Toro REELMASTER 6500 D User manual

PART NO. 95871SL Rev. D
Service Manual
ReelmasterR6500–D/6700–D
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 ADJUSTMENT INSTRUC-
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.
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.
EThe Toro Company – 1996, 1998, 1999, 2002
(With Peugeot Engine)

Reelmaster 6500–D/6700–D

Safety
Product Records
and Manuals
Engine
Hydraulic
System
Electrical
System
Axles, PlanetariesCutting Units
038 3, 038 4, 038 6 and Brakes
Cutting Units
038 7, 038 8, 038 9
Rev. C
Reelmaster 6500–D/6700–D
Table Of Contents
Chapter 1 –Safety
Safety Instructions 1 –1. . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals 1 –4. . . . . . . . . . . . . . . .
Chapter 2 –Product Records and Manuals
Product Records 2 –1. . . . . . . . . . . . . . . . . . . . . . . . . . .
Equivalents and Conversions 2 –2. . . . . . . . . . . . . . . .
Torque Specifications 2 –3. . . . . . . . . . . . . . . . . . . . . . .
Maintenance Quick Reference Aid 2 –7. . . . . . . . . . . .
Equipment Operation
and Service History Report 2 –11. . . . . . . . . . . . . . . .
Chapter 3 –Engine
Introduction 3 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification and Specifications 3 –3. . . . . . . . . . . . . .
Special Tools 3 –11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments 3 –17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 3 –18. . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing and Inspection 3 –27. . . . . . . . . . . . . . . . . . . . .
Fuel System Service 3 –33. . . . . . . . . . . . . . . . . . . . . . .
Timing Belt Replacement 3 –36. . . . . . . . . . . . . . . . . . .
Injection Pump Timing 3 –40. . . . . . . . . . . . . . . . . . . . .
Preparation for Engine Repair 3 –42. . . . . . . . . . . . . . .
Engine Removal and Installation 3 –43. . . . . . . . . . . .
Engine Overhaul 3 –45. . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 4 –Hydraulic System
Specifications 4 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information 4 –3. . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Schematics 4 –6. . . . . . . . . . . . . . . . . . . . . . .
Special Tools 4 –18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 4 –20. . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing 4 –29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments 4 –40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repairs 4 –42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 5 –Electrical System
Wiring Schematics (S/N 50001 –59999) 5 –2. . . . . . . . . .
Wiring Schematics (S/N 60001 & UP) 5 –8. . . . . . . . . . . .
Main Wire Harness Connector Diagram 5 –18. . . . . .
Special Tools 5 –19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 5 –21. . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical System Quick Checks 5 –33. . . . . . . . . . . . .
Component Identification and Testing 5 –35. . . . . . . .
Repairs 5 –49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 6 –Axles, Planetaries and Brakes
Specifications 6 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools 6 –3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments 6 –5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repairs 6 –6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fairfield Torque–Hub Service Manual
Chapter 7 –Cutting Units
Model 03853
Model 03854
Model 03856
Specifications 7 –2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools 7 –3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 7 –5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Set–up and Adjustments 7 –7. . . . . . . . . . . . . . . . . . . .
Service and Repairs 7 –12. . . . . . . . . . . . . . . . . . . . . . .
Chapter 8 –Cutting Units
Model 03857, S/N 80001 –80301
Model 03858, S/N 80001 –81418
Model 03859, S/N 80001 –81992
Specifications 8 –2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools 8–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 8 –5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Set–up and Adjustments 8 –7. . . . . . . . . . . . . . . . . . . .
Service and Repairs 8 –15. . . . . . . . . . . . . . . . . . . . . . .
Chapter 8.1 –Cutting Units
Model 03857, S/N 80302 & Up
Model 03858, S/N 81419 & Up
Model 03859, S/N 81993 & Up
Specifications 8.1 –2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools 8.1–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 8.1 –5. . . . . . . . . . . . . . . . . . . . . . . . . .
Set–up and Adjustments 8.1 –7. . . . . . . . . . . . . . . . . .
Service and Repairs 8.1 –21. . . . . . . . . . . . . . . . . . . . .
Chapter 9 –Wiring Harness Diagram
Wire List 9 –2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Harness Diagram 9 –5. . . . . . . . . . . . . . . . . . . . . .

