Toroメーカー6500-Dの使用説明書/サービス説明書
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NOTE: For Machines With Serial Numbers Below 250000000 : Use this book along with the Kubota Workshop Manu- al, 05 Series Diesel Engine (T oro Part No.
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Safety Product Records and Maintenance Kubota Diesel Engine Hydraulic System Electrical System Axles. Planetaries and Brakes Cutting Units Electrical Diagrams Rev . F Reelmaster 6500-D/6700-D T able Of Contents Chapter 1 - - Safety Safety Instructions 1 - - 1 .
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Safety Rev . F Reelmaster 6500-D/6700-D Safety Page 1 - - 1 Chapter 1 Safety T able of Contents SAFETY INSTRUCTIONS 1 ...................... Before Operating 1 ............................ While Operating 2 ............................. Maintenance and Service 3 .
Rev . E Reelmaster 6500-D/6700-D Page 1 - 2 Safety 7. Remove all debris or other objects that might be picked up and thrown by the reels or fast moving compo- nents from other attached implements. Keep all by- standers away from operating area. 8. Since diesel fuel is highly flammable, handle it careful- ly: A.
Safety Rev . E Reelmaster 6500-D/6700-D Safety Page 1 - - 3 Maintenance and Service 1. Before servicing or making adjustments, stop engine and remove key from the switch. 2. When changing attachments, tires or performing oth- er service, use the correct blocks, hoists and jacks.
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Product Records and Maintenance Rev . E Reelmaster 6500-D/6700-D Page 2 - 1 Product Records and Maintenance Chapter 2 Product Records and Maintenance T able of Contents PRODUCT RECORDS 1 ......................... MAINTENANCE 1 ........................
0.09375 Rev . E Reelmaster 6500-D/6700-D Page 2 - 2 Product Records and Maintenance Equivalents and Conversions.
Product Records and Maintenance Rev . A Reelmaster 6500-D/6700-D Page 2 - 3 Product Records and Maintenance T orque Specifications Recommended fastener torque values are listed in the following tables.
Rev . A Reelmaster 6500-D/6700-D Page 2 - 4 Product Records and Maintenance Standard T orque for Dry , Zinc Plated, and Steel Fasteners (Inch Series) Thread Size Grade 1, 5, & 8w i t hT h i n Heig.
Product Records and Maintenance Rev . A Reelmaster 6500-D/6700-D Page 2 - 5 Product Records and Maintenance Standard T orque for Dry , Zinc Plated, and Steel Fasteners (Metric Series) T h r e a d S i z e Class 8.8 Bolts, Screws, and Studs with R e g u l a r H e i g h t N u t s Class 10.
Rev . A Reelmaster 6500-D/6700-D Page 2 - 6 Product Records and Maintenance Other T orque Specifications SAE Grade 8 Steel Set Screws T h r e a d S i z e Recommended T orque Thread Size Square Head He.
Kubota Diesel Engine Reelmaster 6500-D/6700-D Page 3 - 1 Kubota Diesel Engine Chapter 3 Kubota Diesel Engine T able of Contents INTRODUCTION 2 .............................. SPECIFICA TIONS 3 ............................. GENERAL INFORMA TION 4 ......
Reelmaster 6500-D/6700-D Page 3 - 2 Kubota Diesel Engine Introduction This Chapter gives information about specifications, maintenance, troubleshooting, testing, and repair of the diesel engine used in the Reelmaster 6500-D and 6700-D. Most repairs and adjustments require tools which are commonly available in many service shops.
Kubota Diesel Engine Reelmaster 6500-D/6700-D Page 3 - 3 Kubota Diesel Engine Specifications Item Description Make/Designation Kubota V1505 - - T (E), 4-Cycle, 4 Cylinder , T urbocharged, V ertical, Water Cooled, Diesel Engine Horse Power 42.5 HP @ 3000 RPM Bore 3.
Reelmaster 6500-D/6700-D Page 3 - 4 Kubota Diesel Engine General Information Stopping The Engine IMPORT ANT : Before stopping the engine after mowing or full load operation, cool the turbo -char- ger by allowing the engine to idle at low speed for 5 minutes.
Kubota Diesel Engine Reelmaster 6500-D/6700-D Page 3 - 5 Kubota Diesel Engine Fill Fuel T ank DANGER Under certain conditions, diesel fuel and f uel va- pors are highly flammable and explosive. A fire or explosion from fuel can burn you and others and can cause property damage.
Rev . D Reelmaster 6500-D/6700-D Page 3 - 6 Kubota Diesel Engine Check Cooling System The cooling system is filled with a 50/50 solution of water and permanent ethylene glycol anti-freeze. Check level of coolant at the beginning of each day before s tarting the engine.
Kubota Diesel Engine Reelmaster 6500-D/6700-D Page 3 - 7 Kubota Diesel Engine Adjustments Adjust Throttle Cable 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Release hood latch and open hood.
Reelmaster 6500-D/6700-D Page 3 - 8 Kubota Diesel Engine Adjust Alternator Belt The condition and tension of all belts should be checked periodically as recommended in the maintenance schedules in Chapter 2 - Product Records and Mainte- nance.
Kubota Diesel Engine Reelmaster 6500-D/6700-D Page 3 - 9 Kubota Diesel Engine Service and Repairs Bleed Fuel System 1. Park machine on a level surface, lower cutting units, stop engine, and engage parking brake. Make sure fuel tank is at least half full.
Reelmaster 6500-D/6700-D Page 3 - 10 Kubota Diesel Engine Bleed Air from Fuel Injectors IMPORT ANT : This procedure should be used only if the fuel system has been purged of air through nor- mal priming procedures (see Bleed Fuel System) and engine will not start.
Kubota Diesel Engine Reelmaster 6500-D/6700-D Page 3 - 1 1 Kubota Diesel Engine Clean Radiator and Oil Cooler Remove debris from rear screen, oil cooler and radiator daily , clean more frequently in dirty conditions. IMPORT ANT : Never spray water onto a hot engine as damage to engine may occur .
Reelmaster 6500-D/6700-D Page 3 - 12 Kubota Diesel Engine Fuel Filter/W ater Separator DANGER Under certain conditions, diesel fuel and f uel va- pors are highly flammable and explosive. A fire or explosion from fuel can burn you and others and can cause property damage.
Kubota Diesel Engine Reelmaster 6500-D/6700-D Page 3 - 13 Kubota Diesel Engine 4. Place a suitable container under fuel/water separa- tor , and unscrew filter element and base from the filter head. 5. Unscrew filter element from base and discard ele- ment.
Reelmaster 6500-D/6700-D Page 3 - 14 Kubota Diesel Engine Fuel System Figure 19 1. Fuel Hose 2. Cable Tie 3. Spring Clamp 4. Round Head Screw 5. Lock W asher 6. Sending Unit 7. Gasket 8. Fuel Hose 9. Hose Clamp 10. Stand Pipe 1 1. Fuel Elbow Connector 12.
Kubota Diesel Engine Reelmaster 6500-D/6700-D Page 3 - 15 Kubota Diesel Engine DANGER Under certain conditions, diesel fuel and f uel va- pors are highly flammable and explosive. A fire or explosion from fuel can burn you and others and can cause property damage.
Reelmaster 6500-D/6700-D Page 3 - 16 Kubota Diesel Engine Air Filter General Maintenance 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Release hood latch and open hood.
Kubota Diesel Engine Reelmaster 6500-D/6700-D Page 3 - 17 Kubota Diesel Engine This page is intentionally left blank..
Reelmaster 6500-D/6700-D Page 3 - 18 Kubota Diesel Engine Radiator Figure 24 1. Fan Shroud RH 2. Screw 3. Hex Nut 4. Flat W asher 5. Hex Nut 6. Fan Shroud LH 7. Screw 8. Flat W asher 9. Radiator Support 10. Screw 1 1. Reservoir Bracket 12. Locknut 13.
Kubota Diesel Engine Reelmaster 6500-D/6700-D Page 3 - 19 Kubota Diesel Engine Removal (Fig. 24) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Unlatch and remove rear screen.
Reelmaster 6500-D/6700-D Page 3 - 20 Kubota Diesel Engine Engine Figure 25 1. Muffler 2. Hexnut 3. Lockwasher 4. Screw 5. Flat W asher 6. Muffler Support 7. Screw 8. Lockwasher 9. Locknut 10. Engine Bracket (front RH) 1 1. Fuel Hose 12. Hose Clamp 13.
Kubota Diesel Engine Reelmaster 6500-D/6700-D Page 3 - 21 Kubota Diesel Engine Removal (Fig. 25) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Release hood latch and open hood.
Reelmaster 6500-D/6700-D Page 3 - 22 Kubota Diesel Engine C. High temperature shutdown switch (Fig. 30). Glow plug bus (Fig. 31). 13. Make sure all cable ties securing the wiring harness, fuel lines, or hydraulic hoses to the engine are removed. 14. Connect hoist or lift to the front and rear engine lift tabs.
Kubota Diesel Engine Reelmaster 6500-D/6700-D Page 3 - 23 Kubota Diesel Engine 10. Install radiator support and oil c ooler . 1 1. Install radiator (see Radiator Installation in this sec- tion of this manual). 12. Connect air filter hose to the engine.
Reelmaster 6500-D/6700-D Page 3 - 24 Kubota Diesel Engine This page is intentionally left blank..
Hydraulic System Rev . F Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 1 Chapter 4 Hydraulic System T able of Contents SPECIFICA TIONS 2 ............................. GENERAL INFORMA TION 3 ..................... Hydraulic Hoses 3 ................
Rev . B Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 2 Specifications Item Specification T raction Pump Servo controlled piston pump T raction Relief Pressure 4000 PSI (276 bar) Charge Pressure .
Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 3 General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather , sun, chemicals, very warm storage condi- tions, or mishandling during operation or maintenance.
Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 4 SAE Straight Thread O-Ring Port - Non -adjustable 1. Make sure both threads and sealing surfaces are free of burrs, nicks, scratches, or any foreign material. 2. Always replace the O-ring seal when this type of fit- ting shows signs of leakage.
Hydraulic System Rev . F Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 5 Pushing or T owing T raction Unit In an emergency , the machine can be moved by actuat- ing the bypass valve in the variable displacement hy- draulic pump and pushing or towing the machine.
Rev . F Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 6 Hydraulic Schematics MOW CIRCUIT Hydraulic System Schematic Serial Numbers 210000101 T o 210999999 All solenoids are shown as de-energized. V1 F R F R P4 R5 R3 R6 R6 RH LH IN OUT AUX M8 M9 G1 G2 C.
Hydraulic System Rev . F Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 7 MOW CIRCUIT Hydraulic System Schematic Serial Numbers 220000101 T o 260000499 All solenoids are shown as de-energized. V1 F R F R P4 R5 R3 R6 R6 RH LH IN OUT AUX M8 M9 G1 G2 C.
Rev . F Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 8 Hydraulic System Schematic Serial Numbers 260000500 T o 270999999 All solenoids are shown as de-energized.
Rev . F Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 9 Hydraulic System Schematic Serial Numbers Above 280000000 All solenoids are shown as de-energized.
