Toro REELMASTER 6500 D User manual
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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.
%"
#" !$
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/sat
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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' "' 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
0402 $),*+4 $),*+4 0402
$),*+4 0402 $),*+4 0402
$,4+ 31))( 3)/302
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)
)&2,/* +053,/*
2,/*-&2*)
05/4)26),*+4
2,/* 3.&--
!1))( 3)/302
!1))( 3)/302 +0-()2
2&.) 45')
,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!()#
#+1#/'+% 01,-0
5+!& -'+
1##/'+% -'+
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,/
/'+%
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).
Insertsteering 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&
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2&(-.3* 7845 *3,.3* &3) 6*24:* 0*< +642
8-* 7;.8(-
.,
Cr nkc se c p city is 5.3 qt. with filter.
P rk m chine on level surf ce. Rele se hood
l tch nd open hood.
.,96*
44) &8(-
Remove dipstick from tube c p, wipe cle n nd
reinst ll dipstick into tube c p. Pull it out g in nd
check oil level on dipstick: Oil level must lw ys be in
notch re on dipstick.
.,96*
.578.(0 "9'* &5
If oil level is low, remove tube c p nd dd SAE
15W-40 CD oil until level re ches top of notch on
dipstick. DO NOT OVERFILL.
Inst ll oil tube c p.
Close hood nd secure l tch.
!%!" .,
C p city of system is 3.5 g l.
Check cooling system if low w ter level light
illumin tes.
P rk m chine on level surf ce. Rele se hood
l tch nd open hood.
Remove deg sser t nk c p nd check cool nt
level. 441&38 1*:*1 7-491) '* 95 84 46 &'4:* 8&'7 3
)*,&77*6 8&30 ;-*3 *3,.3* .7 (41)
+ *3,.3* -&7 '**3 6933.3, 56*7796.=*)
-48 (441&38 (&3 *7(&5* .+ )*,&77*6 (&5
.7 6*24:*) &3) (&97* '9637 114;
*3,.3* 84 (441 &8 1*&78 2.398*7 46 938.1
8-* )*,&77*6 (&5 .7 (441 *349,- 84 849(-
;.8-498 '963.3, -&3)
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.,96*
*,&77*6 "&30
If cool nt is low, remove deg sser t nk c p nd
dd 50/50 mixture of w ter nd Peugeot
recommended nti-freeze (Toro P rt No. 93-7213).
" #! $" %
" ! "!
Inst ll deg sser t nk c p.
Close hood nd secure l tch.
# " .,
C p city of fuel t nk is 15 g l.
Remove fuel t nk c p.
Fill t nk to bout one inch below top t nk, not filler
neck with No. 2 diesel fuel. Then inst ll c p.
.,96*
9*1 "&30 &5
! !#
!
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348 7240+ ;./1+ ,/11/3- 8.+ ,9+1 8'30 4
348 ,/11 ,9+1 8'30 ;./1+ +3-/3+ /7 6933/3-
.48 46 ;.+3 2')./3+ /7 /3 '3 +3)147+*
'6+' 1;'<7 ,/11 ,9+1 8'30 4987/*+ '3*
;/5+ 95 '3< 75/11+* */+7+1 ,9+1 (+,46+
78'68/3- 8.+ +3-/3+ "846+ ,9+1 /3 ' )1+'3
7',+8<'5564:+* )438'/3+6 '3* 0++5 )'5
/3 51')+ $7+ */+7+1 ,9+1 ,46 8.+ +3-/3+
431< 348 ,46 '3< 48.+6 596547+
&!$ $ /-
The hydraulic system is designed to operate on
anti-wear hydraulic fluid. The machines reservoir is
filled at the factory with approximately 8.5 gallons of
Mobil 424 hydraulic fluid. .+)0 1+:+1 4, .<*6'91/)
,19/* (+,46+ +3-/3+ /7 ,/678 78'68+* '3* *'/1<
8.+6+',8+6
6495 <*6'91/) 19/* !+)422+3*+* ,46
'2(/+38 8+25+6'896+7 )437/78+381< (+14; =
" 8<5+ '38/;+'6 .<*6'91/) ,19/*
Mobil Mobil Fluid 424
Amoco Amoco 1000
International Harvester Hy-Tran
Texaco TDH
hell Donax TD
Union OIl Hydraulic/Tractor Fluid
Chevron Tractor Hydraulic Fluid
BP Oil BP HYD TF
Boron OIl Eldoran UTH
Exxon Torque Fluid
Conoco Power-Tran 3
Kendall Hyken 052
Phillips HG Fluid
48+ The fluids within this group are interchangeable.
