Toro Reelmaster 6500-D, 6700-D (with Kubota engine) Service Repair Manual

Table of Content – Reelmaster 6500-D, 6700-D (with Kubota engine)

• Preface
• Table Of Contents
• 1 – Safety
• Safety Instructions
• 2 – Product Records and Maintenance
• Product Records
• Maintenance
• Equivalents and Conversions
• Torque Specifications
• 3 – Kubota Diesel Engine
• Introduction
• Specifications
• General Information
• Stopping The Engine
• Check Engine Oil
• Fill Fuel Tank
• Check Cooling System
• Adjustments
• Adjust Throttle Cable
• Adjust Alternator Belt
• Service and Repairs
• Bleed Fuel System
• Bleed Air from Fuel Injectors
• Change Engine Oil and Filter
• Clean Radiator and Oil Cooler
• Fuel Filter, Water Separator
• Replace Fuel Prefilter
• Fuel System
• Air Filter
• Radiator
• Engine
• Kubota Diesel Engine Workshop Manual (S.N below 250000000)
• Kubota 05 E2B Series Workshop Manual (S.N 250000001-270999999)
• Kubota 05-E3B Series Workshop Manual (S.N 280000001 and up)
• 4 – Hydraulic System
• Specifications
• General Information
• Hydraulic Hoses
• Hydraulic Fitting Installation
• Pushing or Towing Traction Unit
• Check Hydraulic Fluid
• Hydraulic Schematics
• Hydraulic Flow Diagrams
• Traction Circuit
• Lower Cutting Units
• Raise Cutting Units
• Mow and Backlap
• Right and Left Turns
• Special Tools
• Troubleshooting
• General Troubleshooting
• Difficult to Find Neutral
• Traction Pedal is Sluggish
• Transmission or Hydraulic System is Operating Hot
• Transmission Operates in One Direction Only
• Transmission Response Sluggish
• Transmission Will Not Operate in Either Direction
• Wheel Motor Turns While Unloaded, But Slows Down or Stops When Load Applied
• Wheel Will Not Turn
• Wheel Motor Will Not Hold Load When System is in Neutral
• Excessive Wheel Motor Case Drain Flow
• Noisy Gear Pump Caused by Cavitation
• Foaming Oil
• Front (Rear) Reels Will Not Turn
• Front (Rear) Reels Do Not Turn or Turn Too Slow
• Front (Rear) Reels Turn Too Fast
• Front (Rear) Reels Turn in Only One Direction
• Front Reels Stop or Won’t Start – During Backlap Only
• Front (Rear) Reels Stop Under Load
• Cutting Units Will Not Raise
• Cutting Units Raise, But Will Not Stay Up
• Cutting Units Lower Too Fast or Too Slow
• Cutting Units Will Not Lower
• Testing
• Before Performing Hydraulic Tests
• Precautions for Hydraulic Testing
• TEST NO. 1: Traction Circuit Charge Pressure
• TEST NO. 2: Traction Circuit Pressure
• TEST NO. 3: Cutting Unit Drive Circuit Pressure
• TEST NO. 4: Gear Pump Section P3 Flow and Relief Valve Pressure
• TEST NO. 5: Gear Pump Section P1 & P2 Flow
• TEST NO. 6: Reel Drive Motor Cross-Over Relief Pressure
• TEST NO. 7: Reel Drive Motor Efficiency
• Adjustments
• Adjust Manifold Relief Valve (R1 and R2)
• Adjust Traction Drive for Neutral
• Adjust Cutting Unit Drop Rates
• Service and Repairs
• General Precautions for Removing and Installing Hydraulic System Components
• Check Hydraulic Lines and Hoses
• Flush Hydraulic System
• Charge Hydraulic System
• Change Hydraulic Fluid
• Replace Hydraulic Oil Filter
• Piston Pump (Traction Pump)
• Servo Control
• Gear Pump
• Wheel Motor
• 4WD Rear Axle Motor
• Reel Motor
• Hydraulic Control Manifolds
• Hydraulic Control Manifold Service
• Lift Cylinders
• Lift Cylinder Service
• Steering Cylinder (2WD)
• Steering Cylinder (4WD)
• Power Steering
• Steering Valve
• Steering Valve Service
• Solenoid Valve SV10 and SV11 Service (RM 6700-D Only)
• Hydraulic Reservoir
• Hydraulic Oil Cooler
• 5 – Electrical System
• Special Tools
• Troubleshooting
• Understanding the Controllers
• Understanding the Diagnostic Lamps
• Using the ACE Diagnostic Display
• TurfDefender Leak Detector
• Leak Detector Troubleshooting Guide
• Starting Problems
• General Run and Transport Problems
• Cutting Unit Operating Problems