Rev . F Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 10 Hydraulic System Schematic Serial Numbers 210000101 T o 210999999 All solenoids are shown as de-energized. Reelmaster 6500-D 4WD (Model 03807) .66 .66 .40 10.8 10.8 6.6 BARS M10 50 1500 1500 4000 276.
Rev . F Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 1 1 Hydraulic System Schematic Serial Numbers 220000101 T o 260000499 All solenoids are shown as de-energized. Reelmaster 6500-D 4WD (Model 03807) .66 .66 .40 10.8 10.8 6.6 BARS M10 50 1500 1500 4000 276.
Rev . F Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 12 Hydraulic System Schematic Serial Numbers 260000500 T o 270999999 All solenoids are shown as de-energized.
Rev . F 12.1 Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - Hydraulic System Schematic Serial Numbers Above 280000000 All solenoids are shown as de-energized.
Rev . F 12.2 Reelmaster 6500-D/6700-D Hydraulic System Page 4 - Hydraulic System Schematic Serial Numbers 210000101 T o 210999999 All solenoids are shown as de-energized. Reelmaster 6700-D 4WD (Model 03808) S1 1 .66 .66 .40 10.8 10.8 6.6 BARS M10 50 1500 1500 4000 276.
Rev . F 12.3 Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - Hydraulic System Schematic Serial Numbers 220000101 T o 260000499 All solenoids are shown as de-energized. Reelmaster 6700-D 4WD (Model 03808) S1 1 .66 .66 .40 10.8 10.8 6.
Rev . F 12.4 Reelmaster 6500-D/6700-D Hydraulic System Page 4 - Hydraulic System Schematic Serial Numbers 260000500 T o 270999999 All solenoids are shown as de-energized. Reelmaster 6700-D 4WD (Model 03808) SV1 SV2 FLOW RA TE CALCULA TED A T 3000 RPM AND 98% EFFICIENCY .
Rev . F 13 Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - Hydraulic System Schematic Serial Numbers Above 280000000 All solenoids are shown as de-energized. Reelmaster 6700-D 4WD (Model 03808) SV1 SV2 FLOW RA TE CALCULA TED A T 3000 RPM AND 98% EFFICIENCY .
Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 14 Hydraulic Flow Diagrams T raction Circuit (4WD Forward Direction Shown) High Pressure Low Pressure (Charge) Return or Suction Flow Reelmaster 6500-D/6700-D F R F R P4 CHARGE PRESSURE RELIEF M8 M9 T P2 12:1 P1 12:1 P3 R4 50 PSI P5 M10 R F 13.
Hydraulic System Rev . C Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 15 T raction Circuit The hydraulic pump assembly is driven by a coupling at- tached to the engine flywheel. The pump assembly con- sists of a three section gear pump, a gerotor charge pump, and a variable displacement piston pump.
Rev . B Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 16 Lower Cutting Units (6700-D Shown) High Pressure Low Pressure (Charge) Return or Suction Flow Reelmaster 6500-D/6700-D are energized. Solenoids SV1, SV3, SV4, SV5, SV6, and SV7 S1 1 MOW CIRCUIT V1 F R F R P4 R5 R6 R6 RH LH IN OUT AUX M8 M9 G1 G2 C.
Hydraulic System Rev . F Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 17 Lower Cutting Units The hydraulic pump assembly is driven by a coupling at- tached to the engine flywheel. The pump assembly con- sists of a three section gear pump, a gerotor charge pump, and a variable displacement piston pump.
Rev . B Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 18 Raise Cutting Units (6700-D Shown) High Pressure Low Pressure (Charge) Return or Suction Flow Reelmaster 6500-D/6700-D and SV7 are energized. Solenoids SV1, SV2, SV3, SV4, SV5, SV6, S1 1 MOW CIRCUIT V1 F R F R P4 R5 R6 R6 RH LH IN OUT AUX M8 M9 G1 G2 C.
Hydraulic System Rev . C Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 19 Raise Cutting Units The hydraulic pump assembly is driven by a coupling at- tached to the engine flywheel. The pump assembly con- sists of a three section gear pump, a gerotor charge pump, and a variable displacement piston pump.
Rev . B Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 20 Mow and Backlap (6700-D ”Mow” Shown) High Pressure Low Pressure (Charge) Return or Suction Flow Reelmaster 6500-D/6700-D are energized. Solenoids MSV1, MSV2, S10, and S1 1 MOW CIRCUIT V1 F R F R P4 R5 R3 R6 R6 RH LH IN OUT AUX M8 M9 G1 G2 C.
Hydraulic System Rev . C Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 21 Mow and Backlap Mow The reel manifold contains two independent control cir- cuits for the front and rear cutting units. Each circuit is supplied by its own gear pump section.
Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 22 Right and Left T urns (6700 -D Shown) High Pressure Low Pressure (Charge) Return or Suction Flow Reelmaster 6500-D/6700-D STEERING CYLINDER AUX IN.
Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 23 Right and Left T urns In addition to supplying hydraulic flow to the cutting unit lift circuits, gear pump section (P3) supplies hydraulic flow to the steering control valve for turning the rear wheels.
Rev . E Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 24 Special T ools NOTE: Order special tools from your T oro Distributor . Some tools may also be available from a local supplier . Hydraulic Pressure T est Kit - TOR47009 Use to take various pressure readings for diagnostic tests.
Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 25 Hydraulic T ester - With Pressure and Flow Capabilities - TOR214678 Figure 12 Y ou must have o-ring face seal (ORFS) adapter fittings for this tester to use it on the Reelmaster 6500 - - D and 6700 - - D.
Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 26 T roubleshooting The cause of an improperly functioning hydraulic sys- tem is best diagnosed with the use of proper testing equipment and a thorough understanding of the com- plete hydraulic system.
Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 27 T ransmission or Hydraulic System is Operating Hot Cause Correction Oil in reservoir is below level. Fill reservoir to proper level. Contaminated oil. Drain reservoir and refill with clean oil.
Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 28 T ransmission Response Sluggish Cause Correction Charge pressure low . TEST NO. 1. Inspect charge relief valve R5. Repair or replace if defective. Servo control valve faulty . Inspect c ontrol valve for: Plugged control orifices.
Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 29 T ransmission Will Not Operate in Either Direction (Continued) Cause Correction Wheel motor(s) worn or damaged. NOTE: If a motor has internal damage, it is likely that the pump and other motor are also damaged.
Rev . E Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 30 Excessive Wheel Motor Case Drain Flow Cause Correction Excessive internal wear in wheel motor . Disassemble motor completely . Inspect parts and replace as necessary . Case drain flow should not exceed 2 gal/m (7.
Hydraulic System Rev . E Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 31 Front (Rear) Reels Will Not T urn (Continued) Cause Correction Relief valve R1 (R2) by-passing oil. TEST NO. 3. Adjust relief valve R1 (R2) if necessary . Do cartridge valve service procedure for valve R1 (R2).
Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 32 Front (Rear) Reels Do Not T urn or T urn T oo Slow (Continued) Cause Correction Gear pump section P1 (P2) inefficient. TEST NO. 5. Repair or replace pump. Reel motor internal leakage (by-passing oil) or malfunctioning cross-over relief valve in motor .
Hydraulic System Rev . E Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 33 Front (Rear) Reels Stop Under Load Cause Correction Relief valve R1 (R2) by-passing oil. TEST NO. 3. Adjust relief valve R1 (R2) if necessary . Do cartridge valve service procedure for valve R1 (R2).
Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 34 Cutting Units Will Not Raise (Continued) Cause Correction Engine high idle RPM too low . See Chapter 3 - Kubota Diesel Engine. See Kubota Workshop Manual. Relief valve R3 by-passing oil. TEST NO. 4.
Hydraulic System Rev . E Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 35 Cutting Units Will Not Lower Cause Correction Solenoid V alve SV1 not shifting. Do electrical diagnostics to make sure that voltage is being applied to SV1 and that there is no electrical fault.
Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 36 T esting The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks (See the Special T ools section in this Chapter .
Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 37 TEST NO. 1: T raction Circuit Charge Pressure 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. 2. Make sure machine is parked on a level surface with the cutting units lowered and of f.
Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 38 TEST NO. 2: T raction Circuit Pressure 1. Make sure hydraulic oil is at normal operating temper- ature before doing test. 2. Drive machine to an open area, lower cutting units, and shut off the engine.
Hydraulic System Rev . B Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 39 TEST NO. 3: Cutting Unit Drive Circuit Pressure Note: The front cutting unit drive circuit is protected by relief valve R1 and the rear circuit by relief valve R2. See Hydraulic Flow Diagrams at the beginning of this chap- ter .
Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 40 TEST NO. 4: Gear Pump Section P3 Flow and Relief V alve Pressure (Using T ester with Pressure Gauges and Flow Meter) 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes.
Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 41 TEST NO. 5: Gear Pump Section P1 & P2 Flow (Using T ester with Pressure and Flow Capabilities) Over a period of time, the gears and wear plates in the pump can wear . A worn pump will by-pass oil and make the pump less efficient.
Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 42 TEST NO. 6: Reel Drive Motor Cross-Over Relief Pressure Use a tee fitting to install pressure gauge in inlet line of motor being tested.
Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 43 2. Determine which reel motor is malfunctioning. Note: The reel motors are connected in series. T o iso- late a faulty motor , you may have to test all three motors in the circuit by starting with the upstream motor first.
Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 44 TEST NO. 7: Reel Drive Motor Efficiency (Using T ester with Pressure Gauges and Flow Meter) High Pressure Low Pressure Flow Outlet hose Case drain hose Case Drain Install tester in series between fitting and hose at motor outlet.
Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 45 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Make sure machine is parked on a level surface with the cutting units lowered and off.
Rev . C Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 46 Adjustments Adjust Manifold Relief V alve (R1 and R2) The hydraulic reel circuit is equipped with a relief valve. V alve (R1) is preset at the factory to 3000 PSI. V alve (R2) on Reelmaster 6500 - - D is set to 2000 PSI.
Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 47 Adjust T raction Drive for Neutral The machine must not creep when traction pedal is re- leased. If it does creep, an adjustment is required. 1. Park machine on a level surface, shut engine off and lower cutting units to the floor .
Rev . F Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 48 Adjust Cutting Unit Drop Rates (Serial Numbers Below 280000000) The cutting unit lift/lower circuit is equipped with adjust- able flow control valves to ensure the cutting units do not drop too quickly and damage the turf.
Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 49 Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components 1.
Rev . F Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 50 Check Hydraulic Lines and Hoses W ARNING Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not hands, to search for leaks.
Hydraulic System Rev . F Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 51 Charge Hydraulic System Note: When initially starting the hydraulic system with new or rebuilt components such as motors, pumps, or lift cylinders, it is important that the hydraulic system be charged properly .
Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 52 Change Hydraulic Fluid Change hydraulic fluid after every 800 operating hours, in normal conditions. If fluid becomes contaminated, contact your local T ORO distributor because the system must be flushed.
Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 53 Replace Hydraulic Oil Filter The hydraulic system filter head is equipped with a ser- vice indicator . With the engine running, view the indica- tor , it should be in the GREEN zone.
Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 54 Piston Pump (T raction Pump) 31 32 33 34 35 36 37 38 40 41 42 43 44 45 1 2 3 4 5 6 7 8 9 10 16 17 19 20 21 22 23 24 25 26 27 28 29 30 11 12 13 14 15 23 23 10 44 5 3 15 47 38 48 41 17 Figure 28 1. Nut 2.
Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 55 Disassembly (Fig. 28) 1. Position the pump into a protected jaw vise, clamping onto the outer portion of the flange, with the cap screws up. Mark the relationship of the working ports (for reas- sembly identification) to the servo control assembly with a scribe.
Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 56 Camplate Inspection: ¯ The finish on the piston shoe surfaces of the camplate should show no signs of scoring. ¯ Inspect camplate bushing (23) surface for wear and surface for coating transfer from bushing.
Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 57 7. Install new cover plate gasket (10) and cover plate (9) to left side of housing and retain with four washers and cap screws (5 & 44). T ighten cap screws to 40 to 48 in- lbs.
Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 58 Servo Control 1 23 4 5 4 6 7 8 9 16 17 18 19 20 21 22 23 24 10 12 13 14 15 11 Figure 33 1. Plug 2. O-ring 3. Retaining Ring 4. Spring Retainer 5. Spring 6. Spool V alve 7. Control Housing 8. Input Shaft 9.
Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 59 5. Apply Loctite #242 or equivalent to set screw (18) and install. Adjust set screw until it bottoms out on input shaft then back out one-quarter turn. 6. Install wiper seal (10) on input shaft.
Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 60 Gear Pump 1 2 3 4 5 6 7 8 9 10 16 17 18 19 20 21 22 23 24 25 27 26 28 29 11 12 13 14 15 30 Figure 35 1. O-ring 2. Front Body 3. Drive Gear Assembly 4. Wearplate 5. Balance Pressure Seal 6. Backup Gasket 7.
Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 61 Repair Information Work in a clean area, cleanliness is extremely important when repairing hydraulic pumps. Before disconnecting the lines, clean port area of pump. Disconnect hydraulic lines, removing pump assembly from vehicle and plug ports.
Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 62 Front Plate, Backplate and Adapter Plates Inspection 1. Oil groove in bushings in front plate, backplate and adapter plates should be in line with dowel pin holes and 180 degrees apart. This positions the oil grooves closest to respective dowel pin holes.
Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 63 This page is intentionally blank..
Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 64 Wheel Motor 1 2 3 4 5 6 7 8 9 10 16 17 18 19 11 12 13 14 15 4 5 Figure 36 1. Retaining Ring 2. Shaft Seal 3. W asher 4. Retaining Ring 5. Thrust Race 6. Thrust Bearing 7. Splined Drive Shaft 8. Screw 9.
Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 65 2. Inspect valve plate (15) on the bronze side next to the piston block for wear . A smooth surface is required. Do not lap valve plate bronze surface. Replace valve plate if any wear exists.
Rev . E Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 66 4WD Rear Axle Motor 1 2 3 4 5 6 7 8 9 10 16 17 11 12 13 14 15 4 5 Figure 38 1. Retaining Ring 2. Spacer 3. Shaft 4. Retaining Ring 5. Thrust Race 6. Thrust Bearing 7. Screw 8. Backplate Assembly 9.
Hydraulic System Rev . E Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 67 Inspection 1. Check the condition of the needle bearing (12) in backplate (8) and replace if necessary . 2. Inspect valve plate (13) on the bronze side next to the piston block for wear .
Rev . E Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 68 Reel Motor (Barnes) 1 2 3 4 5 6 7 8 Use seal protector tool TOR4072 when inserting shaft through seal. NOTE: Seal protector tool is part of TOR4070 Cutting Unit T ool Kit shown in Chapter 7 - Cutting Units.
Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 69 Adjusting V alve (Cross-over Relief V alve) Service Note: The adjusting valve (#8 Fig. 40) must be re- placed as a complete assembly . Disassemble parts for cleaning and inspection only .
Rev . E Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 70 Assembly (Fig. 40) 1. Put flange on a flat surface with shaft seal facing down. Make sure back side of flange is free of contami- nation. 2. Put front bearing block, seal side down, on flange.
Hydraulic System Rev . E Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 71 Disassembly (Fig. 42) 1. Plug motor ports and clean the outside of the motor thoroughly .
Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 72 Hydraulic Control Manifolds 1. Straight Hydraulic Fitting 2. O-ring 3. O-ring 4. Hydraulic T ube 5. 90 _ Hydraulic Fitting 6. O-ring 7. O-ring 8. Control Manifold 9. Flat W asher 10. Safety Switch 1 1.
Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 73 1 3 4 6 9 10 31 21 24 11 12 13 22 27 5 8 31 27 36 35 31 14 29 30 31 29 30 18 23 25 26 29 37 28 19 20 40 30 4 7 26 31 29 30 31 15 17 16 15 16 17 38 15 16 17 39 41 18 19 20 9 10 23 19 18 20 2 1.
Rev . E Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 74 Hydraulic Control Manifold Service 1. Logic Cartridge 2. Seal Kit 3. Rotary Cartridge V alve (flow control) 4. Relief Cartridge V alve (3000 psi) 5. Seal Kit 6. Relief Cartridge V alve (2000 psi) 7.
Rev . F Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 75 1. Reel Manifold 2. Rotary Cartridge V alve (FC1 & FC2) 3. Rotary Handle 4. Solenoid Relief V alve (SV1 & SV2) 5. Solenoid 6. Nut 7. Plug (Zero Leak #8) 8. Spring Pin (4 Used) 9.
Rev . F Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 76 1. Plug (unit serial no. 210000001 - 219999999) 2. Cartridge V alve (4 way) 3. Seal Kit 4. Cartridge V alve (N.O.) 5. Seal Kit 6. Cartridge V alve (N.C.) 7. Solenoid (28 watt) 8. Solenoid Seal 9.
Rev . F 76.1 Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 1. Lift manifold block 2. Nut 3. NWD - - 6 plug 4. Solenoid blocking valve (4 used) 5. Solenoid valve (S3) 6. Solenoid valve (S1) 7. Solenoid valve (S2) 8. Flow control valve (2 used) 9.
Rev . F 76.2 Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 1. Solenoid valve (S3) 2. Solenoid coil (8 used) 3. Solenoid coil 4. Solenoid valve (S2) 5. Solenoid blocking valve (6 used) 6. Flow control valve (5 used) 7. Flow control valve (2 used) 8.
Hydraulic System Rev . E Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 77 Solenoid Operated, Relief and Logic Cartridge V alves 1. Make sure the manifold is clean before removing the cartridge valve and seal kit. Note: Solenoid valves used in mow manifold (Fig.
Rev . E Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 78 3. Make sure manifold is clean before removing the cartridge valve. Remove the valve and seal kit. 4. Visually inspect the manifold port and cartridge valve for damage to sealing surfaces, damaged threads, and contamination.
Hydraulic System Rev . E Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 79 8. Install rotary handle (reel manifold shown in Fig. 46) (Fig. 48): A. Place handle base on flow control v alve and posi- tion alignment mark on base with number 1 on man- ifold.
Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 80 Lift Cylinders Removal and Installation 1. Read the G eneral Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of this chapter .
Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 81 Rear (6700-D #6 or 7 Only) A. Remove both lock nuts and upper link plate. Re- move upper link and rollers from the lift arm and cylin- der clevis (Fig. 52). B. Remove retaining ring from the cylinder cap end pin.
Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 82 Lift Cylinder Service 1. Barrel with Clevis 2. Nut 3. Uni-ring 4. Piston 5. O-ring 6. Rod Seal 7.
Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 83 Disassembly (Fig. 53) 1. Remove oil from lift cylinder into a drain pan by slowly pumping the cylinder shaft. Plug both ports and clean the outside of the cylinder . IMPORT ANT : Prevent damage when clamping the cylinder ’ s barrel into a vise; clamp on the clevis only .
Rev . E Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 84 Steering Cylinder (2WD) 1. Barrel with Clevis 2. Piston Rod 3. Piston 4. Gland 5. Nut 6. Retaining Ring 7.
Hydraulic System Rev . E Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 85 Disassembly (Fig. 54) IMPORT ANT : Prevent damage when clamping the cylinder ’ s barrel into a vise; clamp on the clevis only . Do not close vise enough to distort the barrel.
Rev . D Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 86 Steering Cylinder (4WD) 1 2 3 4 5 6 7 8 9 10 11 1. Barrel with Clevis 2. PTFE Seal 3. O-ring 4.
Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 87 Disassembly (Fig. 55) IMPORT ANT : Prevent damage when clamping the cylinder ’ s barrel into a vise; clamp on the clevis only . Do not close vise enough to distort the barrel. 1.
Rev . E Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 88 Power Steering The Reelmaster R 6500-D/6700 is equipped with power steering. The power steering valve is enclosed in the steering tower at the front of the traction unit.
Hydraulic System Rev . E Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 89 Steering V alve Removal (Figs. 57 and 58) 1. Engage the parking brakes, lower the cutting units to the ground, turn the engine OFF and remove the key from the ignition switch.
Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 90 Steering V alve Service Figure 59 Disassembly Note: Cleanliness is extremely important when repairing steering control units. Work in a clean area. Before disconnecting the hydraulic lines, clean the port area of the steering control unit.
Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 91 Figure 60 Assembly Check all mating surfaces. Replace any parts with scratches or burrs that could cause leakage. Wash all metal parts in clean solvent. Blow them dry with pressur- ized air .
Rev . E Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 92 3. Install the centering springs in the spool (Fig. 61). It is best to install the two flat pieces first. Next, install the curved pieces, three at a time. 4. Fit the retaining ring over the centering springs.
Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 93 Solenoid V alve SV10 and SV1 1 Service (RM 6700 -D Only) Removal Note: Solenoid valves SV10 and SV1 1 provide oil flow to the reel motors of cutting units #6 & 7 (see Hydraulic Schematics and Flow Diagrams in this section of this manual).
Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 94 Hydraulic Reservoir 1. Hydraulic Reservoir 2. Gasket 3. T ank Cover 4. Breather Adapter 5. T ank Breather 6. Capscrew 7. Reservoir Cap 8. O-ring 9. Dipstick 10. Filler Screen 11 . O - r i n g 12. Hydraulic T ube 13.
Hydraulic System Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 95 Removal (Fig. 65) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. Note: The electrical harness does not have to be dis- connected to remove the right fender and control con- sole from the frame.
Reelmaster 6500-D/6700-D Hydraulic System Page 4 - 96 Hydraulic Oil Cooler Removal (Fig. 66) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. CAUTION The radiator and oil cooler may be hot.
Electrical System Reelmaster 6500-D/6700-D Page 5 - 1 Electrical System (Rev . C) Chapter 5 Electrical System T able of Contents ELECTRICAL SCHEMA TICS, ELECTRICAL HARNESS, and CONNECTOR DRA WINGS See Chapter 8 ....... SPECIAL TOOLS 2 ................
Rev . E Reelmaster 6500-D/6700-D Page 5 - 2 Electrical System (Rev . C) Special T ools Order special tools from your T oro Distributor . Some tools may be listed in the Parts Catalog for the Reelmas- ter 6500-D or 6700-D. Some tools may also be available from a local supplier .