6495 <*6'91/) 19/* /4*+-6'*'(1+
" % '38/;+'6 .<*6'91/) ,19/*
Mobil EAL 224 H
48+ The fluid in this group is not compatible with the
fluids in group 1.
!## These hydraulic fluids are specified to
allow optimal operation of the machine in a wide range
of temperatures encountered. The group 1 fluids are a
multi-viscosity hydraulic fluids which allows operation
at lower temperatures without the increased viscosity,
which is associated with straight viscosity fluids.
# When changing from one type of hydraulic fluid
to the other, be certain to remove all the old fluid from
the system, because some brands of one type are not
completely compatible with some brands of the other
type of hydraulic fluid.
!## $7+ 431< 8<5+7 4, .<*6'91/) ,19/*7
75+)/,/+* 8.+6 ,19/*7 )491* )'97+ 7<78+2
*'2'-+
48+ A red dye additive for the hydraulic system fluid
is available in 2/3 oz. bottles. One bottle is sufficient for
4-6 gal. of hydraulic fluid. Order Part No. 44-2500
from your Authorized Toro Distributor
Position machine on a level surface, lower the
cutting units and stop the engine.
Clean area around filler neck and cap of hydraulic
tank. Remove cap from filler neck.
/-96+
<*6'91/) #'30 '5
Remove dipstick from filler neck and wipe it with a
clean rag. Insert dipstick into filler neck; then remove it
and check level of fluid. Fluid level should be within 1/4
inch of mark on dipstick.
If level is low, add appropriate fluid to raise level to
full mark.
Install dipstick and cap onto filler neck.
#!& ! !%
/-
Check oil if external leakage is noted. Use high quality
AE 85W-140 wt. gear lube as replacement.
Capacity of system is 16 oz.
With machine on level surface, position wheel so
the check/drain plug is at either three or nine o'clock
position.
Remove plug. Oil should be to bottom of the hole.
Add gear oil, if necessary, to bring up to proper
level and install plug.
Repeat steps 1-3 on the opposite gear assembly.
!
-+96)
,)'/6%-2 09+
$ "!
3()0 20< -+
The re r xle is shipped from the f ctory filled with SAE
85W-140 wt. ge r lube. Check level before engine is
first st rted nd every 400 hours there fter. C p city is
80 oz. Visu lly inspect for le ks d ily.
Position the m chine on level surf ce.
Remove check plug from one end of xle nd
m ke sure lubric nt is up to bottom of hole. If level is
low, remove the fill plug nd dd enough lubric nt to
bring the level up to the bottom of the check plug holes.
-+96)
,)'/ 09+-00 09+
! "
The tires re over-infl ted for shipping. Therefore,
rele se some of the ir to reduce the pressure. Correct
ir pressure in the front nd re r tires is 15 -20 psi.
!! M int in even pressure in ll tires to
ssure good qu lity-of-cut nd proper m chine
perform nce. DO NOT UNDER INFLATE.
! !!
E ch d y before oper ting, check reel to bedknife
cont ct, reg rdless if qu lity of cut h d previously been
ccept ble. There must be light cont ct cross the full
length of the reel nd bedknife (refer to Adjusting Reel
to Bedknife in Cutting Unit Oper tor's M nu l).
!" # "!
!
