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  9. Toro REELMASTER 6500 D User manual

Toro REELMASTER 6500 D User manual

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!" = 
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9 2+'38 #" %  47   
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('11'89 7+6:/7+2+398


This operator's manual has instru tions on safety, proper set-up and operation, adjustments and maintenan e.
Therefore, anyone involved with the produ t, in luding the operator, should read and understand this manual.
Major se tions are:
- Safety Instru tions
- Spe ifi ations
- Set-up Instru tions
- Before Operating
- Know Your Controls
- Operating Instru tions
- Maintenan e
- S hemati s
This manual emphasizes safety, me hani al and general produ t information. ,  and
 identify safety messages.  Whenever the triangular safety alert symbol appears, understand the safety
message that follows. For omplete safety instru tions, read pages 4- 7.  highlights spe ial
me hani al information and  emphasizes general produ t information worthy of spe ial attention.
  
In some pla es a spark arrester muffler must be used be ause of lo al, state or federal regulations. The spark
arrester available from your lo al Toro Distributor is approved by the United States Department of Agri ulture and
the United States Forest Servi e.
When the mower is used or operated on any California forest, brush or grass overed land, a properly operatĆ
ing spark arrester must be atta hed to the muffler. The operator is violating state law, Se tion 442 Publi  ReĆ
sour es Code if a spark arrester is not used.
Diesel engine exhaust and some of its
constituents are known to the State of
California to cause cancer, birth defects,
or other reproductive harm.
  
   
The model and serial number is on a plate that is
mounted on the left side of frame above footrest
(Fig. 1). Use model and serial number in all
orresponden e and when ordering parts.
To order repla ement parts from an authorized TORO
Distributor, supply the following information:
 Model and serial numbers of the ma hine.
 Part number, des ription and quantity of parts
desired.
 $ Do not order by referen e number if a parts
atalog is being used; use the part number.
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  
 
   2. . . . . . . . . . . . .
Model And Serial Number 2. . . . . . . . . . . . . . . .
  4. . . . . . . . . . . . . . . . . . . .
Before Operating 4. . . . . . . . . . . . . . . . . . . . . . . .
While Operating 4. . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
    6-7. . . . . . .
 8. . . . . . . . . . . . . . . . . . . . . . . . . .
   9. . . . . . . . . . . . . . . . . . . . .
  9-10. . . . . . . . . . . . . . . .
Install Cutting Units 9. . . . . . . . . . . . . . . . . . . . . .
Rear Ballast 10. . . . . . . . . . . . . . . . . . . . . . . . . . . .
  11. . . . . . . . . . . . . . . . . . . . .
Check Engine Oil 11. . . . . . . . . . . . . . . . . . . . . . .
Check Cooling System 11. . . . . . . . . . . . . . . . . .
Fill Fuel ank 11. . . . . . . . . . . . . . . . . . . . . . . . . . .
Check Hydraulic Fluid 12. . . . . . . . . . . . . . . . . . .
Check Planetary Gear Drive Oil 12. . . . . . . . . . .
Check Rear Axle Lubricant (Model 03801) 13. . . .
Check ire Pressure 13. . . . . . . . . . . . . . . . . . . .
Check Reel o Bedknife Contact 13. . . . . . . . . .
Check orque Of Wheel Nuts 13. . . . . . . . . . . . .
   14. . . . . . . . . . . . . . . . . .
  16. . . . . . . . . . . . . .
Starting And Stopping 16. . . . . . . . . . . . . . . . . . .
Priming Fuel System 16. . . . . . . . . . . . . . . . . . . .
Automatic Clip Control 16. . . . . . . . . . . . . . . . . .
Selecting Clip Rate (Reel Speed) 17. . . . . . . . .
Clip Rate Selection Chart 18. . . . . . . . . . . . . . . .
Reel Control Light 18. . . . . . . . . . . . . . . . . . . . . .
Pushing or owing Machine 18. . . . . . . . . . . . . .
Diagnostic Light 19. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic ACE Display 19. . . . . . . . . . . . . . . . .
Checking Interlock Switches 19. . . . . . . . . . . . .
Hydraulic Solenoid Valve Functions 21. . . . . . .
H.O.C. Selection Potentiometer
Replacement 21. . . . . . . . . . . . . . . . . . . . . . . . . . .
Leak Detector Operation (Optional) 21. . . . . . .
Checking Operation 21. . . . . . . . . . . . . . . . . . . .
roubleshooting 25. . . . . . . . . . . . . . . . . . . . . . . .
Operating Characteristics 26. . . . . . . . . . . . . . . .
 27-28. . . . . . . . . . . . . . . . . . . . . . . .
Greasing Bearings And Bushings 27. . . . . . . . .
   28. . . . . . . . . . . . . . .
   29. . . . . . . . .
  30. . . . . . . . . . . . . . . .
   31. . . . . . . . . . . . .
General Air Cleaner Maintenance Practices 31
Servicing Air Cleaner 31. . . . . . . . . . . . . . . . . . . .
   33. . . . . . . . . . . . . . . . . .
Engine Oil And Filter 33. . . . . . . . . . . . . . . . . . . .
Fuel System 33. . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Cooling System 34. . . . . . . . . . . . . . . . .
Engine Fan Belt 35. . . . . . . . . . . . . . . . . . . . . . . .
  36. . . . . . . . . . . . . . .
Changing Hydraulic Fluid 36. . . . . . . . . . . . . . . .
Replacing Hydraulic Filter 36. . . . . . . . . . . . . . .
Checking Hydraulic Lines And Hoses 36. . . . .
Hydraulic System est Ports 37. . . . . . . . . . . . .
Adjusting raction Drive For  Neutral 37. . . . . .
Adjusting Cutting Unit Lift Rate 38. . . . . . . . . . .
  39. . . . . . . . . . . . . . . .
  41. . . . . . . . . . . . . . . . . . . .
Adjusting Service Brakes 41. . . . . . . . . . . . . . . .
  42. . . . . . . . . . . . . . . . . . . . . .
Changing  Planetary Gear Drive Oil 42. . . . . . .
Changing Rear Axle Lubricant 42. . . . . . . . . . . .
Rear Wheel oe-in 43. . . . . . . . . . . . . . . . . . . . .
  44. . . . . . . . . . . . . .
Battery Care 44. . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuses 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Lighting 44. . . . . . . . . . . . . . . . . . . . . . .
  45. . . . . . . . . . . . . . . .
   46. . . . . . . . . . . .
Backlapping 46. . . . . . . . . . . . . . . . . . . . . . . . . . .
    47.
  Back Cover                   