Electrical System Reelmaster 6500-D/6700-D Page 5 - 3 Electrical System (Rev . C) T oro Automated Control Electronics t Diagnostic T ools Diagnostic ACE t Display The diagnostic display is connected to the wiring harness connector located inside the control console to help the user verfiy correct electrical functions of the ma- chine (Fig.
Rev . E Reelmaster 6500-D/6700-D Page 5 - 4 Electrical System (Rev . C) T roubleshooting CAUTION Remove all jewelry , especially rings and watches, before doing any electrical trouble- shooting or testing. Disconnect the battery cables unless the test requires battery voltage.
Electrical System Reelmaster 6500-D/6700-D Page 5 - 5 Electrical System (Rev . C) Fault Identification/Operator W arning: S Alerts operator to several potential problems with audible “beeps” and/or by cutting unit s hut down.
Reelmaster 6500-D/6700-D Page 5 - 6 Electrical System (Rev . C) Using the ACE t Diagnostic Display The primary electronic controller controls most machine functions. The controller determines what function is re- quired for various input switches (i.e.
Electrical System Reelmaster 6500-D/6700-D Page 5 - 7 Electrical System (Rev . C) A. The “inputs displayed ” LED, on lower right column of the Diagnostic ACE, should be illuminated. If “outputs displayed ” LED is illuminated, press the toggle button on Diagnostic ACE to change to “inputs displayed ”L E D .
Reelmaster 6500-D/6700-D Page 5 - 8 Electrical System (Rev . C) IMPORT ANT : The display will show eight (8) individ- ual records with the fault displayed on the 8th re- cord. Each record will be displayed for 10 seconds. Be sure to have the Diagnostic T ool display on Out- puts to see fault.
Electrical System Reelmaster 6500-D/6700-D Page 5 - 9 Electrical System (Rev . C) Note: See Leak Detector T roubleshooting Guide in this section of this manual for additional information. 1. Park machine on a level surface and engage the parking brake.
Reelmaster 6500-D/6700-D Page 5 - 10 Electrical System (Rev . C) Note: If machine must be operable with leak detector disabled, unplug leak detector 4 - - pin connector from 4 - - pin connector of main harness. Do not unplug leak detector alarm. If false alarms are observed : 1.
Electrical System Reelmaster 6500-D/6700-D Page 5 - 1 1 Electrical System (Rev . C) 1. Overlay decal (English shown) 2. “Inputs Displayed” LED (Red) 3. “Outputs Displayed” LED (Green) 4. T oggle button 1 Diagnostic ACE Display Functions Figure 13 3 2 4 3 2 1 7 1.
Reelmaster 6500-D/6700-D Page 5 - 12 Electrical System (Rev . C) Leak Detector T roubleshooting G uide The following is a quick guide to the most common problems likely to be encountered.
Electrical System Reelmaster 6500-D/6700-D Page 5 - 13 Electrical System (Rev . C) Starting Problems Problem Possible Causes All electrical power is dead, including gauges. The battery charge is low . The ignition switch or circuit wiring is faulty . The fusible link from the battery is faulty .
Reelmaster 6500-D/6700-D Page 5 - 14 Electrical System (Rev . C) General Run and T ransport Problems Problem Possible Causes Engine continues to run, but should not, when the ignition switch is turned off. The engine run (ETR) solenoid is stuck open. Ignition switch or circuit wiring is faulty .
Electrical System Reelmaster 6500-D/6700-D Page 5 - 15 Electrical System (Rev . C) Cutting Unit Operating Problems Problem Possible Causes The cutting units remain engaged, but should not, with no operator in the seat. The seat sensor or circuit wiring is faulty .
Reelmaster 6500-D/6700-D Page 5 - 16 Electrical System (Rev . C) Cutting Unit Operating Problems (Continued) Problem Possible Causes None of the cutting units will raise. Raise switch on joystick or circuit wiring is faulty . Solenoid SV1 or circuit wiring is faulty .
Electrical System Reelmaster 6500-D/6700-D Page 5 - 17 Electrical System (Rev . C) Electrical System Quick Checks Battery T est (Open Circuit T est) This is a simple test used to determine the c ondition of the battery at rest. T ool required: Digital Multimeter - DC volts setting.
Reelmaster 6500-D/6700-D Page 5 - 18 Electrical System (Rev . C) Glow Plug System T est This is a fast, simple test that can help you determine a Glow Plug system’s integrity and operation. The test should be run anytime hard starting (cold) is encoun- tered on a diesel engine equipped with a Glow system.
Electrical System Reelmaster 6500-D/6700-D Page 5 - 19 Electrical System (Rev . C) Component T esting For accurate resistance and/or continuity checks, elec- trically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before doing a continuity check).
Reelmaster 6500-D/6700-D Page 5 - 20 Electrical System (Rev . C) Glow and Start Relays The glow relay and the start relay are mounted to the right side frame member below the operator ’s seat. Note: Prior to taking small resistance readings with a digital multi meter , short the test leads together .
Electrical System Reelmaster 6500-D/6700-D Page 5 - 21 Electrical System (Rev . C) Fuses The fuse blocks are located under the control panel and inside the control console. Identification, Function, and Wiring The fuses are held in two fuse blocks. Use Figure 20 to identify each individual fuse and its correct amperage.
Reelmaster 6500-D/6700-D Page 5 - 22 Electrical System (Rev . C) Hydraulic V alve Solenoids These solenoids can be tested using the “Output Checks” feature of the ACE Diagnostic tool. The solenoids can also be tested manually . Note: Prior to taking small resistance readings with a digital multimeter , short the test leads together .
Electrical System Reelmaster 6500-D/6700-D Page 5 - 23 Electrical System (Rev . C) High T emperature W arning and Shutdown Switch The high temperature warning and shut down switch is located on the right side of the water flange that is at- tached to the front of the engine cylinder head.
Reelmaster 6500-D/6700-D Page 5 - 24 Electrical System (Rev . C) W arning Light Cluster Note: Individual light bulbs can be tested by removing them from the lighting cluster and applying 14 VDC to their wiring terminals. T esting Cluster Removed from Connector .
Electrical System Reelmaster 6500-D/6700-D Page 5 - 25 Electrical System (Rev . C) Run (ETR) Solenoid (Solenoid With 3 Wire Connector) The solenoid must be energized for the engine to run.
Reelmaster 6500-D/6700-D Page 5 - 26 Electrical System (Rev . C) Run (ETR) Solenoid (Solenoid With 2 Wire Connector) The run (ETR) solenoid must be energized for the en- gine to run.
Electrical System Reelmaster 6500-D/6700-D Page 5 - 27 Electrical System (Rev . C) Fuel Gauge Sender The sender is located on top of the fuel tank under the right, front fender . 1. Remove blue/green wire and black ground wire from the sender . 2. Remove round head screws and lock washers from the sender and fuel tank.
Reelmaster 6500-D/6700-D Page 5 - 28 Electrical System (Rev . C) Fuel Gauge The fuel gauge can be tested using a new gauge as a substitute or by the use of a DC voltage source and a variable resistance box.
Electrical System Reelmaster 6500-D/6700-D Page 5 - 29 Electrical System (Rev . C) T emperature Sender The sender is located on the left side of the water flange that is attached to the front of the engine cylinder head. There is a blue/white wire attached to the terminal of the switch (Fig.
Rev . E Reelmaster 6500-D/6700-D Page 5 - 30 Electrical System (Rev . C) T emperature Gauge The temperature gauge can be tested using a new gauge as a substitute or by the use of a DC voltage source and a variable resistance box.
Electrical System Reelmaster 6500-D/6700-D Page 5 - 31 Electrical System (Rev . C) Hour Meter The meter is either located on the control panel or under the control panel inside the control console. 1. Connect the positive (+) terminal of a 12 VDC source to the positive terminal of the hour meter .
Reelmaster 6500-D/6700-D Page 5 - 32 Electrical System (Rev . C) Engine Low Oil Pressure Switch The switch is normally closed (NC) and opens with pres- sure. The switch opens at approximately 8 psi. 1. Turn ignition key switch ON. Oil pressure lamp should be on.
Electrical System Reelmaster 6500-D/6700-D Page 5 - 33 Electrical System (Rev . C) Speedometer The speedometer can be tested using a D C pulse gen- erator . CAUTION Make sure the voltage source is turned OFF be- fore connecting it to the electrical circuit to avoid electrical shock and prevent damaging the gauge.
Rev . E Reelmaster 6500-D/6700-D Page 5 - 34 Electrical System (Rev . C) Reel Backlap Switches The front and rear backlap switches are attached to the reel hydraulic manifold block (Fig. 45). When the back- lap control valve (MD1 or MD2) is in the Backlap posi- tion, the switch contacts close.
Electrical System Rev . E Reelmaster 6500-D/6700-D Page 5 - 35 Electrical System (Rev . C) Seat Sensor The sensor consists of two parts. The reed switch is lo- cated on the lower bracket of the seat suspension mech- anism and has a normally open contact.
Reelmaster 6500-D/6700-D Page 5 - 36 Electrical System (Rev . C) Cutting Unit Down Sensor(s) The cutting unit down switch is a normally open (NO) reed switch located on the left front lift arm that closes when the lift arm is in the lowered position.
Electrical System Rev . E Reelmaster 6500-D/6700-D Page 5 - 37 Electrical System (Rev . C) Service and Repairs NOTE: For more component repair information, see the Kubota Workshop Manual, Diesel Engine, 05 Series at the end of Chapter 3 - Kubota Diesel Engines.
Reelmaster 6500-D/6700-D Page 5 - 38 Electrical System (Rev . C) Battery Service The battery is the heart of the electrical system. W ith regular and proper service, battery life can be extend. Additionally , battery and electrical component failure can be prevented.
Electrical System Reelmaster 6500-D/6700-D Page 5 - 39 Electrical System (Rev . C) C. If the dif ference between the highest and lowest cell specific gravity is 0.050 or greater or the lowest cell specific gravity is less than 1.225, charge the bat- tery .
Reelmaster 6500-D/6700-D Page 5 - 40 Electrical System (Rev . C) Charging T o minimize possible damage to the battery and allow the battery to be fully charged, the slow charging meth- od is presented here. This charging method can be ac- complished with a constant current battery charger which is available in most shops.
Electrical System Rev . F Reelmaster 6500-D/6700-D Page 5 - 41 Electrical System (Rev . C) Speedometer Sensor Replacement 1. Thread locknut onto speed sensor to allow full expo- sure of sensor threads. 2. Center a motor piston with the center of the s ensor port (see Sensor Port View in Figure 52 below).
Reelmaster 6500-D/6700-D Page 5 - 42 Electrical System (Rev . C) Installing Optional Lighting (customer supplied) IMPORT ANT : If optional lighting is to be added to the traction unit, use the following schematic and part numbers to prevent damage to the traction unit’ s electrical system.
Axles. Planetaries and Brakes Reelmaster 6500-D/6700-D Page 6 - 1 Axles, Planetaries and Brakes (Rev . C) Chapter 6 Axles, Planetaries and Brakes T able of Contents SPECIFICA TIONS 2 ............................. MAINTENANCE 3 ........................