#
!3659) *6328 ;,))0 2987 %2( 6)%6 ;,))0 &3087
83 = *80& %*8)6 = ,3967 3* 34)6%8-32
%2( %+%-2 %*8)6 ,3967 3* 34)6%8-32 %2( ):=
)6< ,3967 8,)6)%*8)6 %-096) 83 1%-28%-2
4634)6 83659) '390( 6)7908 -2 *%-096) 36 0377 3*
;,))0 %2( 1%< 6)7908 -2 4)6732%0 -2.96<
" #!
3$&5,10 ('$. (Fig. 13) - Controls forwar an
reverse operation. Depress top of pe al to move
forwar an bottom to move backwar . Groun spee
epen s on how far pe al is epresse . For no loa ,
maximum groun spee , fully epress pe al while
throttle is in FAST.
To stop, re uce foot pressure on traction pe al an
allow it to return to center position.
3$&5,10 2((' ,/,5(3 (Fig. 13) - Preset this lever to
limit the amount the traction pe al can be epresse in
the forwar irection to maintain a constant mowing
spee .
,*63(
3$&5,10 ('$.
3$&5,10 2((' ,/,5(3
((. 10531. ,*+5
2(('1/(5(3
((. 10531. ,*+5 (Fig. 13) - When lit, in icates
machine is being operate in a way in which the
automatic reel spee control cannot obtain the esire
clip.
2(('1/(5(3 (Fig. 13) - In icates groun spee at
which machine is traveling.
18(3 18 $,4( 10531. (7(3 (Fig. 14) - The
lever raises an lowers the cutting units an also starts
an stops the reels.
6(. $6*( (Fig. 14)- In icates level of fuel in tank.
0*,0( ,. 3(4463( "$30,0* ,*+5 (Fig. 14) -
In icates angerously low engine oil pressure.
(9 8,5&+ (Fig. 14) - Three positions: OFF, ON /
Preheat an START.
"
0*,0( 8,.. 015 &3$0- 17(3 605,. .18 .6*
.$/2 *1(4 165 (.$9 05(3.1&- .18 2.6*4
/645 &1/2.(5( &9&.( %()13( &10531..(3 8,.. $.:
.18 (0*,0( 51 &3$0-
+3155.( 10531. (Fig. 14) - Move control forwar to
increase engine spee , rearwar to ecrease spee .
0*,0( 11.$05 (/2(3$563( "$30,0* ,*+5 (Fig. 14)
- The light illuminates an engine shuts own when
coolant reaches a angerously high temperature.
.18 .6* 0',&$513 ,*+5 (Fig. 14)- When lit,
in icates glow plugs are on.
+$3*( 0',&$513 (Fig. 14) - Illuminates when system
charging circuit malfunctions.
0$%.( ,4$%.( 8,5&+ (Fig. 14) - Use in
conjunction with lower mow / raise control lever to
operate reels.
"$5(3 ,0 6(. ,*+5 (Fig. 14) - In icates water in fuel
system.
18 "$5(3 (7(. ,*+5 (Fig. 14) - In icates coolant
water level is low.
,*63(
18(3 18 $,4( 10531. (7(3
6(. $6*(
0*,0( 11.$05 (/2(3$563( $6*(
0*,0( ,. 3(4463( "$30,0* ,*+5
0*,0( 11.$05 (/2(3$563( "$30,0* ,*+5
.18 .6* 0',&$513 ,*+5
+$3*( 0',&$513
(9 8,5&+
+3155.( 10531.
0$%.( ,4$%.( 48,5&+
"$5(3 ,0 6(. ,*+5
18 "$5(3 (7(. ,*+5
(.(&513 01% (Fig. 15) - Rotating knob to
appropriate setting informs the electronic controller at
what height-of-cut the machine is being operate
so, esire clip may be obtaine . See section in
manual for operating instructions. Knob is locate
un er control panel.
',) +) (Fig. 15) - S ows total ours t at mac ine
as been operated.
" ,)
%+') &'
',) +)
$%( ."+! (Fig. 16) - Used in conjunction wit
lower mow / raise control lever for backlapping
operation. Switc is located under seat plate. Refer to
Cutting Unit Maintenance, Backlapping.
