ft–lb (1.8 – 2.4 KgM) 75 – 85 ft–lb (10.4 –...

  • Page 355: Roller Bearing And Seal Replacement

    Roller Bearing and Seal Replacement Sharp edge out Lip of seal facing in Figure 47 1. Roller 4. Roller shaft 7. Retaining ring 2. Inner oil seal 5. Inner seal 8. Outer oil seal 3. Bearing 6. Outer seal 9. Washer NOTE: Bearing and seal configurations are the same for B.

  • Page 356: Cutting Unit Installation

    Cutting Unit Installation IMPORTANT: All Reelmaster 6000 Series must have Motor Weight Weight* Motor Weight Motor the on-board controller (ECU) configured for the installed cutting units, otherwise the cutting unit drive circuits will not function. Refer to configuration instruc tions in this manual. Motor Weight* Weight...
  • Page 357 6. Insert a thrust washer onto horizontal shaft of pivot knuckle as shown in figure 51. 7. Insert the horizontal shaft of the pivot knuckle into the mounting tube of the carrier frame (Fig. 51). 8. Secure pivot knuckle to carrier frame with a thrust washer, flat washer and a flange head capscrew (Fig.

  • Page 358: Cutting Unit Selection

    Cutting Unit Selection The Controller must be programmed with the Blade con- 7. Toggle Diagnostic Tool to display Outputs. figuration (number of Blades) on the installed cutting 8. Cycle the Joystick to the Lower position once for units in order for the ClipAce feature to operate proper- each blade on the installed cutting units (e.g.
  • Page 359 Greasing Bearings, Bushings and Pivot Points IMPORTANT: Lubricating cutting units immediately after washing helps purge water out of bearings and increases bearing life. Each cutting unit has (7) grease fittings that must be lu- bricated regularly with No. 2 General Purpose Lithium Base Grease.
  • Page 360 Cutting Units Model 03857, S/N 80302 & Up Page 8.1 – 34 Rev. C Reelmaster 6500–D/6700–D Model 03858, S/N 81419 & Up Model 03859, S/N 81993 & Up...

  • Page 361: Wire List

    Chapter 9 Wire Harness Diagram Table of Contents WIRE LIST ........WIRE HARNESS DIAGRAM .
  • Page 362 WIRE NO. COLOR CONNECTOR LOCATION A CONNECTOR LOCATION B BLACK HARNESS GROUND SPLICE A GROUND TO FRAME BLACK HARNESS GROUND SPLICE G OPTIONAL LIGHTS BLACK HARNESS GROUND SPLICE A LIFT ARM SENSOR – FRONT BLACK HYD. SOLENOID S5A HARNESS GROUND SPLICE A BLACK HYD.
  • Page 363 RED / WHITE CONTROLLER (C/N 1) BACKLAP SWITCH RED / WHITE CONTROLLER (J3) (CAN +) HARNESS CAN + SPLICE Not Used CONTROLLER (C3) SEAT SWITCH VIOLET CONTROLLER (D2) JOYSTICK RAISE VIOLET / RED CONTROLLER (B/M 3) KEY START (S) VIOLET / RED CONTROLLER (A3) HYD.
  • Page 364 BLACK HYD. SOLENOID VS1B HARNESS GROUND SPLICE C BLACK HYD. SOLENOID S4B HARNESS GROUND SPLICE C BLACK HARNESS GROUND SPLICE C HARNESS GROUND SPLICE B YELLOW HARNESS GROUND SPLICE M CONTROLLER INTERCONNECT ORANGE HARNESS POWER SPLICE K LEAK DETECTOR FUSE BLOCK FUSE B4 CONTROLLER INTERCONNECT BLACK HARNESS GROUND SPLICE F...
  • Page 365 TEMP RANGE / DIAGNOSTIC GAUGE IGNITION SPEEDOMETER LIGHT REEL SPEED 112B SENSOR REAR LEFT IGNITION F E D 113B REEL SPEED SENSOR ”I” 110B 114B 57B 24B (FRONT) A B C 118B 121B COMMUNICATION 125B 135A PORT FRAME 101B OPTIONAL GROUND LIGHTS ”J”...
  • Page 366 TEMP RANGE / DIAGNOSTIC GAUGE IGNITION SPEEDOMETER LIGHT REEL SPEED 112B SENSOR REAR LEFT IGNITION F E D 113B REEL SPEED SENSOR ”I” 110B 114B 57B 24B (FRONT) A B C 118B 121B COMMUNICATION 125B 135A PORT FRAME 101B OPTIONAL GROUND LIGHTS ”J”...

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