Toro 6500-D инструкция обслуживания

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. 01090SL) (T ier 1 Emission Engine Models). P ART NO. 01084SL (Rev . F) Service Manual Reelmaster R 6500 - D/6700 - D Preface The purpose of this publication is to provide the s ervice technician wit[...]

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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 .......................... Chapter 2 - - Product Records and Maintenance Product Records 2[...]

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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 ..................... Safety Instructions The REELMASTER 6500-D and 6700-D were tested [...]

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. Use an approved fuel container . B. D[...]

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. Al- ways chock or block the wheels and use jack stands or solid wood b[...]

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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 ............................... EQUIV ALENTS AND CONVERSIONS 2 ........... Decimal and Millimeter Equivalents 2 ...........[...]

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. For critical applications, as determined by T oro, either the recommended torque or a torque that is unique to the application is clearly identified[...]

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 Height Nuts SAE Grade 1 Bolts, Screws, Studs, & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) SAE Grade 5 Bolts, Screws, Studs, &a[...]

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 10.9 Bolts, Screws, and Studs with R e g u l a r H e i g h t N u t[...]

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 Hex Socket 1/4 - - 20 UNC 140 + 20 in - - lb 73 + 12 in - - lb 5/16 - - 18 UNC 215 + 35 in - - lb 145 + 20 in - - lb 3/8 - - 16 UNC 35 + 10 ft - - lb 18[...]

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 ..................... Stopping the Engine 4 ......................... Check Engine Oil 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. Special tools are d[...]

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 3.07 in. (78 mm) Stroke 3.09 in. (78 mm) T otal Displacement 91.4 cu. in. (1498 cc) T o[...]

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. Failure to do so may lead to turbo-charger trouble. Check Engine Oil 1. Park machine on a l[...]

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. • Use a funnel and fill the fuel tank outdoors, in an open area, when[...]

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. System capacity is about 10 quarts (9.4 l). IMPORT ANT : Clean debris off the sc[...]

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. 3. Position throttle lever forward so it stops against the seat base[...]

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. 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key[...]

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. 2. Release hood latch and open hood. DANGER Under certain conditions, diesel fuel and f uel va-[...]

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. 1. Park machine on a level surface, lower cutting units, stop engine, and engage park[...]

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 . 1. Park machine on a level surface, lower cutting un[...]

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. • Use a funnel and fill the fuel tank outdoors, in an open area, when the en[...]

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. 6. Lubricate gasket on new filter element and O-ring with clean diesel fuel. 7. Screw filter [...]

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. Grommet 13. T ank Cap 14. Fuel T ank 15. Drain Clamp 16. Drain Fitting 17. Cap Screw 18. Flat [...]

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. • Use a funnel and fill the fuel tank outdoors, in an open area, when the engine is [...]

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. 3. Check air cleaner , seals, and intake hose for dam- age which could cause an air leak. B[...]

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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. Overflow Hose (to ground) 14. Hose Clamp 15. Overflow Reservoir 16. Overflow Hose (to radiator) 17[...]

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. 3. Unscrew knobs and pivot oil cooler rearward. 4. Release hood latch and open hood. [...]

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. Locknut 14. Flat W asher 15. Fuel Pump 16. Fuel Hose 17. Locknut 18. Fuel Hose 19. Fuel Filter/W a[...]

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. 3. Disconnect both battery cables at the battery (see Battery Service in Chapter 5 [...]

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. 15. Remove the nuts, washers, and cap [...]

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. 13. Install muffler assembly . 14. Connect both battery cables to the battery (see Bat- tery Serv[...]

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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 ............................. Hydraulic Fitting Installation 3 ................... Pushing or T owing Traction Unit[...]

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 250 PSI (17 bar) Reel/Steering/Lift Pump 3 section, positive displacement gear type pump Maximum Operating Pressure 3000 PSI (207 bar) Steering Relief[...]

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. These conditions can cau[...]

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. 3. Lubricate the O-ring with a light coating of oil.[...]

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. IMPORT ANT : Do not push or tow the machine faster than 2 to 3 MPH (3 to 4.8 km/h)[...]