" ,)
$%( ."+!
)$ %* (Fig. 17) - Two foot pedals operate
individual w eel brakes for turning assistance, parking
and to aid in obtaining better side ill traction. Locking
pin connects t e pedals for parking brake operation
and transport.
" ,)
)$ %*
)$"& )$ +!
'$"& "&
)$"& )$ +! (Fig. 17) - A knob on t e left side
of console actuates parking brake lock. To engage
parking brake, connect pedals wit locking pin, pus
down on bot pedals and pull parking brake latc out.
To release parking brake, depress bot pedals until
parking brake latc retracts.
+ (Fig. 18) - Seat adjusting lever allows 4 inc fore
and aft adjustment. Seat adjusting knob adjusts seat
for operators weig t. To adjust seat fore and aft, pull
lever on left side of seat assembly outward. After
moving seat to desired location, release lever to lock
seat into position. To adjust for operators weig t, turn
spring tension knob; clockwise to increase tension,
counterclockwise to decrease spring tension
" ,)
+ #,*+"& -)
+ #,*+"& &'
&'02& 3&26*$*/( 02 .",*/( "%+534.&/43 40 4)&
."$)*/& 3401 &/(*/& "/% 2&.06& ,&8 '20.
4)& 37*4$)
Sit on the seat, keep foot off traction pedal. Assure
parking brake is engaged, traction pedal is in
NEUTRAL, throttle is in SL W position and the
ENABLE / DISABLE switch is in the DISABLE position.
/(*/& 7*-- /04 $2"/, 06&2 5/4*- -07 -5(
".1 (0&3 054 &-"8 */ /4&2-0$, -07
1-5(3 .534 $0.1-&4& $8$-& #&'02& $0/420--&2
7*-- "--07 &/(*/& 40 $2"/,
Turn ignition switch to N / Preheat position. An
automatic timer will control preheat for approximately 6
seconds. /(*/& 7*-- /04 $2"/, 06&2 5/4*- 12&)&"4
-*()4 (0&3 0'' After preheat, turn key to START
position. CRANK ENGINE F R N L NGER THAN 15
SEC NDS. Release key when engine starts. If
additional preheat is required, turn key to FF position
then to N / preheat position. Repeat process as
required.
Run engine at idle speed or partial throttle until
engine warms up.
To stop, move all controls to NEUTRAL and set
parking brake. Return throttle to the idle position, turn
key to FF and remove it from switch.
! *(
)& '5&- 3834&. ."8 /&&% 40 #&
12*.&% 7)&/ " /&7 &/(*/& *3 34"24&% '02 4)& '*234
4*.& *' *4 25/3 054 0' '5&- 02 *' ."*/4&/"/$& *3
1&2'02.&% 0/ 4)& '5&- 3834&.
Unlatch and raise hood.
Insert a 3/16" hose over bleed screw and run other
end into a container to catch fuel.
Loosen fuel filter / water separator bleed screw
(Fig. 19) a few turns. Pump priming plunger until a
steady stream of fuel comes out of hole in bleed screw.
When fuel stops foaming, tighten the bleed screw
during the downstroke of the priming plunger. Wipe up
any spilled fuel.
Pump priming plunger until resistance is felt. Try to
start engine. If engine does not start repeat step 3.
04& It may be necessary to bleed the air out of the fuel
line between the fuel filter / water separator and the
injection pump. To do this, loosen the fitting on the
injection pump (Fig. 20) and repeat bleeding
procedure.
*(52&
2*.&2 -5/(&2-&&% $2&7
*(52&
/+&$4*0/ 5.1 *44*/(
The RM 6500-D is equipped with an electronic
controller which is programmed to achieve automatic
clip control. The machine will automatically adjust the
reel speed to attain the desired clip as the traction
speed changes. In order for the controller to know what
clip is desired, the software must have been properly
set, by your distributor or dealer, to either 5, 7 or 11
blade and the height-of-cut selector knob must be
properly set.