  
he REELMAS ER 6500ĆD was tested and certified by
ORO for compliance with the B71.4Ć1990
specifications of the American National Standards
Institute. 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, concern, 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. o reduce the potential for
injury or death, comply with the following safety
instructions.
 
  Read and understand the contents of this manual
before starting and operating the machine. Become
familiar with the controls and know how to stop the
machine and engine quickly. A free replacement
manual is available by sending the complete model
and serial number to:
he oro Company
8111 Lyndale Avenue South
Bloomington, Minnesota 55420-1196.
 Never allow children to operate the machine. Do
not allow adults to operate machine without proper
instruction. Only trained operators who have read this
manual should operate this machine.
 Never operate the machine when under the
influence of drugs or alcohol.
 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 machine. Also tighten any loose nuts,
bolts or screws to ensure machine is in safe operating
condition.
 Always wear substantial shoes.  Do not operate
machine 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.
 Assure interlock switches are adjusted correctly so
engine cannot be started unless traction pedal is in
NEU RAL and cutting units are DISENGAGED.
 Remove all debris or other objects that might be
picked up and thrown by the reels or fast moving
components from other attached implements. Keep all
bystanders away from operating area.
 Since diesel fuel is highly flammable, handle it
carefully:
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.
 
 Sit on the seat when starting and operating the
machine.
 Before starting the engine:
A. Engage the parking brake.
B. Make sure traction pedal is in NEU RAL,
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.
 Seating capacity is one person. herefore, never
carry passengers.
 Do not run engine in a confined area without
adequate ventilation. Exhaust fumes are hazardous
and could possibly be deadly.
 Check interlock switches daily for proper
operation. If a switch fails, replace it before operating
the machine. he interlock system is for your
protection, so do not bypass it. Replace all interlock
switches every two years.
 Using the machine demands attention and to
prevent loss of control:
A. Operate only in daylight or when there is good
artificial 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.
 raverse slopes carefully. Do not start or stop
suddenly when traveling uphill or downhill.