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.U. 3 MD2 MOW2 BKLP2 BACKLAP FC2 PSI P2 C.U. 5 C.U. 1 MOW CIRCUIT C.U. 4 BACKLAP MOW MD1 BKLP[...]

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.U. 3 MD2 MOW2 BKLP2 BACKLAP FC2 PSI P2 C.U. 5 C.U. 1 MOW CIRCUIT C.U. 4 BACKLAP MOW MD1 BKLP1 MO[...]

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. Reelmaster 6500-D 2WD (Model 03806) SV1 SV2 G3 #3 #2 #4 SV5 C5 C6 SV4 C4 RAISE LOWER PT CD3 CD2 T #1 #5 C3 SV3 C2 SV2 C1 ST SV1 P3 C1 C2 P FD1[...]

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. Reelmaster 6500-D 2WD (Model 03806) SV1 SV2[...]

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 276.0 M8 3.5 103.0 1.16 19.0 2.48 40.6 DISPLACEMENT PRESSURE COMPONENT P1 P2 P3 P4 P5 M1 M2 [...]

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 276.0 M8 3.5 103.0 1.16 19.0 2.48 40.6 DISPLACEMENT PRESSURE COMPONENT P1 [...]

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. Reelmaster 6500-D 4WD (Model 03807) SV1 SV2 G3 #3 #2 #4 SV5 C5 C6 SV4 C4 RAISE LOWER PT CD3 CD2 T #1 #5 C3 SV3 C2 SV2 C1 ST SV1 P3 C1 C2 P FD1 SV8[...]

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. Reelmaster 6500-D 4WD (Model 03807) SV1 SV2[...]

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 276.0 M8 3.5 103.0 1.16 19.0 2.48 40.6 DISPLACEMENT PRESSURE COMPONENT P1 P2 P3 P4 P5[...]

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 6.6 BARS M10 50 1500 1500 4000 276.0 M8 3.5 103.0 1.16 19.0 2.48 40.6 DISPLACEMENT PRESSURE COMPONE[...]

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 13.8:1 250 PSI R3 1500 PSI SYSTEM RELIEF 4000 PSI SYSTEM R[...]

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. Pushing the top of the traction pedal engag[...]

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.U. 3 MD2 MOW2 BKLP2 BACKLAP FC2 PSI P2 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. Gear pump section (P3) provides oil flow [...]

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.U. 3 MD2 MOW2 BKLP2 BACKLAP FC2 PSI[...]

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. Gear pump section (P3) provides oil flow [...]

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.U. 3 MD2 MOW2 BKLP2 BACKLAP FC2 PSI P2 C.U.[...]

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. Gear pump s ec- tion (P1) supplies hydraulic power to the front cutting units, while section (P2[...]

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 OUT LH RH STEERING CONTROL V ALVE (RIGHT TURN) (FROM P3) (TO LIFT MANIFOLD) V1 STEERING CYLINDER AUX IN ↓⎝⎛ LH RH STEERING CONTROL V ALVE (LEFT[...]

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. With the the engine running and the steering wheel in the neutral position ([...]

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. Quick disconnect fittings provided attach directly to mating[...]

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. 1. INLET HOSE: Hose connected from the system cir- cuit to the inlet side [...]

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. A hydraulic system with an excessive increase in heat or noise is a potential failure. Should eit[...]

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. Oil in system too light. Drain reservoir and refill with proper viscosity oil. Heat e[...]

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. Damaged mounting gasket. Misadjusted or damaged neutral return spr[...]

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. Inspect wheel motors and repair or replace if worn or damaged. Pump [...]

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 (7.6 L/m) at full pressure. Noisy Gear Pump Caused by Cavitation Cause Correct[...]

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). Replace faulty valve. Solenoid V alve SV10 and/or SV1 1 not [...]

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 . TEST NO. 6 & 7. Repair or replace r eel[...]

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). Replace faulty valve. Gear pump section P1 (P2) inefficient. TEST NO. 5[...]

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. Replace faulty valve. Lift arm pivots bindings. Lubricate bushings. Inspect for damage. Repair or[...]

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. See Chapter 5 - Electrical System. T est solenoid coil. Replace if faulty . [...]