The range of possible reel speeds is a minimum of
about 500 RPM and a maximum of about 1400 RPM.
As long as the desired clip requires a reel speed within
this range, the machine will maintain the desired clip. If
the traction speed is too slow or too fast to allow the
desired clip, the Reel Control light (on the front control
panel) will illuminate, indicating that the desired clip is
not being maintained. For example, if the traction
speed is zero, the reels will still run at the minimum
speed of about 500 RPM, which will result in a clip
smaller than desired and cause the Reel Control light to
illuminate. The approximate ranges of traction speed
which will result in the desired clip are as follows for
several of the possible heights of cut:
11 .38 in. 1.9 mph 6.0 mph
11 .50 in. 2.6 mph 7.6 mph
7 .62 in. 2.1 mph 6.0 mph
7 .75 in. 2.5 mph 7.2 mph
5 .63 in. 1.5 mph 4.5 mph
5 .88 in. 2.1 mph 6.0 mph
. .& +!$%1
/%0
%)'(2.&32 )-),3, 0!#2).-
/%%$
!6),3, 0!#2).-
/%%$
0.#%$30% &.0 ,!)-2!)-)-' /0./%0 #+)/ 0!2%
%2 1%+%#2.0 *-." 2. #.00%#2 +%22%0 1%22)-' %0 #(!02 +.#!2%$ 3-$%0 1%!2 /+!2%
!)-2!)- '0.3-$ 1/%%$ 5()#( /0%4%-21 0%%+ #.-20.+ +)'(2 &0., )++3,)-!2)-'
To a hieve a onsistent, high quality of ut, and a
uniform after ut appearan e, it is important that the
reel speed be mat hed to the height of ut. The
ma hine ontroller is programmed to automati ally
ontrol the reel speed to give the orre t lip, even as
the tra tion speed hanges. In order to ontrol the reel
speed as desired, the ontroller must know the height
of ut of the ma hine, and whether the ma hine is
equipped with 5, 7 or 11 blade reels.
Adjust the HOC sele tor knob as follows:
Insure the onfiguration s reen, set, by the
distributor, is on the orre t setting. (5, 7 or 11 blade.)
Verify the height-of- ut setting on the utting
units. Using the olumn of the hart on page 18 or hart
under the seat plate, listing either 5, 7 or 11 blade reels,
find the height of ut listing nearest the a tual
height-of- ut setting. Look a ross the hart to find
the letter orresponding to that height of ut.
Turn the HOC sele tor knob to the letter setting
determined in step 2.
. Operate the ma hine for several days, then
examine the ut to ensure satisfa tion with the quality
of ut. The height of ut knob may be set one position
on either side of the position indi ated on the hart to
a ount for differen es in grass ondition, grass length
removed, and personal preferen e of the
superintendent. For a ut with more grass removed
but slightly more lip visibility, move the HOC sele tor
knob one position higher than spe ified. For a ut with
less grass removed and slightly less lip visibility, move
the HOC sele tor know one position lower than
spe ified.
)'30%
%+%#2.0 -."
3++ /%%$ There may be times when it is desirable
for the reels to run at full speed regardless of the
tra tion speed of the ma hine. Examples of this are
verti al utting or heavy s alping. In su h ases, the
HOC sele tor knob may be set to position "A" whi h will
indi ate to the ma hine ontroller to run the reels at full
speed at all times.
!"$ #$"%$ #
% #!
/3 22
/3 22
/3 22
/3 22
/3 22
/3 22
/3 22
/3 22
/3 22
/3 22
/3 22
/3 22
/3 22
/3 22
! /3 22
! "$ " #! #$ "$
% #!
/3 22
/3 22
/3 22
/3 22
/3 22
/3 22
/3 22
/3 22
/3 22
/3 22
/3 22
/3 22
/3 22
/3 22
! /3 22
34(
!47/8/43 +/-.84,98
1'*+ %
34(
!47/8/43 +/-.84,98
1'*+ %
% #!