Reelmaster 6500–D/6700–D

CAUTION
Rev. B
Reelmaster 6500–D/6700–D Page 1 – 1 Safety
Chapter 1
Safety
Table of Contents
SAFETY INSTRUCTIONS 1. . . . . . . . . . . . . . . . . . . . . .
Before Operating 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
While Operating 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance and Service 3. . . . . . . . . . . . . . . . . . . . .
SAFETY AND INSTRUCTION DECALS 4. . . . . . . . . .
Safety Instructions
The REELMASTER 6500-D and 6700–D was tested
and certified by TORO for compliance with the
B71.4-1990 specifications of the American National
Standards Institute when ballast is added. See Opera-
tor’s Manual for ballast requirements. Although hazard
control and accident prevention partially are dependent
upon the design and configuration of the machine, these
factors are also dependent upon the awareness, con-
cern, and proper training of the personnel involved in the
operation, transport, maintenance, and storage of the
machine. Improper use or maintenance of the machine
can result in injury or death. To reduce the potential for
injury or death, comply with the following safety instruc-
tions.
TO REDUCE THE POTENTIAL FOR INJURY
OR DEATH, COMPLY WITH THE FOLLOWING
SAFETY INSTRUCTIONS.
Before Operating
1.Read and understand the contents of this manual be-
fore starting and operating the machine. Become famil-
iar with the controls and know how to stop the machine
and engine quickly. A free replacement manual is avail-
able by sending the complete model and serial number
to:
The Toro Company
8111 Lyndale Avenue South
Minneapolis, Minnesota 55420–1196.
Use the Model and Serial Number when referring to your
machine. If you have questions about this Service
Manual, please contact:
The Toro Company
Commercial Service Department
8111 Lyndale Avenue South
Minneapolis, Minnesota 55420.
2. Never allow children to operate the machine. Do not
allow adults to operate machine without proper instruc-
tion. Only trained operators who have read this manual
should operate this machine.
3. Never operate the machine when under the influence
of drugs or alcohol.
4. Keep all shields, safety devices and decals in place.
If a shield, safety device or decal is defective, illegible or
damaged, repair or replace it before operating the ma-
chine. Also tighten any loose nuts, bolts or screws to en-
sure machine is in safe operating condition.
5. Always wear substantial shoes. Do not operate ma-
chine while wearing sandals, tennis shoes, sneakers or
when barefoot. Do not wear loose fitting clothing that
could get caught in moving parts and possibly cause
personal injury. Wearing safety glasses, safety shoes,
long pants and a helmet is advisable and required by
some local ordinances and insurance regulations.
6. Assure interlock switches are adjusted correctly so
engine cannot be started unless traction pedal is in
NEUTRAL and cutting units are DISENGAGED.
Safety

Rev. B Reelmaster 6500–D/6700–D Page 1 –2
Safety
7. Remove all debris or other objects that might be
picked up and thrown by the reels or fast moving compo-
nents from other attached implements. Keep all by-
standers away from operating area.
8.Since diesel fuel is highly flammable, handle it careful-
ly:
A. Use an approved fuel container.
B. Do not remove fuel tank cap while engine is hot or
running.
C. Do not smoke while handling fuel.
D. Fill fuel tank outdoors and only to within an inch of
the top of the tank, not the filler neck. Do not overfill.
E. Wipe up any spilled fuel.
While Operating
9. Sit on the seat when starting and operating the ma-
chine.
10. Before starting the engine:
A. Engage the parking brake.
B. Make sure traction pedal is in NEUTRAL, throttle
is in SLOW and the ENABLE / DISABLE switch is in
DISABLE.
C. After engine is started, release parking brake and
keep foot off traction pedal. Machine must not
move. If movement is evident, the neutral return
mechanism is adjusted incorrectly; therefore, shut
engine off and adjust until machine does not move
when traction pedal is released.
11. Seating capacity is one person. Therefore, never
carry passengers.
12. Do not run engine in a confined area without ade-
quate ventilation. Exhaust fumes are hazardous and
could possibly be deadly.
13. Check interlock switches daily for proper operation.
If a switch fails, replace it before operating the machine.
The interlock system is for your protection, so do not by-
pass it. Replace all interlock switches every two years.
14. Using the machine demands attention and to pre-
vent loss of control:
A. Operate only in daylight or when there is good ar-
tificial light.
B. Drive slowly
C. Watch for holes or other hidden hazards.
D. Look behind machine before backing up.
E. Do not drive close to a sand trap, ditch, creek or
other hazard.
F. Reduce speed when making sharp turns and
turning on a hillside.
G. Avoid sudden stops and starts.
15. Traverse slopes carefully. Do not start or stop sud-
denly when traveling uphill or downhill.
16. Operator must be skilled and trained in how to drive
on hillsides. Failure to use caution on slopes or hills may
cause loss of control and vehicle to tip or roll possibly re-
sulting in personal injury or death. On 4 wheel drive
model, always use the seat belt and ROPS together.
17. If engine stalls or loses power and cannot make it to
the top of a slope, do not turn machine around. Always
back slowly straight down the slope.
18. DON’T TAKE AN INJURY RISK! When a person or
pet appears unexpectedly in or near the mowing area,
STOP MOWING. Careless operation, combined with
terrain angles, ricochets, or improperly positioned
guards can lead to thrown object injuries. Do not resume
mowing until area is cleared.
19. Do not touch engine, muffler or exhaust pipe while
engine is running or soon after it is stopped. These
areas could be hot enough to cause burns.
20.If cutting unit strikes a solid object or vibrates abnor-
mally, stop cutting units immediately, turn engine off, set
parking brake and wait for all motion to stop. Inspect for
damage. If reel or bedknife is damaged, repair or re-
place it before operating. Do not attempt to free blocked
cutting unit by reversing reel direction. Damage to reel
may result.
21. Before getting off the seat:
A. Move traction pedal to neutral.
B. Set parking brake.
C. Disengage cutting units and wait for reels to stop.
D. Stop engine and remove key from switch.
E. Do not park on slopes unless wheels are chocked
or blocked.