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 .) Before Performing Hydraulic T ests I[...]

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. Make sure engine is off[...]

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. 3. Connect a 10,000 psi gauge to traction circuit test port for function to be checked (Fig. 1[...]

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 . 1. Make sure hydraulic oil is at normal op[...]

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. 2. Make sure machine is parked on a level surface with the c[...]

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. Eventually , enough oil can by- pass to cause[...]

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. NOTE: Inlet is front hose. High Pressure Low Pressure Flow Reel Manifold Block M4 R7 R7 M1 R7 R7 M5 R7 R7 Figure 19 Note: One way to find a bad reel motor is t[...]

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. 3. Lower cutting units, engage parking brake and stop th[...]

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. NOTE: Outlet is rear hose. Disconnect case drain hose (small diame[...]

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. Make sure engine is of f and the[...]

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. V alve (R2) on Reelmaster 6700 - - D is set to 3000 PSI. Howev- er [...]

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 . Depress only the right brake pedal and engage [...]

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. Center (#1), Outside Front (#4 & 5) and Rear (6700 -D #6 &[...]

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. Before removing any parts from the hydraulic sys- tem, park machine on a level surface, engage parking brake, lower cutting units or atta[...]

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 fluid escaping under pressure can have sufficient force to penetrate the skin[...]

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 . Air must be purged from the system and its components to re[...]

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. Contaminated fluid looks milky or black when compared to clean oil. 1. Turn engine of f and[...]

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. When the indicator is in the RED zone, the filter element should be changed. IMPORT ANT : Use on[...]

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. Retaining Ring 3. Retaining Ring 4. Sealing W asher 5. Screw 6. Rotating Kit Assembly 7. Serv[...]

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. Remove the four [...]

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. 12. T o remove servo piston assembly (7) from housing, start with the four each cap scr[...]

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. (4.5 to 5.4 Nm). 8. T o assemble cradle assembly , press dowels (46) into cradle and install crad[...]

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. O-ring 10. Wiper Seal 11 . O - r i n g 12. Adapter 13. Ball 14. Pin 15. Neutral Lockout Sw[...]

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. 7. Install new O-ring (2) onto plug (1) and install plug. Adjust plug until there is[...]

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. Plug 8. Front Plate Assembly 9. Copper W asher 10. Screw 1 1. Shaft Seal 12. W asher 13. I[...]

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. Thoroughly clean the outside of pu[...]

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. 2. Replace the backplate, front plate or[...]

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. Backplate Assembly 10. O-ring 1 1. Speed Pickup Sensor (RH wheel motor only) 12. Dowel Pin 13[...]

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. 3. Inspect the piston block surface that makes contact with valve plate. This surface s[...]

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. O-ring 10. Dowel Pin 11 . D o w e l P i n 12. Needle Bearing 13. V alve Plate 14. Rotating[...]

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 . A smooth surface is required. Do not lap valve plate bronze surface. Replace valve [...]

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. Figure 40 1. Retaining Ring 2. Shaft Seal 3. Flange 4. E-Seal 5. O-ring 6. Dowel [...]

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 . 1. Disassemble the adjusting valve parts. DO NOT at- tempt to remove the valve seat. It is [...]

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. 3. Apply a light coating of oil to exposed face of bearing block. Put tape or seal protector to[...]

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 . After cleaning, remove plugs and drain any oil out of the motor . 2. Use a marker to make a diagonal line across the front flange, body and rear cover to allow correct compo- nent a[...]

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. T est Port Fitting 12. O-ring 13. T est Port Cap 14. Switch Bracket 15. Lock W asher 16. Cap S[...]

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. Hydraulic Hose 2. Hydraulic Hose 3. Hydraulic Hose 4. O-ring 5. Lift Manifold 6. Hydra[...]

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. Rotary Cartridge V alve (4 way) 8. Seal Kit 9. Cartridge V alve (N.O.) 10. Seal Kit 1 1. [...]

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. Ball 10. Dowel Pin 11 . O - - r i n g 12. Backlap Switch (NO) (2 Used) 13. Orifice ([...]

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. Plug 10. O-ring 11 . P l u g 12. O-ring 13. Plug 14. O-ring 15. Solenoid (20 watt) 16. Cartr[...]