Reelmaster 6500-D/6700-D Page 6 - 2 Axles, Planetaries and Brakes (Rev . C) Specifications Item Specification Front wheel lug nut torque 85 to 100 ft-lbs. (1 15 to 136 Nm) Rear wheel lug nut torque 85 to 100 ft-lbs. (1 15 to 136 Nm) Steering cylinder bolt torque 100 to 125 ft-lbs.
Axles. Planetaries and Brakes Reelmaster 6500-D/6700-D Page 6 - 3 Axles, Planetaries and Brakes (Rev . C) Maintenance Changing Planetary Gear Drive Lubricant Planetary gear drive lubricant should be changed every 800 hours of operation.
Reelmaster 6500-D/6700-D Page 6 - 4 Axles, Planetaries and Brakes (Rev . C) Changing Rear Axle Lubricant Rear axle lubricant should be changed every 800 hours of operation. Rear axle lubricant should be SAE 85W-140 gear lube. 1. Position machine on a level surface.
Axles. Planetaries and Brakes Reelmaster 6500-D/6700-D Page 6 - 5 Axles, Planetaries and Brakes (Rev . C) Adjustments Service Brake Adjustment Adjust the service brakes when there is more than 1 inch of “free travel” of the brake pedal, or when the brakes do not work effectively .
Reelmaster 6500-D/6700-D Page 6 - 6 Axles, Planetaries and Brakes (Rev . C) Rear Wheel T oe-in Adjustment After every 800 operating hours or annually , check rear wheel toe-in. T o check toe-in, rotate the steering w heel so the rear wheels point straight ahead.
Axles. Planetaries and Brakes Rev . E Reelmaster 6500-D/6700-D Page 6 - 7 Axles, Planetaries and Brakes (Rev . C) Repairs Planetary Wheel Drive Service 1 2b 3 4 5 6 7 8 9 10 16 17 18 22 21 19 20 23 24 25 11 12 13 14 15 2d 2c 2a Figure 9 1. Spindle 2. Seal Kit 3.
Rev . E Reelmaster 6500-D/6700-D Page 6 - 8 Axles, Planetaries and Brakes (Rev . C) 8. Remove capscrews (25) and remove ring gear (18). 9. Remove retaining r ing (10) and thrust washer (9). 10. Use a puller to remove spindle (1) from housing (6). Remove bearing cone (8).
Axles. Planetaries and Brakes Rev . E Reelmaster 6500-D/6700-D Page 6 - 9 Axles, Planetaries and Brakes (Rev . C) Brake Service 1 2 5 6 9 4 8 7 10 75 to 85 ft-lbs 3 Figure 1 1 1. Capscrew 2. Wheel Motor 3. O-ring 4. Brake Cable 5. Flange Head Screw 6.
Reelmaster 6500-D/6700-D Page 6 - 10 Axles, Planetaries and Brakes (Rev . C) 1 2 3 4 5 6 7 8 9 10 11 12 13 Figure 12 1. Brake Housing - LH 2. Seal 3. Pull Rod 4. Clevis Pin 5. Link 6. Cotter Hair Pin 7. Stationary Disc 8. Rotating Disc 9. Retaining Ring 10.
Axles. Planetaries and Brakes Reelmaster 6500-D/6700-D Page 6 - 1 1 Axles, Planetaries and Brakes (Rev . C) Rear Axle Service (2WD) 1. Screw 2. Spindle Cap 3. Retaining Ring 4. Thrust W asher 5. Flange Bushing 6. Rear Axle Assembly 7. Spindle - RH 8. Axle Pivot Pin 9.
Reelmaster 6500-D/6700-D Page 6 - 12 Axles, Planetaries and Brakes (Rev . C) Axle Pivot Bushings The rear axle must be held in place snugly by the axle pin. Excessive movement of the axle, which is charac- terized by erratic steering, usually indicates worn bush- ings.
Axles. Planetaries and Brakes Reelmaster 6500-D/6700-D Page 6 - 13 Axles, Planetaries and Brakes (Rev . C) 12. Mount the axle to the frame with the axle pin. Install washer(s) and axle pivot pin. Secure the axle pivot pin in place with the thrust washer and jamnut.
Reelmaster 6500-D/6700-D Page 6 - 14 Axles, Planetaries and Brakes (Rev . C) Rear Axle Service (4WD) 1. Stop Pin 2. Axle Pivot Pin 3. Axle Assembly 4. Slotted Nut 5. Cotter Pin 6. W asher 7. Spacer 8. Dust Seal 9. Ball Joint 10. Hydraulic Cylinder 1 1.
Axles. Planetaries and Brakes Rev . E Reelmaster 6500-D/6700-D Page 6 - 15 Axles, Planetaries and Brakes (Rev . C) Removal (Fig. 15) 1. Engage the parking brakes, lower the cutting units to the ground, turn the engine OFF and remove the key from the ignition switch.
Reelmaster 6500-D/6700-D Page 6 - 16 Axles, Planetaries and Brakes (Rev . C) Bevel Gear Case and Axle Case The following procedures assume the rear axle assem- bly has been removed from the machine. Removal 1. Remove the mounting screws, nuts, and lock wash- ers.
Axles. Planetaries and Brakes Reelmaster 6500-D/6700-D Page 6 - 17 Axles, Planetaries and Brakes (Rev . C) 5. Remove the knuckle pin mounting screws and the knuckle pin. Remove the gasket and any remaining gas- ket material from either mating surface (Fig.
Reelmaster 6500-D/6700-D Page 6 - 18 Axles, Planetaries and Brakes (Rev . C) Installation 1. Coat new shaft seal with grease and install in axle case as shown (Fig. 22). 1. Axle case 2. Bevel gear case 3. Shaft seal Figure 22 1 2 3 2. Install the lower bevel gear , and bevel gear shaft in the axle case cover .
Reelmaster 6500-D/6700-D Page 6 - 19 Axles, Planetaries and Brakes (Rev . C) 5. Determine necessary quantity of support shims. A. Lubricate the axle case support bushing with a thin coat of grease and slide axle case support onto knuckle pin. B. Position support shims that were removed during disassembly between axle case support and axle case.
Reelmaster 6500-D/6700-D Page 6 - 20 Axles, Planetaries and Brakes (Rev . C) 9. Remove the bevel gear case/axle case assembly from the axle support. Coat a new O-ring with grease and temporarily install the axle cover assembly . Position a dial indicator at the tooths center .
Axles. Planetaries and Brakes Reelmaster 6500-D/6700-D Page 6 - 21 Axles, Planetaries and Brakes (Rev . C) Axle Shafts The following procedures assume the rear axle assem- bly has been removed from the machine. Removal 1. Remove the axle c over mounting screws.
Reelmaster 6500-D/6700-D Page 6 - 22 Axles, Planetaries and Brakes (Rev . C) Input Shaft/Pinion Gear Figure 32 1 1. Nut 2. Lockwasher 3. Stud 4. Locknut 5. Stake washer 6. Oil Seal 7. O-ring 8. Seal Collar 9. Inner Bearing 10. O-ring 1 1. Outer Bearing 12.
Axles. Planetaries and Brakes Reelmaster 6500-D/6700-D Page 6 - 23 Axles, Planetaries and Brakes (Rev . C) 5. Set the bearing preload by securing the bearing case in a vise. Thread a M12 x 1.5 hex. hd. capscrew into the splined end of the input shaft/pinion gear and slowly tighten the locknut until 4.
Reelmaster 6500-D/6700-D Page 6 - 24 Axles, Planetaries and Brakes (Rev . C) Differential Gear The following procedures assume the rear axle assem- bly has been removed from the machine. Removal 1. Remove bevel gear case/axle c ase assemblies (see Bevel Gear Case/Axle Case Assembly in this section of this manual).
Axles. Planetaries and Brakes Reelmaster 6500-D/6700-D Page 6 - 25 Axles, Planetaries and Brakes (Rev . C) Inspection 1. Measure the dif ferential side gear O.D. and the dif- ferential case I.D. to determine the side gear to case clearance (Fig. 39). Replace components as necessary .
Rev . E Reelmaster 6500-D/6700-D Page 6 - 26 Axles, Planetaries and Brakes (Rev . C) Installation 1. If the ring gear was removed from the differential case, use medium strength Loctite thread locker and tighten the mounting screws from 22 to 25 ft-lb (30 to 34 N - - m).
Axles. Planetaries and Brakes Rev . E Reelmaster 6500-D/6700-D Page 6 - 27 Axles, Planetaries and Brakes (Rev . C) Pinion Gear to Ring Gear Engagement The final position of the pinion gear is verified by using the gear contact pattern method as described in the fol- lowing procedure.
Rev . E Reelmaster 6500-D/6700-D Page 6 - 28 Axles, Planetaries and Brakes (Rev . C) Gear Pattern Movement Summary Every gear has a characteristic pattern. The illustrations show typical patterns only and explain how patterns shift as gear location is changed.
Cutting Units Reelmaster 6500-D/6700-D Page 7 - 1 Cutting Units Chapter 7 Cutting Units T able of Contents SPECIFICA TIONS 2 ............................. SPECIAL TOOLS 3 ............................. TROUBLESHOOTING 5 ......................... SET -UP AND ADJUSTMENTS 7 .
Reelmaster 6500-D/6700-D Page 7 - 2 Cutting Units Specifications Figure 1 REEL CONSTRUCTION: Fairway reels. All welded. 5, 7 or 1 1 blades. HEIGHT OF CUT RANGE: 5B l a d e -1 ”t o1 - 3 / 4 ”( 2 5 - 4 4m m ) 7B l a d e -1 / 2 ”t o1 ”( 1 3 - 2 5m m ) 11 B l a d e -3 / 8 ”t o3 / 4 ”( 1 0 - 1 9m m ) Note: Use bedknife Part No.
Cutting Units Rev . E Reelmaster 6500-D/6700-D Page 7 - 3 Cutting Units Special T ools Order special tools from your T oro distributor . Some tools may have been supplied with your machine or available as TORO parts. Some t ools may also be avail- able from a local supplier .
Reelmaster 6500-D/6700-D Page 7 - 4 Cutting Units Bedknife Screw T ool - TOR510880 This screwdriver-type bit is made to fit T oro bedknife at- taching screws. Use this bit with a torque wrench to se- cure the bedknife to the bedbar . Make sure bedbar threads are clean and use new screws.
Cutting Units Reelmaster 6500-D/6700-D Page 7 - 5 Cutting Units T roubleshooting There are a number of factors that can contribute to un- satisfactory quality of cut, some of w hich may be turf conditions.
Reelmaster 6500-D/6700-D Page 7 - 6 Cutting Units Factor Possible Problem/Correction 5. Bedknife to reel adjustment. Check bedknife to reel contact daily . Bedknife must have light contact all across reel. No contact will cause cutting edges to become dull.
Cutting Units Reelmaster 6500-D/6700-D Page 7 - 7 Cutting Units Set -up and Adjustments IMPORT ANT : T oro strongly recommends the use of a leveling plate when setting-up or adjusting any reel type cutting unit. The leveling plate will help to ensure accu- rate and consistent adjustments.
