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

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

Preface
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