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. Solenoid coil (6 used) 10. Solenoid coil 1 1. Orifice (.063) 12. Straight fitting [...]

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. Solenoid coil spacer 9. Lift manifold block 10. Orifice (.063) 1 1. Straight fitting (3 used) 12[...]

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. 45) and lift manifold (Fig. 47) have an O - - ring on each side of coil. 2. For sol[...]

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. A. Contamination may cause valves to stick or hang up, it can b[...]

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. Secure base with two (2) set screws. Apply a light coating of grease to chamfer on top of b[...]

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 . 2. Disconnect hydraulic hoses from lift cylinder . 3. Remove/install lift cylinders. Front Cent[...]

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. Remove cylinder pin with remaining retaining ring from the frame a[...]

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. O-ring 8. Back-up Ring 9. Head 10. Dust Seal 1 1. Collar 12. Shaft with Clevis 13. Grease Fitting Figure 53 FRONT LEFT AND FRONT RIGHT LIFT CYLINDER #4 & 5 REAR LIFT CYLINDER #2 & 3 REAR LIF[...]

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 . Do no[...]

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. Dust Seal 8. Uni - - ring 9. O-ring 10. Rod Seal 11 . O - r i n g 12. Backup Ring Figure 54 1 5 3 8 9 10 11 12 6 4 7 2[...]

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. 1. After removing cylinder , pump oil out of cylinder into a drain pan by SLOWL Y moving rod [...]

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. Piston 5. O-ring 6. U-cup 7. Gland 8. Wiper 9. Piston Rod Assembly 10. O-ring 1 1. Locknut Figure 55[...]

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. After removing cylinder , pump oil out of cylinder into a drain pan by SLOWL Y moving rod and pist[...]

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. As the steering wheel is turned, the steering valve meters hy- draulic fluid to the double-acting steering cylinder o[...]

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. 2. Remove the front center cutting unit (see Chap- ter 7-Cutting Units in this manual). 3. Remo[...]

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. Before disassembly , drain the oil, then plug the ports [...]

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 . Do not wipe parts dry with paper towels or cloth. Lint in a hydraulic system will cause[...]

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. 5. Apply a light coating of clean hydraulic fluid to t he spool and slide it i[...]

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). Note: Read the General Precautions f[...]

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. O-ring 14. T ee Hydraulic Fitting 15. Hydraulic Hose 16. Suction Hose 17. Hose C[...]

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. T o avoid possible burns, allow the engine and cooling systems to cool befor[...]

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 ............................. TROUBLESHOOTING 4 ......................... Understanding the Controllers 4 .........[...]

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 . Digital Multimeter The meter can test electrical components and circuit[...]

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. 3 and 4)[...]

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. For effective troubleshooting and repairs, you must have a good understa[...]

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. Diagnostics: S Do troubleshooting by connecting one of the follow- ing devices to the loopback connector: - Diagnostic A[...]

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. seat sensor , key switch, etc.) and energizes the outputs to actuate sole- noids or relays for th[...]

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 . Do not hold button . B. The Di[...]

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. The Problem circuit will be flash- ing. Records will rep[...]

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. 2. Open control panel cover . Locate leak detector harness loopback connector with hydraulic symb[...]

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. Oil level may be low causing air to be drawn out of system. Check oil [...]

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. LED lit if oil level is too high 2. LED lit if oil level is OK 3. LED lit if o[...]

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. The hand-held Diagnostic ACE is helpful for identifying specific problems 4-Beep Faults are Occurring Oil level is incorrect Check oil level on a level surface Ma[...]

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 . The 20 ampere fuse to the ignition switch is open. St[...]

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 . Engine continues to run, but should not, when the tra[...]

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 . Cutting units run, but should not, when raised. Units shut off with enable disable sw[...]

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 . Solenoid SV2 or circuit wiring is faulty . A hydraulic problem exists (see T roub[...]

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. T est instructions: Set the multimeter to the DC V olts set- ting. [...]

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. Remember - there are 2 types of Glow Pl u[...]

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). NOTE: For more component testing information, see t[...]