Reelmaster 6500-D/6700-D Page 7 - 8 Cutting Units Bedknife to Reel Adjustment IMPORT ANT : The reel and bedknife must be parallel to insure the cutting unit cuts grass across the bedknife, and the reel and bedknife wear evenly . Note: T oro recommends light contact between the reel and bedknife.
Cutting Units Reelmaster 6500-D/6700-D Page 7 - 9 Cutting Units C. Recheck reel to bedknife contact on both ends of the bedknife. If necessary , repeat step B. Note: Reel to bedknife contact may become too tight or too loose after previous adjustment; therefore, turn bedknife adjustment knob, accordingly , for light contact.
Reelmaster 6500-D/6700-D Page 7 - 10 Cutting Units Checking or Adjusting Attitude (Used Cutting Units) As a starting point for adjusting cutting unit attitude, the cutting unit may be set up using the dimensions from the New Cutting Unit Set Up Guide found in the C utting Unit Operator ’s Manual.
Cutting Units Reelmaster 6500-D/6700-D Page 7 - 1 1 Cutting Units Leveling Front Roller IMPORT ANT : T oro strongly recommends the use of a leveling plate when setting - - up or adjusting any reel type cutting unit. The leveling plate will help to ensure accurate and consistent adjustments.
Rev . E Reelmaster 6500-D/6700-D Page 7 - 12 Cutting Units Final Height of Cut Adjustment 1. Rotate the cutting unit vertical and place the gauge bar across front and rear rollers (Fig. 18). 2. Adjust rear roller until it contacts the gauge bar on both sides.
Cutting Units Reelmaster 6500-D/6700-D Page 7 - 13 Cutting Units Rear Shield Adjustment Under most conditions, best dispersion is attained when rear shield is closed (front discharge).
Rev . E Reelmaster 6500-D/6700-D Page 7 - 14 Cutting Units Daily Adjustments Prior to each day’s mowing, or as required, each cutting unit must be checked to verify proper bedknife - - to - - reel contact. This must be performed even though quali - ty of cut is acceptable.
Cutting Units Rev . E Reelmaster 6500-D/6700-D Page 7 - 15 Cutting Units TO A VOID PERSONAL INJUR Y , NEVER PLACE HANDS OR FEET IN REEL AREA WHILE ENGINE IS RUNNING. CHANGING ENGINE SPEED WHILE BACKLAPPING MA Y CAUSE REELS TO ST ALL. NEVER CHANGE ENGINE SPEED WHILE BACKLAPPING.
Reelmaster 6500-D/6700-D Page 7 - 16 Cutting Units Bedbar Removal and Installation 24 25 1 28 29 30 31 32 123 4 5 67 8 9 14 15 16 17 18 20 21 23 22 12 13 1 4 15 32 31 33 34 35 36 37 38 39 10 10 11 19 26 27 27 1. Screw 2. W asher 3. Quad Ring 4. Locknut 5.
Cutting Units Reelmaster 6500-D/6700-D Page 7 - 17 Cutting Units Removal 6. Loosen bedknife adjusting knob to loosen bedknife to reel contact. 7. Loosen locknut on bedknife adjuster assembly and disengaging adjuster from bedbar (Fig. 25). 8. Remove bedbar leveling screw from L.
Rev . E Reelmaster 6500-D/6700-D Page 7 - 18 Cutting Units Bedknife Replacement and Regrinding 1. Remove bedbar from cutting unit. 2. Use bedknife screw tool TOR510880 to remove bed- knife screws. Remove bedknife (Fig. 27). 3. Remove all rust, scale and corrosion from bedbar sur- face before installing new bedknife.
Cutting Units Reelmaster 6500-D/6700-D Page 7 - 19 Cutting Units Preparing Reel for Regrinding 1. Check to make sure r eel bearings are in good condi- tion and properly adjusted before regrinding the reel. Make sure the cutting unit frame and roller brackets are true and not bent or damaged from impacts with trees, posts or cart path edges.
Rev . E Reelmaster 6500-D/6700-D Page 7 - 20 Cutting Units Reel and Reel Bearings 1 2 3 4 4 6 3 5 8 7 12 11 9 10 18 15 16 14 15 17 17 19 Use tool TOR4064 Pack bearings with No. 2 general purpose grease Apply anti - - seiz e lubricant to internal Use tool TOR4074 to install threaded spline insert.
Cutting Units Rev . E Reelmaster 6500-D/6700-D Page 7 - 21 Cutting Units Reel Bearing Adjustment T o insure long life of the reel bearings, periodically check if reel end play exists. The reel bearings can be checked and adjusted as follows: Note: Bearing and bearing housing were preset at factory as indicated with a paint mark.
Rev . E Reelmaster 6500-D/6700-D Page 7 - 22 Cutting Units Reel Removal 1. Remove weight from cutting unit. 2. Remove bedbar assembly . 3. Remove front roller assembly . 4. Loosen set screw and remove bearing adjustment nut from L.H. bearing housing. 5.
Cutting Units Reelmaster 6500-D/6700-D Page 7 - 23 Cutting Units Roller and Frame Service 13 - - 17 ft - - lb 13 - - 17 ft - - lb 13 - - 17 ft - - lb 75 - - 85 ft - - lb (1.
Reelmaster 6500-D/6700-D Page 7 - 24 Cutting Units Roller Bearing and Seal Replacement 3 8 6 5 2 7 9 Sharp edge out Lip of seal facing in 2 3 567 8 9 4 1 4 1 1. Roller 2. Inner Oil Seal 3. Bearing 4. Roller Shaft 5. Inner Seal 6. Outer Seal 7. Retaining Ring 8.
Cutting Units Reelmaster 6500-D/6700-D Page 7 - 25 Cutting Units Cutting Unit Installation Cutting unit models 03860, 03861, and 03862 can be installed at any of the mounting locations on the traction unit. Figure 1 shows the orientation of the hydraulic drive motor for each of the five locations.
Reelmaster 6500-D/6700-D Page 7 - 26 Cutting Units 12. Insert steering pin into the pivot knuckle if you wish to keep cutting units locked in a straight line during op- eration. If no steering pin is used, the cutting units will steer themselves as the traction unit turns (Fig.
Cutting Units Rev . E Reelmaster 6500-D/6700-D Page 7 - 27 Cutting Units Lubrication Each cutting unit has seven grease fittings that must be lubricated regularly with No.
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Groomer Reelmaster 6500 - - D/6700 - - D Groomer (Rev . C) Page 7.1 - - 1 Chapter 7.1 Groomer T able of Contents TROUBLESHOOTING 2 ......................... Factors Affecting Grooming 2 ................... Groomer Reel Mechanical Problems 3 ..........
Reelmaster 6500 - - D/6700 - - D Groomer (Rev . C) Page 7.1 - - 2 T roubleshooting Factors Affecting Grooming There are a number of factors that can affect the perfor- mance of grooming. These factors vary for different golf courses and from fairway to fairway .
Groomer Reelmaster 6500 - - D/6700 - - D Groomer (Rev . C) Page 7.1 - - 3 Groomer Reel Mechanical Problems Problem Possible Causes Correction No rotation of the groomer reel. Seized groomer reel or idler bear- ing(s) in groomer side plate(s). Broken or damaged idler spring.
Reelmaster 6500 - - D/6700 - - D Groomer (Rev . C) Page 7.1 - - 4 Adjustments CAUTION Never work on the groomer with the engine running. Always stop the engine and remove the key from the ignition switch before working on the groomer . Groomer Height/Depth Adjustment Note: Grooming is performed above the soil level.
Groomer Reelmaster 6500 - - D/6700 - - D Groomer (Rev . C) Page 7.1 - - 5 Service and Repairs Groomer Belt Replacement The groomer drive belt should be inspected/replaced annually or after 750 hours of operation.
Reelmaster 6500 - - D/6700 - - D Groomer (Rev . C) Page 7.1 - - 6 Groomer Reel Figure 4 1. Groomer reel assembly 2. Square key 3. Cap screw 4. Flat washer 5. Groomer plate 6. Retaining plate 7. Idler arm spacer 8. T orsion spring 9. Idler assembly 10.
Groomer Reelmaster 6500 - - D/6700 - - D Groomer (Rev . C) Page 7.1 - - 7 5. Slide pulley spacer (item 19) from shaft. 6. Remove two ( 2) cap screws (item 26) that secure height of cut assembly (non - - drive side) to the cutting unit side plates (Fig.
Reelmaster 6500 - - D/6700 - - D Groomer (Rev . C) Page 7.1 - - 8 Groomer Reel Service Inspect groomer reel blades frequently for damage and wear . Straighten bent blades with a pliers. Either replace worn blades or reverse the blades to put the sharpest blade edge forward (Fig.
Groomer Reelmaster 6500 - - D/6700 - - D Groomer (Rev . C) Page 7.1 - - 9 Idler Assembly The drive side plate assembly groomer kit incorporates the idler system for tensioning the groomer drive belt . A torsion spring is used to maintain proper belt tension.
Reelmaster 6500 - - D/6700 - - D Groomer (Rev . C) Page 7.1 - - 10 Groomer Drive Figure 12 1. Flange nut 2. Groomer belt cover 3. Groomer drive belt 4. Flange head screw (3 used) 5. Drive pulley 6. Idler assembly 7. T orsion spring 8. Idler arm spacer 9.
Groomer Reelmaster 6500 - - D/6700 - - D Groomer (Rev . C) Page 7.1 - - 1 1 7. Remove two ( 2) flange head screws (item 20) that secure drive housing to cutting unit side plate. 8. Slide drive housing assembly from cutting unit. Lo- cate and retrieve o - - ring ( item 25).
Reelmaster 6500 - - D/6700 - - D Groomer (Rev . C) Page 7.1 - - 12 Groomer Height of Cut Assembly Figure 15 1. Groomer reel assembly 2. Grease seal 3. Bearing 4. Height of Cut screw 5. W asher 6. Lock nut 7. Grease fitting 8. Bearing housing 9. Grease seal 10.
Groomer Reelmaster 6500 - - D/6700 - - D Groomer (Rev . C) Page 7.1 - - 13 Disassembly (Fig. 15) 1. Remove groomer height of cut assembly from cut- ting unit (see Groomer Reel Removal in this section). 2. Disassemble groomer height of cut assembly using Figure 15 as a guide.
Reelmaster 6500 - - D/6700 - - D Groomer (Rev . C) Page 7.1 - - 14.
Units DP A Cutting Rev . E Reelmaster 6500 - - D/6700 - - D DP A Cutting Units Page 7.2 - - 1 Chapter 7.2 DP A Cutting Units T able of Contents SPECIFICA TIONS 2 ............................. GENERAL INFORMA TION 3 ..................... Cutting Unit Operator ’s Manual 3 .
Rev . E Reelmaster 6500 - - D/6700 - - D DP A Cutting Units Page 7.2 - - 2 Specifications Figure 1 Frame Construction: Precision machined die cast alu- minum cross member with two (2) bolt - - on cast ductile iron side plates. Reel Construction: Reels are 22 inches (55.