 !%  !"!
 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 resulting in personal injury or death. On 4
wheel drive model, always use the seat belt and ROPS
together.
 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.
 ! !  "%    hen a person
or pet appears unexpectedly in or near the mowing
area, ! $. 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.
 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.
 If cutting unit strikes a solid object or vibrates
abnormally, 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 replace it before operating. Do not attempt to
free blocked cutting unit by reversing reel direction.
Damage to reel may result.
  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.
!
 Before servicing or making adjustments, stop
engine and remove key from the switch.
 Make sure machine is in safe operating condition
by keeping all nuts, bolts and screws tight.
 Make sure all hydraulic line connectors are tight,
and all hydraulic hoses and lines are in good condition
before applying pressure to the system.
 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.
Hydraulic 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 doctor familiar with this form of injury or gangrene
may result.
 Before disconnecting or performing any work on
the hydraulic system, all pressure in system must be
relieved by stopping engine and lowering  cutting units
to the ground.
 If major repairs are ever needed or assistance is
desired, contact an Authorized Toro Distributor.
 To reduce potential fire hazard, keep engine area
free of excessive grease, grass, leaves and dirt.  Clean
protective screen on front of engine frequently.
 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
moving parts. Keep everyone away.
 Do not overspeed the engine by changing
governor setting. To assure safety and accuracy, have
an Authorized Toro Distributor check maximum engine
speed.
 Shut engine off before checking or adding oil to the
crankcase.
 Disconnect battery before servicing the machine.
If battery voltage is required for troubleshooting or test
procedures, temporarily connect the battery.
 At the time of manufacture, the machine
conformed to the safety standards for riding mowers.
To assure optimum 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 nonĆconformance with the safety
standards, and the warranty may be voided.
"  " #
This unit has an equivalent continuous AĆweighted
sound pressure at the operator ear of: 82 dB(A), based
on measurements of identical machines per Directive
84/538/EEC and amendments.
#! #
&,'0.+
This unit does not exceed a vibration level of 2.5 m/s
at the hands based on measurements of identical
machines per ISO 5349 procedures.
$)-*( -'/
This unit does not exceed a vibration level of .5 m/sat
the posterior based on measurements of identical
machines per ISO 2631 procedures.

 #    
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.
    
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
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     
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

' "' Peugeot, 4 cylinder, 4 cycle, overhead cam,
116 cu. in (1.9 liter) displacement liquid cooled diesel
engine. 38 hp (28 kW); governed to 2500 rpm high idle;
23.5:1 compression ratio, 3.27" (83 mm) bore x 3.46"
(88 mm) stroke. Automatic glow plug/starter interlock
system. Heavy duty, 2 stage, remote air cleaner.
"' *& All welded formed steel frame, includes
tie-down loops.
((%"'  1+,& Rear-mounted, cross-flow
agricultural type radiator; 7 fins per inch. Approx. 7.5
quart (7.1 liter) capacity. Air to oil cooler mounted to
rear of radiator tips outward for cleaning. Removable
oil cooler/radiator screen.
-% 1+,& Rotary fuel injection pump with
energized-to-run (ETR) fuel flow solenoid.
Replaceable spin-on fuel filter/water separator with
water sensor. Fuel capacity: 15 gallon (64 liter).
*,"(' 1+,& Servo-controlled hydrostatic
system driving double planetary gear reduction front
wheel drives. Foot pedal control of forward/reverse
ground speed.
(*( ,"R !% *". 1+,& ('%1 Rear
drive axle coupled to hydrostatic transmission via
overrunning clutch for full time on-demand 4 wheel
drive. A Roll Over Protective Structure (ROPS) and seat
belt are standard.
*(-' ) 0-10 mph forward; 0-4 mph reverse.
-,,"'  '", *". 1+,& Reel motors feature quick
disconnect for removal or installation onto cutting unit.
Cutting units can be driven from either end.
, Deluxe high back suspension seat with
adjustable fore and aft travel, weight and height. Tool
box at left side of seat.
,*"'  1+,&  Power steering with dedicated
power source.
"*+: Two rear steering tires: 20 x 10.00Ć10, tubeless,
6Ćply rating. Two front traction drive tires: 29 x 14.00Ć15
tubeless, 6Ćply rating. Recommended tire pressure for
front and rear tires is 15-20 psi.
*$+ ndividual totally enclosed, multi-disc, wet
brakes and parking brakes on front traction wheels.
Hydrostatic braking through traction drive.
%,*"% ,-*+ 12 volt, 530 cold cranking
amperes at 0_ F (-18_ C), 85 minute reserve capacity
at 80_F(27_ C), maintenance free battery. 55 amp
alternator with l.C. regulator/rectifier. Automotive type
electrical system. Seat switch, reel and traction
interlock switches.
(',*(%+ Foot operated traction and brake pedals.
Hand operated throttle, speed control lever, parking
brake lock, ignition switch with automatic preheat
cycle, single joy stick control for cutting unit on/off and
lift lower. Cutting unit backlap switch located under
operator's seat. Height-of-cut selector knob located
under control panel.
- + Hour meter, speedometer, fuel gauge,
temperature gauge, 4 bank warning lamp: oil
pressure, water temperature, amps, and glow plug. 2
bank warnlng lamp: water in fuel, water level.
" '(+,"+ The Automatic Control Electronics,
ACET system allows precise timing and control of
machine functions for maximum reliability. Toro
standard diagnostic display connects to an electronic
control unit to pin point any electrical problems quickly
and easily. Available DATA LOGT system allows
mechanic to find intermittent problems.
'*% )"","('+ ))*(0
Width-of-Cut: 96 in.
Overall Width:
Transport 84 in.
Operational 110 in.
Overall Length: 120 in.
Height:
Without ROPS installed: 60 in.
With ROPS installed: 84 in.
Weight:
Model 03800 3200 lbs.*
Model 03801 3300 lbs.*
 *With 5 Blade Cutting Units & full fluid levels
)"","('+ ' +" ' +-#, ,( !'  /",!(-, '(,"