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 . The me- ter will display a small resistance va[...]

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. Each fuse holder has the fol[...]

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 . The me- te[...]

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. There is a green/white wire attached to the switch (Fig. 23)[...]

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 . 1. Apply 14 VDC to pin D. 2. Ground pins F , A, and E. 3. Lamps 1, 2, and 3 should ligh[...]

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. It is mounted on the engine block near the injection pump. In Place T esting Note: Prior to taking small resistance readings with a digital multimeter , short th[...]

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. It is mounted on the engine block near the injection pump. In Place T esting Note: Prior to taking small resistance readings with a digital multimeter , short the test[...]

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. 3. Remove sender and gasket f[...]

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. CAUTION Make sure the voltage source is turned OFF be- fore connecting it to the electrical circuit to avoid electrical shock and prevent damag[...]

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. 35). 1. Lower coolant level in the engine and remove the [...]

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. CAUTION Make sure the voltage source is turned OFF be- fore connecting it to the electrical circuit to avoid electrical [...]

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 . 2. Connect the negative (-) terminal of the voltage[...]

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. If lamp is not on: 1. Disconnect wire from switch and touch wire to a good ground, such[...]

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. 1. Connect speedometer to the pulse[...]

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. This feature allows only one person to backlap any of t[...]

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. The switch actuator is located on the upper plate of the seat suspen- sion mechanism and is mad[...]

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. As the lift arm is lowered, a bracket on the lift arm comes close to the switch, causing the reed s[...]

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. Battery Storage If the machine will be stored for more than 30 days 1. Remove the batter[...]

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. CAUTION When working with batteries, use extreme cau- tion to avoid slashing or sp[...]

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 . Charge at the recommended rate and time giv- en in Charging or until all cells specific gravi[...]

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. CAUTION Follow the manufac[...]

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). NOTE: Use a suitable tool to feel when a mot[...]

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. Installation Instructions 1. Install a relay into the ope[...]

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 ............................... Changing Planetary Gear Drive Lubricant 3 ....... Changing Rear Axle Lubricant 4 ..........[...]

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. (136 to 169 Nm) Rear wheel toe-in 0.000 to 0.125 in. (0.0 to 3.0 mm)[...]

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. There are 2 separate oil reser- voirs (one for each front wheel) that require draining and refilling with SAE 85W[...]

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. 2. Clean area around the c heck plugs, drain plugs, and fill/vent plug (Fig. 3, 4, &[...]

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 . Free travel is the distance the brake pedal moves before braking[...]

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. Measure the center-to- center distance, at axle height, in front and rear of steer- ing[...]

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. Bearing Cone 4. Bearing Cup 5. Wheel Stud (8 used) 6. Housing 7. Bearing Cup 8. Bearing[...]

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). 1 1. Remove and discard all seals. 12. If bearings will be replaced, use a pul[...]

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. Brake Assembly 7. Splined Shaft 8. Retaining Ring 9. Planetary Wheel Drive 10. Flange Head Screw ([...]

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. Gasket 11 . A c t u a t o r 12. Extension Spring 13. Ball Inspection and Repair (Fig. 12) 1.[...]

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. Sleeve Bushing 10. Slotted Nut 1 1. Thrust Washer 12. Grease Fitting 13. Thrust W[...]

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. T o correct the problem, replace the bushings. 1. Disconnect the hydraulic hoses[...]

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. 13. Remove the jackstands and lower the machine to the floor . 14. Lubricate the ste[...]

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. Retaining Ring 12. Grease Fitting 13. O-ring 14. 90 _ Hydraulic Fitting 15. O-ring 16. Hydraulic [...]

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. 2. Drain r ear axle lubricant (see Changing Rear Axle Lubricant in this section of [...]

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. Remove the bevel gear case/axle case assembly and O-ring from the axle support (Fig. 1[...]

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. 20). 6. While holding the bevel gear case, tap the upper end of the bevel gear shaft out of t[...]

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 . Coat a new O-ring with grease and inst[...]

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. Ins[...]

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 . Prevent the axle from turning and measure the lower bevel gear to axle g[...]

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. Remove t h ea x l ec o v e rf r o mt h ea x l ec a s ea sa na s s e m b l y (Fig. 29). 2[...]