Units DP A Cutting Rev . E Reelmaster 6500 - - D/6700 - - D DP A Cutting Units Page 7.2 - - 3 General Information Cutting Unit Operator ’s Manual The Cutting Unit Operator ’s Manual provides informa- tion regarding the operation, general maintenance and maintenance intervals for the DP A cutting units on your Reelmaster machine.
Rev . E Reelmaster 6500 - - D/6700 - - D DP A Cutting Units Page 7.2 - - 4 Special T ools Special tools for servicing T oro Commercial Products are available from your T oro Distributor . Some tools may have been supplied with y our machine or are available as TORO parts.
Units DP A Cutting Rev . E Reelmaster 6500 - - D/6700 - - D DP A Cutting Units Page 7.2 - - 5 Plastic Plug T oro Part Number: 94 - - 2703 This plug is used for placement into the side plate bear- ing housing when the hydraulic reel motor is removed. It prevents dirt and debris from entering the cutting reel bearing area.
Rev . E Reelmaster 6500 - - D/6700 - - D DP A Cutting Units Page 7.2 - - 6 Cutting Unit T ool Kit T oro Part Number: T OR4070 This tool kit includes special tools required for rebuilding the cutting unit and cutting unit drive motor on the Reelmaster 6500 - - D/6700 - - D series of machines.
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Rev . E Reelmaster 6500 - - D/6700 - - D DP A Cutting Units Page 7.2 - - 8 Factors That Can Affect Cutting Performance There are a number of factors that can contribute to un- satisfactory quality of cut, some of w hich may be turf conditions.
Rev . E Units DP A Cutting Reelmaster 6500 - - D/6700 - - D DP A Cutting Units Page 7.2 - - 9 Factor Possible Problem/Correction Reel and bedknife sharpness A reel and/or bedknife that has rounded cutting edges or “rifling” (grooved or wavy appearance) cannot be corrected by tightening the bedknife to reel contact.
Rev . E Reelmaster 6500 - - D/6700 - - D DP A Cutting Units Page 7.2 - - 10 Factor Possible Problem/Correction Roller condition and roller type Make sure rollers rotate freely . Repair roller bearings as necessary . See Roller Service in the Service and Repairs section of this chapter .
Units DP A Cutting Rev . E Reelmaster 6500 - - D/6700 - - D DP A Cutting Units Page 7.2 - - 1 1 Set Up and Adjustments Characteristics CAUTION Never install or work on the cutting units or lift arms with the engine running. Always stop en- gine and remove key first.
Rev . E Reelmaster 6500 - - D/6700 - - D DP A Cutting Units Page 7.2 - - 12 Reel Bearing Adjustment T o insure cut quality and long life of the cutting reel bear- ings, periodically check reel bearing adjustment.
Units DP A Cutting Rev . E Reelmaster 6500 - - D/6700 - - D DP A Cutting Units Page 7.2 - - 13 Leveling Rear Roller The precision machined components of the cutting unit frame keep the rear roller and cutting reel in alignment (parallel).
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Units DP A Cutting Rev . E Reelmaster 6500 - - D/6700 - - D DP A Cutting Units Page 7.2 - - 15 Service and Repairs Hydraulic Reel Motor IMPORT ANT : When performing maintenance pro- cedures on the cutting units, carefully position the cutting unit reel motors to prevent damage to the motors or hydraulic hoses.
Rev . E Reelmaster 6500 - - D/6700 - - D DP A Cutting Units Page 7.2 - - 16 Backlapping DANGER TO A VOID PERSONAL INJUR Y OR DEA TH: D Never place hands or feet in the reel area while the engine is running. D When backlapping, run engine at idle speed only .
Units DP A Cutting Rev . E Reelmaster 6500 - - D/6700 - - D DP A Cutting Units Page 7.2 - - 17 9. T o make an adjustment to the cutting units while backlapping, turn reels OFF by moving the Lower Mow/ Raise lever rearward; move the Enable/Disable switch to Disable and turn the engine OFF .
Rev . E Reelmaster 6500 - - D/6700 - - D DP A Cutting Units Page 7.2 - - 18 Bedbar Assembly 1. Bedbar 2. Bedknife 3. Screw (8 used) 4. Bedbar adjuster shaft (2 used) 5. Flange bushing (4 used) 6. Cap screw (2 used) 7. Detent (2 used) 8. W ave washer (2 used) 9.
Units DP A Cutting Rev . E Reelmaster 6500 - - D/6700 - - D DP A Cutting Units Page 7.2 - - 19 CAUTION Contact with the reel, bedknife or other cutting unit parts can result in personal injury . Use heavy gloves when handling the bedbar . 6. Remove bedbar assembly from cutting unit.
Rev . E Reelmaster 6500 - - D/6700 - - D DP A Cutting Units Page 7.2 - - 20 Bedbar Adjuster Service Figure 21 1. Bedbar assembly 2. Compression spring 3. Lock nut 4. Bedbar adjuster shaft 5. Flange bushing 6. Cap screw 7. Detent 8. W ave washer 9. Retaining ring 10.
Units DP A Cutting Rev . F Reelmaster 6500 - - D/6700 - - D DP A Cutting Units Page 7.2 - - 21 Bedknife Replacement and Grinding Bedknife Removal 1. Remove bedbar from cutting unit (see Bedbar Re- moval in this section). 2. Remove screws from bedbar using a socket wrench and bedknife screw tool (see Special T ools).
Rev . E Reelmaster 6500 - - D/6700 - - D DP A Cutting Units Page 7.2 - - 22 Reel Assembly Removal and Installation 1. Bedbar assembly 2. Rubber bushing (2 used) 3. Flange bushing (2 used) 4. Plastic washer (4 used) 5. Metal washer (2 used) 6. Bedbar pivot bolt (2 used) 7.
Units DP A Cutting Rev . E Reelmaster 6500 - - D/6700 - - D DP A Cutting Units Page 7.2 - - 23 Reel Assembly Removal (Fig. 25) 1. Position machine on a c lean and level surface, lower cutting units, stop engine, engage parking brake and re- move key from the ignition switch.
Rev . E Reelmaster 6500 - - D/6700 - - D DP A Cutting Units Page 7.2 - - 24 3. Carefully slide the cutting reel with bearings and grease seals into the RH side plate. Make sure that bearing is fully seated into side plate. 4. On LH side plate, loosen set screw (item 21) and back - - off (loosen) bearing adjuster nut (item 20) one complete turn.
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Rev . E Reelmaster 6500 - - D/6700 - - D DP A Cutting Units Page 7.2 - - 26 Reel Assembly Service 1. Cutting reel 2. Threaded insert (RH thread) 3. Retaining ring 4. Grease seal 5. Bearing 6. Threaded insert (LH thread) 7. Retaining ring groove 8. Groove indicating LH threads 9.
Rev . E Units DP A Cutting Reelmaster 6500 - - D/6700 - - D DP A Cutting Units Page 7.2 - - 27 Inspection of Cutting Reel (Fig. 27) 1. Inspect reel bearings to insure that they spin freely and have minimal axial play . The bearing balls must be free of deformation and scoring.
Rev . E Reelmaster 6500 - - D/6700 - - D DP A Cutting Units Page 7.2 - - 28 Preparing Reel for Grinding Note: Before grinding a cutting reel, make sure that all cutting unit components are in good condition. Depend- ing on type of grinder used, faulty cutting unit compo- nents can affect grinding results.
Rev . E Units DP A Cutting Reelmaster 6500 - - D/6700 - - D DP A Cutting Units Page 7.2 - - 29 This page is intentionally blank..
Rev . E Reelmaster 6500 - - D/6700 - - D DP A Cutting Units Page 7.2 - - 30 Front Roller Removal (Fig. 29) 1. Position machine on a c lean and level surface, lower cutting units, stop engine, engage parking brake and re- move key from the ignition switch.
Units DP A Cutting Rev . E Reelmaster 6500 - - D/6700 - - D DP A Cutting Units Page 7.2 - - 31 Rear Roller Removal (Fig. 30) 1. Position machine on a c lean and level surface, lower cutting units, stop engine, engage parking brake and re- move key from the ignition switch.
Rev . E Reelmaster 6500 - - D/6700 - - D DP A Cutting Units Page 7.2 - - 32 Roller Service (Greasable Bearings with Retaining Ring) 1. Roller tube (front Wiehle shown) 2. Roller shaft 3. Inner oil seal 4. Grease fitting 5. Ball bearing 6. Inner seal 7.
Units DP A Cutting Rev . E Reelmaster 6500 - - D/6700 - - D DP A Cutting Units Page 7.2 - - 33 Removal (Figs. 31 and 32) 1. Remove retaining r ing from both ends of roller . 2. Support r oller assembly and press one end of roller shaft to remove seals and bearing from opposite end of roller .
Rev . E Reelmaster 6500 - - D/6700 - - D DP A Cutting Units Page 7.2 - - 34 Roller Service (Greasable Bearings with Bearing Nut) Disassembly (Fig. 33) 1.
Units DP A Cutting Rev . E Reelmaster 6500 - - D/6700 - - D DP A Cutting Units Page 7.2 - - 35 3. From the roller tube end with only the inner seal installed, carefully install the roller shaft into the roller tube. Make sure that seals are not damaged as shaft is installed.
Rev . E Reelmaster 6500 - - D/6700 - - D DP A Cutting Units Page 7.2 - - 36 Rear Roller Brush (Optional) 1. Roller brush shaft 2. Roller brush 3. Lock nut (2 used) 4. J - - bolt (2 used) 5. High HOC roller brush (optional) 6. Excluder seal (2 used) 7.
Units DP A Cutting Rev . E Reelmaster 6500 - - D/6700 - - D DP A Cutting Units Page 7.2 - - 37 Disassembly (Fig. 39) 1. Position machine on a c lean and level surface, lower cutting units, stop engine, engage parking brake and re- move key from the ignition switch.
Rev . E Reelmaster 6500 - - D/6700 - - D DP A Cutting Units Page 7.2 - - 38 3. If drive bearing housing w as disassembled, install new components noting proper orientation as shown in Figures 42 and 43. A. Install bearing on s haft by pressing equally on the inner and outer bearing races.
Units DP A Cutting Rev . E Reelmaster 6500 - - D/6700 - - D DP A Cutting Units Page 7.2 - - 39 5. Check that roller brush has light contact w ith rear roll- er (Fig. 46). If contact is incorrect, brush operation will be adversely affected. Also make sure that brush shaft is parallel with rear roller .
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Rev . E Reelmaster 6500 - - D/6700 - - D DP A Groomer Page 7.3 - - 1 Chapter 7.3 DP A Groomer T able of Contents GROOMING PERFORMANCE 2 .................. TROUBLESHOOTING 3 ......................... Groomer Reel Mechanical Problems 3 ........... ADJUSTMENTS 4 .
Rev . E Reelmaster 6500 - - D/6700 - - D DP A Groomer Page 7.3 - - 2 Grooming Performance There are a number of factors that can affect the perfor- mance of grooming. These factors vary for different golf courses and from fairway to fairway . It is important to in- spect the turf frequently and vary the grooming practice with turf needs.