Safety
Rev. B
Reelmaster 6500–D/6700–D Page 1 –3 Safety
Maintenance and Service
22. Before servicing or making adjustments, stop en-
gine and remove key from the switch.
23. When changing attachments, tires or performing
other service, use the correct blocks, hoists and jacks.
Always chock or block the wheels and use jack stands
or solid wood blocks to support the raised machine. If the
machine is not properly supported by blocks or jack
stands, the machine may move or fall, resulting in per-
sonal injury.
24. Make sure machine is in safe operating condition by
keeping all nuts, bolts and screws tight.
25. Make sure all hydraulic line connectors are tight, and
all hydraulic hoses and lines are in good condition be-
fore applying pressure to the system.
26. Keep body and hands away from pin hole leaks in
hydraulic lines that eject high pressure hydraulic fluid.
Use cardboard or paper to find hydraulic leaks. Hydrau-
lic fluid escaping under pressure can penetrate skin and
cause injury. Fluid accidentally injected into the skin
must be surgically removed within a few hours by a doc-
tor familiar with this form of injury or gangrene may re-
sult.
26. Before disconnecting or performing any work on the
hydraulic system, all pressure in system must be re-
lieved by stopping engine and lowering cutting units to
the ground.
28. If major repairs are ever needed or assistance is de-
sired, contact an Authorized Toro Distributor.
29. To reduce potential fire hazard, keep engine area
free of excessive grease, grass, leaves and dirt. Clean
protective screen on front of engine frequently.
30. If engine must be running to perform maintenance
or an adjustment, keep hands, feet, clothing and other
parts of the body away from cutting units and other mov-
ing parts. Keep everyone away.
31. Do not overspeed the engine by changing governor
setting. To assure safety and accuracy, have an Autho-
rized Toro Distributor check maximum engine speed.
32. Shut engine off before checking or adding oil to the
crankcase.
33. Disconnect battery before servicing the machine. If
battery voltage is required for troubleshooting or test
procedures, temporarily connect the battery.
34. At the time of manufacture, the machine conformed
to the safety standards for riding mowers. To assure op-
timum performance and continued safety certification of
the machine, use genuine Toro replacement parts and
accessories. Replacement parts and accessories made
by other manufacturers may result in non-conformance
with the safety standards, and the warranty may be
voided.