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. Input Shaft/Pinion Gear 13. Bearing Case 14. Shim 15. Screw 16. Gear Case 17. Gasket 18. Cove[...]

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 4.0 to 6.0 in-lbs. (0.4 to 0.7 Nm) of force is req[...]

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). IMPORT ANT : Do not interchange ri[...]

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 . SIDE GEAR TO CASE CLEARANCE: 0.002 to 0.012 in. (0.05 to 0.30 mm)[...]

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). 2. Apply molybdenum disulfide lubricant (Three Bond 1901 or equivalent) to the[...]

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. GEAR TOOTH DEFINITIONS (Fig. 43): To e - - the portion of the too[...]

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. 1. If contact is toward the heel or base of the gear (Fig. 46): A. Install thicker or add[...]

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 .................. Bedknife to Reel Adjustment 8 ................... Adjusting [...]

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. 93-9774 for h[...]

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 . Gauge Bar Assembly Use gauge bar to verify height of cut and bedknife att[...]

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. T ighten screws to a torque of 250 - 300 in.lb. (28 - 34 Nm) [...]

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. T urf conditions such as excessive thatch, “sponginess” or attempting to cut off too m uch grass height may not always be overcome by adjust[...]

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. Excessive contact accelerates wear; quality of cut may be adversely affected. Adjust so you [...]

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. Note: Right and left ends of cutting unit is determined by s[...]

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. However , for dry and/or sparse condi- tions a .001-.[...]

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. D. Retighten pivot hub [...]

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. However , because of wear to the bedknife and reel[...]

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. Con- tact your local T oro Distributor for ordering a leve[...]

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. Note: Make sure gauge bar is in contact with the front roller at all times to keep desired[...]

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). When conditions are heavy or wet, rear shield may be opened. 1. T o open rear shield, loosen flange head capscrews securing shield to right side plate, rotate shield[...]

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. 1. Lower cutting units onto a hard surface, shut off en- gine and remove k[...]

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. ONL Y BACKLAP A T IDLE ENGINE SPEED. NEVER A TTEMPT TO TURN REELS BY HA[...]

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. Pivot Hub - RH 6. Sideplate - RH 7. Reel Frame 8. Bushing Assembly 9. Flange Bushing 10. Flat [...]

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.H. side of cut- ting unit. 9. Remove fasteners securing L.H. and R.H. be[...]

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. 4. Install new bedknife: A. Make[...]

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. 2. Remo[...]

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. Apply Locite 242 to threads Tighten to 75 - - 85 ft [...]

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. 1. Loosen reel to b[...]

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. Use a hammer and punch to drive out roll pins from L.H. bearing housing. Remove L.H. bearing hou[...]

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 (1.8 - - 2.4 KgM) (1.8 - - 2.4 KgM) (10.4 - - 11.8 KgM) (1.8 - - 2.4 KgM) 1 2 3 4 5 6 7 8 17 18 19 20 21 22 23 24 25 26 27 9 10 11 12 13 20 22 16 15 14 28 29 30 31 32 33 34 35 36 2[...]

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. Outer Oil Seal 9. W asher Figure 37 Note: Bearing and seal configurations are the same f[...]

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. For any of the loca- tions requiring the motor to b[...]

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. 40). 13. Hook spring wire around bottom of steering pin (Fig. 40). 14. [...]

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. 2 General Purpose Lithium Base Grease (Fig. 42). IMPORT ANT : Lubricating cutting units immediately af- ter washing helps purge water out of bearings and in- creases bearing life[...]

Reelmaster 6500-D/6700-D Page 7 - 28 Cutting Units This page is intentionally left blank.[...]

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 ........... ADJUSTMENTS 4 .............................. Groomer Height/Depth Adjustment 4 ............ SERVI[...]

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 . It is important to in- spect the turf frequently and vary the grooming practice with tu[...]

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. The groomer belt is worn, broken or damaged. Identify and replace faulty be[...]

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. When adjusting groomer height/de[...]

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. 1. Park machine on a clean and level surface, lower cutting units completely to the ground, stop engine, en- gage parking brake and remov[...]