Rev . E Reelmaster 6500 - - D/6700 - - D DP A Groomer Page 7.3 - - 3 T roubleshooting Groomer Reel Mechanical Problems Problem Possible Causes Correction No rotation of the groomer reel. The groomer drive belt needs to be adjusted. Seized groomer reel or idler bear- ing(s) in groomer side plate(s).
Rev . E Reelmaster 6500 - - D/6700 - - D DP A Groomer Page 7.3 - - 4 Adjustments CAUTION Never work on the groomer with the engine running. Always stop the engine, remove the key from the ignition switch and wait for all machine movement to stop before working on the groomer .
Rev . E Reelmaster 6500 - - D/6700 - - D DP A Groomer Page 7.3 - - 5 Service and Repairs CAUTION Never work on the groomer with the engine running. Always stop the engine, remove the key from the ignition switch and wait for all machine movement to stop before working on the groomer .
Rev . E Reelmaster 6500 - - D/6700 - - D DP A Groomer Page 7.3 - - 6 Groomer Plate Assembly Figure 4 1. Groomer reel 2. Pulley spacer 3. W asher (as required) 4. Square key 5. Driven pulley 6. Flange nut 7. Socket head screw 8. Idler plate 9. Idler pulley assembly 10.
Rev . E Reelmaster 6500 - - D/6700 - - D DP A Groomer Page 7.3 - - 7 B. Remove flange head screw (item 1 1) that retains drive pulley . Pull drive pulley from drive shaft.
Rev . E Reelmaster 6500 - - D/6700 - - D DP A Groomer Page 7.3 - - 8 2. Install groomer plate assembly to groomer non - - drive side of cutting unit: A. Carefully position non - - drive side groomer plate onto groomer shaft and slide to cutting unit. B.
Rev . E Reelmaster 6500 - - D/6700 - - D DP A Groomer Page 7.3 - - 9 This page is intentionally blank. DP A Groomer.
Rev . E Reelmaster 6500 - - D/6700 - - D DP A Groomer Page 7.3 - - 10 Groomer Reel Figure 8 1. Groomer reel 2. Pulley spacer 3. W asher 4. Square key 5. Driven pulley 6. Flange nut 7. Socket head screw 8. Idler plate 9. Idler pulley assembly 10. Lock nut 1 1.
Rev . E Reelmaster 6500 - - D/6700 - - D DP A Groomer Page 7.3 - - 1 1 Installation (Fig. 8) 1. Position cutting unit on a level surface. If cutting unit is attached to traction unit, make sure to stop engine, en- gage parking brake and remove key from the ignition switch.
Rev . E Reelmaster 6500 - - D/6700 - - D DP A Groomer Page 7.3 - - 12 Groomer Reel Service Inspect groomer reel blades frequently for damage and wear . Straighten bent blades with a pliers. Either replace worn blades or reverse the blades to put the sharpest blade edge forward (Fig.
Rev . E Reelmaster 6500 - - D/6700 - - D DP A Groomer Page 7.3 - - 13 6. Place e xcluder seals on groomer shaft. 7. Install o - - ring on non - - drive end of groomer shaft. 8. Install groomer reel back on cutting unit (see Groom- er Reel Installation in this section).
Rev . E Reelmaster 6500 - - D/6700 - - D DP A Groomer Page 7.3 - - 14 Groomer Pivot Hub Figure 14 1. Groomer drive shaft 2. Ball bearing 3. Grease seal 4. Retaining ring 5. Pivot hub 6. Retaining ring 7. Extension spring 8. Retaining ring 9. Idler plate 10.
Rev . E Reelmaster 6500 - - D/6700 - - D DP A Groomer Page 7.3 - - 15 Disassembly (Fig. 14) 1. Remove pivot hub assembly (with idler plate) from cutting unit (see Groomer Plate Assembly Removal in this section). 2. Remove retaining r ing (item 4) that secures idler plate to pivot hub.
Rev . E Reelmaster 6500 - - D/6700 - - D DP A Groomer Page 7.3 - - 16 Height Adjuster Assembly Figure 16 1. Groomer plate (LH drive shown) 2. Shoulder bolt 3. Ball joint rod 4. Jam nut 5. Compression spring 6. Flange head screw 7. Lower ramp 8. External snap ring 9.
Electrical Diagrams Reelmaster 6500-D/6700-D Page 8 - 1 Electrical Diagrams Chapter 8 Electrical Diagrams T able of Contents ELECTRICAL SCHEMA TICS Reelmaster 6500-D Model 03806 & 03807 Serial No. 210000001 - 210999999 Electrical Schematic 3 .....
Reelmaster 6500-D/6700-D Page 8 - 2 Electrical Diagrams This page is intentionally blank..
Rev . E Electrical Schematic Reelmaster 6500-D Model 03806 & 03807 All relays and solenoids are shown as de-energized. All ground wires are black. Serial Numbers 210000001 - - 210999999 ST ART REL.
Rev . E Electrical Schematic Reelmaster 6500-D Model 03806 & 03807 All relays and solenoids are shown as de-energized. All ground wires are black. Serial Numbers 220000001 & Up Reelmaster 6500.
Rev . E Electrical Schematic Reelmaster 6700-D Model 03808 All relays and solenoids are shown as de-energized. All ground wires are black. Serial Numbers 210000001 - - 210999999 HIGH TEMP SHUTDOWN SWI.
Rev . E Electrical Schematic Reelmaster 6700-D Model 03808 All relays and solenoids are shown as de-energized. All ground wires are black. Serial Numbers 220000001 & Up HIGH TEMP SHUTDOWN SWITCH #.
Rev . E Ignition Switch Circuit (20 Amp Fuse) Reelmaster 6500 - - D/6700 - - D HIGH TEMP SHUTDOWN SWITCH IF EQUIPPED Reelmaster 6500-D/6700-D Page 8 - 7 Electrical Diagrams.
Rev . E HIGH TEMP SHUTDOWN SWITCH IF EQUIPPED Controller #1 Power Circuit (10 Amp Fuses) Reelmaster 6500 - - D/6700 - - D Reelmaster 6500-D/6700-D Page 8 - 8 Electrical Diagrams.
Rev . E Controller #1 Logic Circuit (5 Amp Fuse) Reelmaster 6500-D/6700-D HIGH TEMP SHUTDOWN SWITCH IF EQUIPPED Reelmaster 6500-D/6700-D Page 8 - 9 Electrical Diagrams.
Rev . E Controller #2 Power Circuit (15 Amp Fuse) Reelmaster 6700-D HIGH TEMP SHUTDOWN SWITCH P a g e1o f2 IF EQUIPPED Reelmaster 6500-D/6700-D Page 8 - 10 Electrical Diagrams.
Rev . C Controller #2 Power Circuit (15 Amp Fuse) Reelmaster 6700 - - D P a g e2o f2 #7 REEL #6 REEL SV7 SV6 Reelmaster 6500-D/6700-D Page 8 - 1 1 Electrical Diagrams.
Rev . E HIGH TEMP SHUTDOWN SWITCH IF EQUIPPED Accessory Power and Controller #2 Reelmaster 6500 - - D/6700 - - D Logic Circuit (7.5 Amp Fuse) Page 1 of 2 Reelmaster 6500-D/6700-D Page 8 - 12 Electrica.
Rev . C Accessory Power and Controller #2 Reelmaster 6500 - - D/6700 - - D Logic Circuit (7.5 Amp Fuse) Page 2 of 2 #7 REEL #6 REEL SV7 SV6 Reelmaster 6500-D/6700-D Page 8 - 13 Electrical Diagrams.
Rev . E HIGH TEMP SHUTDOWN SWITCH IF EQUIPPED Starter , Glow Plugs, and Alternator Circuits Reelmaster 6500 - - D/6700 - - D (Fusible Links) Reelmaster 6500-D/6700-D Page 8 - 14 Electrical Diagrams.
Rev . E HIGH TEMP SHUTDOWN SWITCH IF EQUIPPED Optional Lighting Circuit (10 Amp Fuse) Reelmaster 6500 - - D/6700 - - D Reelmaster 6500-D/6700-D Page 8 - 15 Electrical Diagrams.
Rev . E Optional T urfDefender Leak Detector Reelmaster 6500-D/6700-D TURF DEFENDER LEAK DETECT OR 2D 1B 3B 2C 1E 2E 1C 3C 2A 2F 1F 3F AB C D AA BB CC EE ELECTRIC SOLENOID VA LV E RED/WHITE BLACK/WHIT.
Wire Harnesses Reelmaster 6500-D/6700-D P5 P3 P4 P45 J24 J25 J23 P12 P7 & P8 P29 P6 P37 P14 P15 P13 J5 P10 J6 P1 1 J4 J2 J3 Console Harness Neutral Switch Harness P41 J22 J21 Engine Harness Main H.
Reelmaster 6500-D/6700-D Page 8 - 18 Electrical Diagrams Electrical Connector Drawing Reelmaster 6500-D/6700-D P19 MSV1 Solenoid Located on reel manifold Cavity Wi re A Y e llow/ Wh ite BB l a c k P20.
Reelmaster 6500-D/6700-D Page 8 - 19 Electrical Diagrams Electrical Connector Drawing (Cont.) Reelmaster 6500-D/6700-D J13 Diagnostic Light Located i n steering colum n Wire Color Violet/Red P35 SV5 S.
Reelmaster 6500-D/6700-D Page 8 - 20 Electrical Diagrams Secondary (#2) Electronic Controller Harness and Reelmaster 6700-D SV6 Solenoid Located on lift manifold Cavity Wi re A Brown/White BB l a c k .
デバイスToro 6500-Dの購入後に（又は購入する前であっても）重要なポイントは、説明書をよく読むことです。その単純な理由はいくつかあります：
Toro 6500-Dをまだ購入していないなら、この製品の基本情報を理解する良い機会です。まずは上にある説明書の最初のページをご覧ください。そこにはToro 6500-Dの技術情報の概要が記載されているはずです。デバイスがあなたのニーズを満たすかどうかは、ここで確認しましょう。Toro 6500-Dの取扱説明書の次のページをよく読むことにより、製品の全機能やその取り扱いに関する情報を知ることができます。Toro 6500-Dで得られた情報は、きっとあなたの購入の決断を手助けしてくれることでしょう。
Toro 6500-Dを既にお持ちだが、まだ読んでいない場合は、上記の理由によりそれを行うべきです。そうすることにより機能を適切に使用しているか、又はToro 6500-Dの不適切な取り扱いによりその寿命を短くする危険を犯していないかどうかを知ることができます。
ですが、ユーザガイドが果たす重要な役割の一つは、Toro 6500-Dに関する問題の解決を支援することです。そこにはほとんどの場合、トラブルシューティング、すなわちToro 6500-Dデバイスで最もよく起こりうる故障・不良とそれらの対処法についてのアドバイスを見つけることができるはずです。たとえ問題を解決できなかった場合でも、説明書にはカスタマー・サービスセンター又は最寄りのサービスセンターへの問い合わせ先等、次の対処法についての指示があるはずです。