Rev. B Reelmaster 6500–D/6700–D
Page 1 –4
Safety
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.
ON RIGHT FENDER
(Part No. 93–6686)
Hydraulic Oil Only
ON LEFT FENDER
(Part No. 93–6680)
Diesel Fuel Only
IN TOOL BOX
(Part No. 93–3728)
Quick Reference Aid
UNDER SEAT PLATE
(Part No. 98–8110)
Selecting Clip Rate & Solenoid
Wire Identification
INSIDE CONTROL BOX
(Part No. 94–6349)
Fuse Locations
UNDER FLOOR PLATE
(Part No. 93–6693)
WARNING: Moving Parts
under floor plate
INSIDE CONTROL BOX
(Part No. 93–1268)
Operating Instructions
H.O.C. Selector
ON TOP OF STEERING TOWER
(Part No. 93–1263)
Brake Operation & reel Control Lamp

Safety
Rev. B
Reelmaster 6500–D/6700–D Page 1 –5 Safety
ON LIFT ARMS
(Part No. 93–6687)
Do Not Step
ON TOOL BOX
(Part No. 93–1262)
WARNING: Read Operating &
Safety Instructions
ON TOWER
(Part No. 93–6699)
Mowing Speed Control
ON FRAME UNDER
MUFFLER
(Part No. 93–1265)
WARNING: Hot Surface
Do Not Touch!
ON CONSOLES
(Part No. 93–6689)
WARNING: No Riders
ON ROLL BAR ROOF
(Part No. 93–8050)
(Model 03804 only)
WARNING: Fasten Seat Belt
ON ROLL BAR
(Part No. 92–7540)
(Model 03804 only)
ROPS Serial Tag
ON BACKLAP BRACKET
(Part No. 93–1264)
WARNING: Read Backlap, Operating
& Safety Instructions
ON UNDERSIDE OF SEAT PLATE
(Part No. 98–8108)
Solenoid Wire Identification
ON UNDERSIDE OF SEAT PLATE
(Part No. 98–8109)
Solenoid Wire Identification

Reelmaster 6500–D/6700–D
Page 1 –6
Safety

Rev. C
Reelmaster 6500–D/6700–D Page 2 – 1 Product Records and Manuals
Chapter 2
Product Records and Manuals
Table of Contents
PRODUCT RECORDS 1. . . . . . . . . . . . . . . . . . . . . . . . .
EQUIVALENTS AND CONVERSIONS 2. . . . . . . . . . .
Decimal and Millimeter Equivalents 2. . . . . . . . . . . .
U.S. to Metric Conversions 2. . . . . . . . . . . . . . . . . . .
TORQUE SPECIFICATIONS 3. . . . . . . . . . . . . . . . . . .
Fastener Identification 3. . . . . . . . . . . . . . . . . . . . . . . .
Capscrew Markings and Torque Values – U.S. 4. .
Capscrew Markings and Torque Values – Metric 5.
Other Torque Specifications 6. . . . . . . . . . . . . . . . . . .
Conversion Factors 6. . . . . . . . . . . . . . . . . . . . . . . . . .
QUICK REFERENCE MAINTENANCE AID 7. . . . . . .
Bearing and Bushing Lubrication 8. . . . . . . . . . . . . .
OPERATION AND SERVICE HISTORY REPORT 11.
Product Records
Record information about your machine on the OPERA-
TION AND SERVICE HISTORY REPORT form. Use
this information when referring to your machine.
Insert Operator’s Manuals and Parts Catalogs for your
machine at the end of this section.
Product Records
and Manuals

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

Product Records
and Manuals
Rev. C
Reelmaster 6500–D/6700–D Page 2 –3 Product Records and Manuals
Torque Specifications
Recommended fastener torque values are listed in the
following tables. For critical applications, as determined
by Toro, either the recommended torque or a torque that
is unique to the application is clearly identified and spe-
cified in this Service Manual.
These Torque Specifications for the installation and
tightening of fasteners shall apply to all fasteners which
do not have a specific requirement identified in this Ser-
vice Manual. The following factors shall be considered
when applying torque: cleanliness of the fastener, use
of a thread sealant (Loctite), degree of lubrication on the
fastener, presence of a prevailing torque feature, hard-
ness of the surface underneath the fastener’s head, or
similar condition which affects the installation.
As noted in the following tables, torque values should be
reduced by 25% for lubricated fasteners to achieve
the similar stress as a dry fastener. Torque values may
also have to be reduced when the fastener is threaded
into aluminum or brass. The specific torque value
should be determined based on the aluminum or brass
material strength, fastener size, length of thread en-
gagement, etc.
The standard method of verifying torque shall be per-
formed by marking a line on the fastener (head or nut)
and mating part, then back off fastener 1/4 of a turn.
Measure the torque required to tighten the fastener until
the lines match up.
Fastener Identification
Grade 1 Grade 5 Grade 8
Inch Series Bolts and Screws
Class 8.8 Class 10.9
Metric Bolts and Screws