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. Flange nut (3 used) 1 1. Drive pulley 12. Flange head screw (3 used) 13. Groomer belt cover 14. Gr[...]

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. 6). Support groomer to prevent it from falling. Slide height of cut assembly from groomer . Locat[...]

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. 7). Blades that are rounded to the midpoint of the blade tip must be r[...]

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. Removal (Fig. 10) 1. Remove groomer belt cover and drive belt from groomer drive side of cu[...]

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. Retaining plate 10. Retaining plate spacer (2 used) 1 1. Flange nut 12. Driven pulley 13. Retai[...]

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). 9. Remove shaft and bearings from housing (Fig. 14): A. Remove retaining rin[...]

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. Adjustment bracket 1 1. Height of Cut bracket 12. Height of Cut bracket 13. Adjustment br[...]

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. Assembly (Fig. 15) 1. If bearing housing were disassembled, install bear- [...]

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 ................ SPECIAL TOOLS 4 ............................. F ACTORS THA T[...]

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 (55.9 cm.) in length and 7 inch (17.8 cm) in diameter . High strength, low alloy ste[...]

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. Additionally , [...]

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. Gauge Bar Assembly T oro Part Number: 108 - - 6715 Use gauge bar to verify he[...]

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. Figure 5 Cutting Unit Kicks[...]

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. TOR4064 Spanner W rench (not used on DP A) TOR4065 Inner [...]

Rev . E Units DP A Cutting Reelmaster 6500 - - D/6700 - - D DP A Cutting Units Page 7.2 - - 7 This page is intentionally blank.[...]

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. T urf conditions such as excessive thatch, “sponginess” or attempting to cut off too m uch grass heigh[...]

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. Grind cutting reel to remove [...]

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 . Refer to Cutting Unit Operator ’s Manual for roller options.[...]

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. The dual knob bedknife - - to - - reel adjustment system in- corporated in this cut[...]

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. Check Reel Bearing Adjustment 1. Remove hydraulic reel motor from cutting unit (see Hydraulic Reel Motor Removal in the Service and Re- p[...]

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). If the side plates are disassembled or as the cutting reel wears, a limited amount of side plate adjust- ment i[...]

Rev . E Reelmaster 6500 - - D/6700 - - D DP A Cutting Units Page 7.2 - - 14 This page is intentionally blank.[...]

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. Removal 1. Park machine on a clean and[...]

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 . D While backlapping, the reels may stall and then restart. D Do not attempt to restart reel[...]

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 . After adjustments have been completed, repeat steps 5 - - 8[...]

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. Retaining ring (2 used) 10. Bedbar adjuster screw (2 used) 1 1. Washer (2 used) 12. Comp[...]

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. 7. Inspect flange bushings (item 15) and rubber bush- ings (item 1[...]

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. Bedbar adjuster screw 1 1. Washer 14 to 16 ft - - lb ( 1 9t o2 1N - - m ) Antiseize[...]

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). Discard screws. Remove bedknife [...]

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. Lock nut (2 used) 8. Shoulder bolt (3 used per side plate) 9. LH side plate 1[...]

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. 2. Remove the cutting unit from the machine and place on a flat work area.[...]

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. 5. [...]

Rev . E Units DP A Cutting Reelmaster 6500 - - D/6700 - - D DP A Cutting Units Page 7.2 - - 25 This page is intentionally blank.[...]

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. Bearing shoulder 10. Reel spider Figure 27 85 to 95 ft - - lb (1 15 to[...]

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. 2. Inspect the reel shaft as follows. If reel damage is de- tected, repl[...]

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. Note: When grinding, be careful to not over[...]

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. 2. Remove the cutting unit from the machine and place on a level working surface. Use cutting [...]

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. 2. Remove the cutting unit from the machine and place on a level working sur[...]

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. Outer seal 8. Retaining ring 9. Outer oil seal 10. Roller washer Figure 31 v 9 10 8 7 1 2 3 4 6 5[...]

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 . Press on other end of roller s haft to remove re- mainin[...]

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. Remove bearing lock nut from each end of roller shaft. 2. Loosely secure roller assembly in bench vise and lightly tap one end of roller shaft until outer seals and bearing are removed from opposi[...]