• Electrical System Quick Checks
• Battery Test (Open Circuit Test)
• Charging System Test
• Voltage Drop Testing
• Glow Plug System Test
• Starting System Test
• Component Testing
• Ignition Switch
• Glow and Start Relays
• Fuses
• Hydraulic Valve Solenoids
• High Temperature Warning and Shutdown Switch
• Warning Light Cluster
• Run (ETR) Solenoid
• Fuel Gauge Sender
• Fuel Gauge
• Temperature Sender
• Temperature Gauge
• Hour Meter
• Electronic Controller(s)
• Parking Brake Switch
• Engine Low Oil Pressure Switch
• Speedometer Sensor
• Speedometer
• Reels Enable, Disable Switches
• Reel Backlap Switches
• Traction Neutral Switch
• Seat Sensor
• Joystick Raise and Lower, Mow Switches
• Cutting Unit Down Sensor(s)
• Cutting Unit #6 and #7 Reel On, Off Solenoids
• Service and Repairs
• Battery Storage
• Battery Care
• Battery Service
• Speedometer Sensor Replacement
• Installing Optional Lighting
• 6 – Axles, Planetaries and Brakes
• Specifications
• Maintenance
• Changing Planetary Gear Drive Lubricant
• Changing Rear Axle Lubricant
• Adjustments
• Service Brake Adjustment
• Rear Wheel Toe-in Adjustment
• Repairs
• Planetary Wheel Drive Service
• Brake Service
• Rear Axle Service (2WD)
• Rear Axle Service (4WD)
• Bevel Gear Case and Axle Case
• Differential Shafts
• Axle Shafts
• Input Shaft, Pinion Gear
• Differential Gear
• Pinion Gear to Ring Gear Engagement
• 7 – Cutting Units
• Specifications
• Special Tools
• Troubleshooting
• Set-up and Adjustments
• Bedknife to Reel Adjustment
• Adjusting and Leveling Rollers
• Front Grass Shield Adjustment
• Rear Shield Adjustment
• Lift Chain Adjustment
• Adjusting Turf Compensation Spring
• Adjusting Front Cutting Unit Travel
• Daily Adjustments
• Service and Repairs
• Backlapping
• Bedbar Removal and Installation
• Bedknife Replacement and Regrinding
• Preparing Reel for Regrinding
• Reel and Reel Bearings
• Roller and Frame Service
• Roller Bearing and Seal Replacement
• Cutting Unit Installation
• Lubrication
• 7.1 – Groomer
• Troubleshooting
• Adjustments
• Groomer Height, Depth Adjustment
• Service and Repairs
• Groomer Belt Replacement
• Groomer Reel
• Groomer Reel Service
• Idler Assembly
• Groomer Drive
• Groomer Height of Cut Assembly
• 7.2 – DPA Cutting Units
• Specifications
• General Information
• Cutting Unit OperatorŁs Manual
• Special Tools
• Factors That Can Affect Cutting Performance
• Set Up and Adjustments
• Characteristics
• Reel Bearing Adjustment
• Leveling Rear Roller
• Service and Repairs
• Hydraulic Reel Motor
• Backlapping
• Bedbar Assembly
• Bedbar Adjuster Service
• Bedknife Replacement and Grinding
• Reel Assembly Removal and Installation
• Reel Assembly Service
• Preparing Reel for Grinding
• Front Roller
• Rear Roller
• Roller Service (Greasable Bearings with Retaining Ring)
• Roller Service (Greasable Bearings with Bearing Nut)
• Rear Roller Brush (Optional)
• 7.3 DPA Groomer
• Grooming Performance
• Troubleshooting
• Adjustments
• Groomer Height, Depth Adjustment
• Service and Repairs
• Groomer Drive Belt Replacement
• Groomer Plate Assembly
• Groomer Reel
• Groomer Reel Service
• Groomer Pivot Hub
• Height Adjuster Assembly
• 8 – Electrical Diagrams
• Electrical Schematics (RM6500)
• Electrical Schematics (RM6700)
• Ignition Switch Circuit (20A fuse)
• Controller #1 Power Circuit (10A fuse)
• Controller #1 Logic Circuit (5A fuse)
• RM6700 Controller #2 Power Circuit (15A fuse)
• Accessory Power and Controller #2 Logic Circuit (7.5A fuse)
• Starter, Glow Plugs and Alternator Circuits (Fuseable Links)
• Optional Lighting Circuit (10A fuse)
• Optional Turf Defender Leak Detector
• Wire Harness and Electrical Connector Drawings
• Wire Harnesses
• Electrical Connector Drawing
• Secondary (#2) Electrical Controller Harness and Electrical Connector Drawing