!  "!  "
04) Use this chart as a checklist to assure all parts necessary for assembly have been received. Without  these
parts, total setĆup cannot be completed. ome parts may have already been assembled at factory.
! ""%#!
Counterweight  3
Counterweight w/speed sensor  2
O-ring-large 10 Mount counterweights & motors to cutting units
peed ensor  2
O-ring-small  2
peed ensor holder  2
Capscrew M6 x 20 mm  2
Lynch Pin  5 Mount cutting units to traction unit
teering Pin  5
Diagnostic ACE Display Overlay  2 Use with Diagnostic ACE Display for diagnosing
machine malfunction
( tore in service shop until needed)
EEC Certificate  2
Operator's Manual (Traction Unit)  2 Read before operating machine.
Parts Catalog  1
Registration Card  1 Fill out and return to Toro

!"# !" #"!
 "" All Reelmaster 6000 eries must be set up with the RM CONFIG software, part no. 95-3480,
otherwise the cutting unit drive circuits will not function. Refer to Installation Instructions supplied with kit.
!" #"" #"! ,* 
Cutting unit models 03854, 03855 and 03856 can be
installed at any of the five mounting locations on the
traction 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 end of the cutting unit, install a counter
weight on the left end of the cutting unit. For the
locations requiring the motor to be mounted on the left
end, install a counter weight on the right end of the
cutting unit.
Two of the counter weights provided with the tractor
include speed sensor assemblies. These need to be
installed on cutting units to be mounted in the front
center and left rear positions on the tractor.
,*52) 
0402 $),*+4
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04) Counter weight mounting capscrews are
shipped installed to right end of the cutting units. The
capscrews on left end are to be used for securing the
hydraulic motor.
 Remove cutting units from cartons. Assemble and
adjust per Cutting Unit Operator's Manual.
 Remove protective plugs from each end of cutting
unit.
 Lubricate and install a large O-ring into bearing
housing groove on each end of cutting unit (Fig. 3 & 5).
,*52) 
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 2,/*-&2*)
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 2&.) 45')
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 
,1# Before installing cutting unit motors or
counterweights with speed sensors, lubricate internal
splines of cutting unit reels shafts with grease.
 Install a counter weight onto appropriate end of
each cutting unit with capscrews provided (Fig. 3 ).
 Install (2) shims on pivot shaft of each cutting unit
carrier frame (Fig. 4).
 Insert the pivot shaft of the carrier frame into the
mounting hole at the end of the pivot knuckle (Fig. 4).
'%2/# 
 //'#/ $/*#
 '3,1 0&$1
 '3,1 (+2!()#
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 #+1#/'+% 01,-0
 5+!& -'+
 1##/'+% -'+
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 Guide the pivot knuckle in place between the two
rubber centering stops on the carrier frame (Fig. 4).
 Insert the lynch pin into the cross hole on the pivot
shaft (Fig. 4). (If pin does not fit, remove one of the
shims from the pivot shaft.)
 Mount the motor to the drive end of the cutting unit
and secure with two capscrews provided (Fig. 5).
'%2/# 
 ,1,/
 /'+%
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
 On front center and left rear cutting units, plug
speed sensor wire harness connector into traction unit
wire harness connector.
 On motor side of cutting unit, insert speed sensor
end of harness into frame tube and route to
counterweight.
 Install small O-ring onto speed sensor and insert
sensor into hole in counterweight (Fig. 3).
 Secure sensor to counterweight with a sensor
holder and a  M6 x 20 mm capscrew (Fig. 3).
 Insertsteering pin into either front or rear mounting
hole on pivot knuckle, using one of the following
locations:
Rear Mounting Hole-Keeps cutting unit in straight
line.
Front Mounting Hole-Allows cutting unit to steer
itself as traction unit turns.
  Hook wire around bottom of pin.
 
Model 03800 (2 heel Drive)  complies with the ANSI
B71.4-1990 Standard when 100 lbs. of calcium
chloride ballast is added to rear wheels and rear weight
kit (Part No. 94-2836) is installed.
Model 03801 (4 heel Drive)  complies with the ANSI
B71.4-1990 Standard when 100 lbs. of calcium
chloride ballast is added to rear wheels.
 $  -2+!12/# ,!!2/0 '+  1'/# 4'1&
!)!'2* !&),/'"# /#*,3# 2+'1 $/,* 12/$ /# 0
.2'!()5 0 -,00' )# , -/#3#+1 -,00' )# "*%# 1,
12/$ '**#"'1#)5 0,( $$#!1#" /# 4'1& 41#/