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. 4. Install new bearing and outer seals into second end of roller tube: A. [...]

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. Brush bearing housing (drive) 8. Spacer 9. Flat washer (as required) 10. Driven pulley 1 1. Flange[...]

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. 2. T o remove roller brush from brush shaft: A. Remove the non - - drive brush beari[...]

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. Install the bearing so that the bearing seal is closest to t[...]

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 . 6. Lubricate g rease fittings on brush housings[...]

Rev . E Reelmaster 6500 - - D/6700 - - D DP A Cutting Units Page 7.2 - - 40 This page is intentionally blank.[...]

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 .............................. Groomer Height/Depth Adjustment 4 ............ SERVICE AND [...]

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. IMPORT ANT[...]

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). Broken or damaged idler spring. The groomer drive [...]

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 . NOTE: The Groomer Installation Instructions provide information regardin[...]

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 . NOTE: The Groomer Installation Instructions provide information [...]

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. Lock nut 1 1. Flange head screw 12. Drive pulley 13. Retaining ring 14. Extension[...]

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. Locate and retrieve square key (item 4) from drive shaft. NOTE: T o prevent groomer shaft from turning when removing driven pulley , use wrench on shaft flats to hold groomer sha[...]

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. Position pivot hub to cutting unit. C. Secure groomer components to cutting unit side plate with[...]

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. Flange head screw 12. Drive pulley 13. Retaining ring 14. Extension spring 15. Pivot hub a[...]

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. 2. Apply a light coating of grease to seal lips in groomer plate assemblies.[...]

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. 1 1). Blades that are rounded to the midpoint of the blade tip mus[...]

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). 1. Groomer shaft 2. Broomer strap Figure 13 1 2 2 2 2 DP A Groomer[...]

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. O - - ring (7” cutting unit only) 4 3 1 2 9 10 8 5 6 7 Apply Grease to Seal Lip NOTE: The [...]

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. Slide idler plate from pivot hub. 3. Remove retaining ring (item[...]

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. Upper ramp 10. Bushing 1 1. Flat washer 12. Groomer adjuster 13. Detent spring 14. [...]

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 Model 03806 & 03807 Serial No. 220000001 & Up Electr[...]

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 RELAY 2A RUN (ETR) SOLENOID OUTPUTS INPUTS B A I Y X RUN ST ART S 3C 2B 3M ENGINE WA TER TEMP SENSOR ST ART - - KEY SWITCH ST ARTER 1S 1B SV1 SV2 SV3 1E [...]

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-D/6700-D Page 8 - 4 Electrical Diagrams[...]

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 SWITCH #7 REEL #6 REEL SV7 SV6 Reelmaster 6500-D/6700-D Page 8 - 5 Electrical Diagrams[...]

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 #7 REEL #6 REEL SV7 SV6 Reelmaster 6500-D/6700-D Page 8 - 6 Electrical Diagrams[...]

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 Electrical Diagrams[...]

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/WHITE TO LEAK DETECTOR CONNECTOR OF MAIN HARNESS RED/YELLOW BLACK/YELLOW + -- (RED) ALARM TURF DEFENDER COMMUNICA TION PORT AND LOOPBACK CONNECTOR YELLOW [...]

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 Harness P24 J15 J16 J18 J19 J20 P39 P38 P27 P22 P23 J8 J9 P16 J17 J10 J1 1 J1 J14 J13 P42 P21 P43 P20 P33 P32 P31 P35 P34 P36 P28 P30 P40 P25 P41 P38 P[...]

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 Front Lift Arm Located on l eft hand front lift arm Cavity Wi re AB l a c k / W h i t e BB l a c k P1 1 Warnin g ligh t cluster Located under the con[...]

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 Solenoid Located on lift manifold Cavity W ir e A Red/Blue BB l a c k P31 SV2 Solenoid Located on lift manifold Cavity W ire A Orange/Blue BB l a c k P[...]

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 #6 Lift Arm Located on right side rear lift arm Cavity Wire A Red/Y ellow BB l a c k 123 Joystick Located under the control console Cavity Wi re 1B l [...]