Rev. C Reelmaster 6500–D/6700–D
Page 2 –4
Product Records and Manuals
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)
Thread Size Grade 1, 5, &
8 with Thin
Height Nuts
SAE Grade 1 Bolts, Screws, Studs, &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
SAE Grade 5 Bolts, Screws, Studs, &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
SAE Grade 8 Bolts, Screws, Studs, &
Sems with Regular Height Nuts
(SAE J995 Grade 5 or Stronger Nuts)
in–lb in–lb N–cm in–lb N–cm in–lb N–cm
# 6 –32 UNC
10 + 2
13 + 2
147 + 23
15 + 2 170 + 20 23 + 2 260 + 20
# 6 –40 UNF 10 + 2 13 + 2 147 + 23 17 + 2 190 + 20 25 + 2 280 + 20
# 8 –32 UNC
13 + 2
25 + 5
282 + 30
29 + 3 330 + 30 41 + 4 460 + 45
# 8 –36 UNF 13 + 2 25 + 5 282 + 30 31 + 3 350 + 30 43 + 4 485 + 45
# 10 –24 UNC
18 + 2
30 + 5
339 + 56
42 + 4 475 + 45 60 + 6 675 + 70
# 10 –32 UNF 18 + 2 30 + 5 339 + 56 48 + 4 540 + 45 68 + 6 765 + 70
1/4 –20 UNC 48 + 7 53 + 7 599 + 79 100 + 10 1125 + 100 140 + 15 1580 + 170
1/4 –28 UNF 53 + 7 65 + 10 734 + 113 115 + 10 1300 + 100 160 + 15 1800 + 170
5/16 –18 UNC 115 + 15 105 + 17 1186 + 169 200 + 25 2250 + 280 300 + 30 3390 + 340
5/16 –24 UNF 138 + 17 128 + 17 1446 + 192 225 + 25 2540 + 280 325 + 30 3670 + 340
ft–lb ft–lb N–m ft–lb N–m ft–lb N–m
3/8 –16 UNC 16 + 2 16 + 2 22 + 3 30 + 3 41 + 4 43 + 4 58 + 5
3/8 –24 UNF 17 + 2 18 + 2 24 + 3 35 + 3 47 + 4 50 + 4 68 + 5
7/16 –14 UNC 27 + 3 27 + 3 37 + 4 50 + 5 68 + 7 70 + 7 95 + 9
7/16 –20 UNF 29 + 3 29 + 3 39 + 4 55 + 5 75 + 7 77 + 7 104 + 9
1/2 –13 UNC 30 + 3 48 + 7 65 + 9 75 + 8 102 + 11 105 + 10 142 + 14
1/2 –20 UNF 32 + 3 53 + 7 72 + 9 85 + 8 115 + 11 120 + 10 163 + 14
5/8 –11 UNC 65 + 10 88 + 12 119 + 16 150 + 15 203 + 20 210 + 20 285 + 27
5/8 –18 UNF 75 + 10 95 + 15 129 + 20 170 + 15 230 + 20 240 + 20 325 + 27
3/4 –10 UNC 93 + 12 140 + 20 190 + 27 265 + 25 359 + 34 375 + 35 508 + 47
3/4 –16 UNF 115 + 15 165 + 25 224 + 34 300 + 25 407 + 34 420 + 35 569 + 47
7/8 –9 UNC 140 + 20 225 + 25 305 + 34 430 + 45 583 + 61 600 + 60 813 + 81
7/8 –14 UNF 155 + 25 260 + 30 353 + 41 475 + 45 644 + 61 660 + 60 895 + 81
Note: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
oil, graphite, or thread sealant such as Loctite.
Note: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
Note: The nominal torque values listed above for
Grade 5 and 8 fasteners are based on 75% of the mini-
mum proof load specified in SAE J429. The tolerance is
approximately + 10% of the nominal torque value. Thin
height nuts include jam nuts.