/3 22
/3 22
/3 22
/3 22
/3 22
/3 22
/3 22
/3 22
/3 22
/3 22
/3 22
/3 22
/3 22
/3 22
! /3 22
% #! 988/3- 93/87 ;/11 '1;'<7 693 '8 ,911 75++* /3 8./7 547/8/43
34(
!47/8/43 +/-.84,98
1'*+ %
" $" $
The Ree Contro ight, ocated on the front contro
pane , is used to give feedback to the operator that the
machine contro er is ab e to achieve the desired c ip. If
the machine is operated at a traction speed which is
too ow or too high, the machine contro er may not be
ab e to set the ree speed at the required va ue to
achieve the desired c ip. If this occurs, the Ree Contro
ight wi i uminate.
If the Ree Contro ight i uminates, it means one of the
fo owing things:
The machine is being operated at a traction speed
too s ow to a ow desired c ip.
or
The machine is being operated at a traction speed
too fast to a ow desired c ip. To correct the situation,
change the traction speed unti the ight goes out.
or
A foreign object, such as a stick, piece of turf, etc. is
restricting ree rotation.
If changing the traction speed or removing the foreign
object does not cause the ight to go out, and the Ree
Contro ight remains i uminated regard ess of traction
speed, then a service issue is indicated. In this case,
refer to the Diagnostic Disp ay section of this manua ,
check service manua or contact your oca authorized
Toro Distributor..
!%# " $ &
In an emergency, the Ree master 6500-D can be
moved by actuating the by-pass va ve in the variab e
disp acement hydrau ic pump and pushing or towing
the machine.
! "$$ 4 348 597. 46 84; 8.+ 2')./3+ ,'78+6
8.'3 25. 02.6 (+)'97+ /38+63'1
86'372/77/43 *'2'-+ 2'< 4))96 $.+ (<5'77
:'1:+ 2978 (+ 45+3 ;.+3+:+6 8.+ 2')./3+ /7
597.+* 46 84;+*
By-pass va ve is ocated on top of variab e
disp acement pump (Fig. 22). Rotate the va ve 90_, in
either direction, to open and a ow oi to by-pass
interna y. Because f uid is by-passed, the machine
can be moved - s ow y - without damaging the
transmission.
Close by-pass valve before starting the engine.
However, do not exceed 5-8 ft-lb (7-11 N m) torque
to close the valve.
5//+/) 4*' '/)+/' 7+4* 4*' %81$33
6$-6' 01'/ 7+-- &$53' 4*' 42$/3.+33+0/ 40 06'2*'$4
+)52'
8$33 !$-6'
+)
The RM 6500-D is equipped with a diagnostic light
which indicates if the electronic controller is
functioning correctly. The diagnostic light is located on
the steering tower panel. hen the electronic
controller is functioning correctly and the key switch is
moved to the ON position, the controller diagnostic
light will be illuminated for approximately 6 seconds.
The light will not illuminate if the controller detects a
malfunction in the electrical system.
+)52'
-'&420/+& 0/420--'2 +)*4
If the diagnostic light is not illuminated when the key
switch is in the ON position, this indicates that the
electronic controller is not operating. Possible causes
are:
Loopback connector (under control panel
cover) is not connected.
The electronic controller light is burned out.
Fuses are blown.
Not functioning correctly.
Check electrical connections, input fuses and
diagnostic light bulb to determine malfunction. Make
sure loopback connector is secured to wire harness
connector.
#
The RM 6500-D is equipped with an electronic
controller which controls most machine functions. The
controller determines what function is required for
various input switches (i.e. seat switch, key switch,
etc.) and turns on the outputs to actuate solenoids or
relays for the requested machine function.
For the electronic controller to control the machine as
desired, each of the input switches, output solenoids
and relays must be connected and functioning
properly.
The Diagnostic ACE display is a tool to help the user
verify correct electrical functions of the machine.