Rev. C
Reelmaster 6500–D/6700–D Page 2 –5 Product Records and Manuals
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners)
Thread Size
Class 8.8 Bolts, Screws, and Studs with
Reg lar Height N ts
Class 10.9 Bolts, Screws, and Studs with
Reg lar Height N ts
Thread Size Regular Height Nuts
(Class 8 or Stronger Nuts) Regular Height Nuts (Class 10 or Stronger Nuts)
M5 X 0.8 57 + 5 in–lb 640 + 60 N–cm 78 + 7 in–lb 885 + 80 N–cm
M6 X 1.0 96 + 9 in–lb 1018 + 100 N–cm 133 + 13 in–lb 1500 + 150 N–cm
M8 X 1.25 19 + 2 ft–lb 26 + 3 N–m 27 + 2 ft–lb 36 + 3 N–m
M10 X 1.5 38 + 4 ft–lb 52 + 5 N–m 53 + 5 ft–lb 72 + 7 N–m
M12 X 1.75 66 + 7 ft–lb 90 + 10 N–m 92 +9 ft–lb 125 +12 N–m
M16 X 2.0 166 +15 ft–lb 225 + 20 N–m 229 + 22 ft–lb 310 + 30 N–m
M20 X 2.5 325 + 33 ft–lb 440 + 45 N–m 450 + 37 ft–lb 610 + 50 N–m
Note: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
oil, graphite, or thread sealant such as Loctite.
Note: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
Note: The nominal torque values listed above are
based on 75% of the minimum proof load specified in
SAE J1199. The tolerance is approximately + 10% of the
nominal torque value.
Product Records
and Maintenance

Rev. C Reelmaster 6500–D/6700–D
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Product Records and Manuals
Other Torque Specifications
SAE Grade 8 Steel Set Screws
Thread Size
Recommended Torque
Thread Size Square Head Hex Socket
1/4 –20 UNC 140 + 20 in–lb 73 + 12 in–lb
5/16 –18 UNC 215 + 35 in–lb 145 + 20 in–lb
3/8 –16 UNC 35 + 10 ft–lb 18 + 3 ft–lb
1/2 –13 UNC 75 + 15 ft–lb 50 + 10 ft–lb
Thread Cutting Screws
(Zinc Plated Steel)
Type 1, Type 23, or Type F
Thread Size Baseline Torque*
No. 6 –32 UNC 20 + 5 in–lb
No. 8 –32 UNC 30 + 5 in–lb
No. 10 –24 UNC 38 + 7 in–lb
1/4 –20 UNC 85 + 15 in–lb
5/16 –18 UNC 110 + 20 in–lb
3/8 –16 UNC 200 + 100 in–lb
Wheel Bolts and Lug Nuts
Thread Size Recommended Torque**
7/16 –20 UNF
Grade 5 65 + 10 ft–lb 88 + 14 N–m
1/2 –20 UNF
Grade 5 80 + 10 ft–lb 108 + 14 N–m
M12 X 1.25
Class 8.8 80 + 10 ft–lb 108 + 14 N–m
M12 X 1.5
Class 8.8 80 + 10 ft–lb 108 + 14 N–m
** For steel wheels and non–lubricated fasteners.
Thread Cutting Screws
(Zinc Plated Steel)
Thread
Size
Threads per Inch
Baseline Torq e*
Size Type A Type B Baseline Torque*
No. 6 18 20 20 + 5 in–lb
No. 8 15 18 30 + 5 in–lb
No. 10 12 16 38 + 7 in–lb
No. 12 11 14 85 + 15 in–lb
* Hole size, material strength, material thickness & finish
must be considered when determining specific torque
values. All torque values are based on non–lubricated
fasteners.
Conversion Factors
in–lb X 11.2985 = N–cm N–cm X 0.08851 = in–lb
ft–lb X 1.3558 = N–mN–m X 0.7376 = ft–lb

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Product Records
and Manuals

Rev. C Reelmaster 6500–D/6700–D
Page 2 –8
Product Records and Manuals
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
hours of operation or immediately after every washing.
1. The grease fitting locations and quantities are: Cut-
ting unit carrier frame and pivot (2 ea.) (Fig. 1); Rear axle
tie rod (2), Steering cylinder ball joints (2), (Fig. 2); Front
lift cylinders (3), (Fig. 4 and 8); Rear lift cylinder pivot (2),
(Fig. 5); Lift arm pivot (3), (Fig. 6); Rear axle pivot (Fig. 7)
Rear lift arm pivots (2) (Fig. 3) and Brake pedal shaft (1)
(Fig. 9).
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6

Rev. C
Reelmaster 6500–D/6700–D Page 2 –9 Product Records and Manuals
Figure 7 Figure 8
Figure 9
Product Records
and Manuals

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