"
The purpose of the interlock switches are to prevent
the engine from cranking or starting unless the traction
pedal is in NEUTRAL, the Enable / Disable switch is in
DISABLE and the Lower Mow / Raise control is in the
neutral position. In addition, the engine will stop when
the traction pedal is depressed with operator off the
seat.
"
#
9
# 9
" # 9
#
" !
#
# # "
0 6'2+(8 +/4'2-0&, 37+4&* (5/&4+0/
Park machine on a level surface, lower the cutting
units, stop the engine and engage the parking brake.
Open control panel cover. Locate wire harness and
connector. Carefully unplug loopback connector from
harness connector.
Connect the Diagnostic ACE display connector to
the harness connector. Make sure correct overlay
decal is positioned on Diagnostic ACE display.
"!)&
"& &#'' # $##($&'
Turn the key switch to the ON position, ut do not
start machine.
Note: The red text on the overlay decal refers to input
switches and the green text refers to outputs.
"!)&
"!#$'("
The inputs displayed" LED, on lower right column
of the Diagnostic ACE, should e illuminated. If
outputs displayed" LED is illuminated, press and
release the toggle utton, on Diagnostic ACE, to
change LED to inputs displayed". Do not hold utton
down.
The Diagnostic ACE will illuminate the LED
associated with each of the inputs when that input
switch is closed.
Individually, change each of the switches from open to
closed (i.e., sit on seat, engage traction pedal, etc.),
and note that the appropriate LED on Diagnostic ACE
will link on and off when corresponding switch is
closed. Repeat on each switch that is possi le to e
changed y hand.
If switch is closed and appropriate LED does not
turn on, check all wiring and connections to switch
and/or check switches with an ohm meter. Replace any
defective switches and repair any defective wiring.
The Diagnostic ACE also has the a ility to detect which
output solenoids or relays are turned on. This is a quick
way to determine if a machine malfunction is electrical
or hydraulic.
$ *&" + $)(%)( )#("$#
Park machine on a level surface, lower the cutting
units, stop the engine and engage the parking rake.
Open control panel cover. Locate wire harness and
connectors near controller. Carefully unplug loop ack
connector from harness connector. Set HOC selector
kno to position "A".
Connect the Diagnostic ACE connector to the
harness connector. Make sure correct overlay decal is
positioned on Diagnostic ACE.
Turn the key switch to the ON position, ut do not
start machine.
Note: The red text on the overlay decal refers to input
switches and the green text refers to outputs.
The outputs displayed" LED, on lower right
column of Diagnostic ACE, should e illuminated. If
inputs displayed" LED is illuminated, press the toggle
utton, on Diagnostic ACE, to change LED to outputs
displayed".
$( It may e necessary to toggle etween inputs
displayed" and outputs displayed" several times to do
the following step. To toggle ack and forth, press
toggle utton once. This may e done as often as
required. DO NOT HOLD BUTTON.
Sit on the seat and attempt to operate the desired
function of the machine. The appropriate output LED's
should illuminate to indicate that the ECU is turning on
that function. (Refer to the list on page 21 to e certain
of the specified output LED's.
$( If any output LED is linking, this indicates an
electrical pro lem with that OUTPUT. Repair / replace
defective electrical parts immediately. To reset a
linking LED, turn the key switch OFF", then ack
ON".
If no output LED's are linking, ut the correct output
LED's do not illuminate, verify that the required input
switches are in the necessary positions to allow that
function to occur. Verify correct switch function.
If the output LED's are on as specified, ut the machine
does not function properly, this indicates a
non-electrical pro lem. Repair as necessary.
$( Due to electrical system constraints, the output
LED's for START", PREHEAT" and ETR/ALT" may
not link even though an electrical pro lem may exist
for those functions. If the machine pro lem appears to
e with one of these functions, e certain to check the
electrical circuit with a volt / ohm meter to verify that no
electrical pro lem exists to these functions.
If each input switch is in the correct position and
functioning correctly, ut the output LED's are not
correctly illuminated, this indicates an ECU pro lem. If
this occurs, contact your Toro Distri utor for
assistance.
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