Toro Reelmaster 6500-D 6700-D (Peugeot Engine) Mower Service Repair Workshop Manual

PART NO. 95871SL Rev. D Service Manual Reelmaster R 6500–D/6700–D Preface (With Peugeot Engine) The purpose of this publication is to provide the service technician with information for troubleshooting, testing, and repair of major systems and components on the Reelmaster 6500–D and 6700–D. REFER TO THE TRACTION UNIT AND CUTTING UNIT OPERATOR’S MANUALS FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUC- TIONS. Space is provided in Chapter 2 of this book to insert the Operator’s Manuals and Parts Catalogs for your machine. Replacement Operator’s Manuals are available by sending complete Model and Serial Num- ber to: The Toro Company 8111 Lyndale Avenue South Minneapolis, MN 55420 The Toro Company reserves the right to change product specifications or this publication without notice. ING, or CAUTION, PERSONAL SAFETY This safety symbol means DANGER, WARN- INSTRUCTION. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions may result in personal injury. NOTE: A NOTE will give general information about the correct operation, maintenance, service, testing or repair of the machine. IMPORTANT: The IMPORTANT notice will give important instructions which must be followed to pre- vent damage to systems or components on the machine. E The Toro Company – 1996, 1998, 1999, 2002

Reelmaster 6500–D/6700–D

Table Of Contents Chapter 1 – Safety Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 1 Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 – 4 Chapter 2 – Product Records and Manuals Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 1 Equivalents and Conversions . . . . . . . . . . . . . . . . 2 – 2 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 2 – 3 Maintenance Quick Reference Aid . . . . . . . . . . . . 2 – 7 Equipment Operation and Service History Report . . . . . . . . . . . . . . . . 2 – 11 Chapter 3 – Engine Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 2 Identification and Specifications . . . . . . . . . . . . . . 3 – 3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 11 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 17 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 18 Testing and Inspection . . . . . . . . . . . . . . . . . . . . . 3 – 27 Fuel System Service . . . . . . . . . . . . . . . . . . . . . . . 3 – 33 Timing Belt Replacement . . . . . . . . . . . . . . . . . . . 3 – 36 Injection Pump Timing . . . . . . . . . . . . . . . . . . . . . 3 – 40 Preparation for Engine Repair . . . . . . . . . . . . . . . 3 – 42 Engine Removal and Installation . . . . . . . . . . . . 3 – 43 Engine Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 45 Chapter 4 – Hydraulic System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 2 General Information . . . . . . . . . . . . . . . . . . . . . . . . 4 – 3 Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . 4 – 6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 18 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 20 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 29 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 40 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 42 Chapter 5 – Electrical System Wiring Schematics (S/N 50001 – 59999) . . . . . . . . . . 5 – 2 Wiring Schematics (S/N 60001 & UP) . . . . . . . . . . . . 5 – 8 Main Wire Harness Connector Diagram . . . . . . 5 – 18 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 19 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 21 Electrical System Quick Checks . . . . . . . . . . . . . 5 – 33 Component Identification and Testing . . . . . . . . 5 – 35 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 49 Chapter 6 – Axles, Planetaries and Brakes Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 3 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 5 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 6 Fairfield Torque–Hub Service Manual Chapter 7 – Cutting Units Model 03853 Model 03854 Model 03856 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 5 Set–up and Adjustments . . . . . . . . . . . . . . . . . . . . 7 – 7 Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 7 – 12 Chapter 8 – Cutting Units Model 03857, S/N 80001 –80301 Model 03858, S/N 80001 – 81418 Model 03859, S/N 80001 – 81992 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 5 Set–up and Adjustments . . . . . . . . . . . . . . . . . . . . 8 – 7 Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 8 – 15 Chapter 8.1 – Cutting Units Model 03857, S/N 80302 & Up Model 03858, S/N 81419 & Up Model 03859, S/N 81993 & Up Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 – 2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1– 3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 – 5 Set–up and Adjustments . . . . . . . . . . . . . . . . . . 8.1 – 7 Service and Repairs . . . . . . . . . . . . . . . . . . . . . 8.1 – 21 Chapter 9 – Wiring Harness Diagram Wire List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 2 Wire Harness Diagram . . . . . . . . . . . . . . . . . . . . . . 9 – 5 Reelmaster 6500–D/6700–D Rev. C Safety Product Records and Manuals Engine Hydraulic System Electrical System Axles, Planetaries Cutting Units 03853, 03854, 03856 and Brakes Cutting Units 03857, 03858, 03859

Reelmaster 6500–D/6700–D

Chapter 1 Safety Table of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 1 Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safety Instructions The REELMASTER 6500-D and 6700–D was tested and certified by TORO for compliance with the B71.4-1990 specifications of the American National Standards Institute when ballast is added. See Opera- tor’s Manual for ballast requirements. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, con- cern, and proper training of the personnel involved in the operation, transport, maintenance, and storage of the machine. Improper use or maintenance of the machine can result in injury or death. To reduce the potential for injury or death, comply with the following safety instructions. Maintenance and Service . . . . . . . . . . . . . . . . . . . . . 3 SAFETY AND INSTRUCTION DECALS . . . . . . . . . . 4 CAUTION TO REDUCE THE POTENTIAL FOR INJURY OR DEATH, COMPLY WITH THE FOLLOWING SAFETY INSTRUCTIONS. Safety3 Before Operating 1. Read and understand the contents of this manual before starting and operating the machine. Become familiar with the controls and know how to stop the machine and engine quickly. A free replacement manual is available by sending the complete model and serial number to: The Toro Company 8111 Lyndale Avenue South Minneapolis, Minnesota 55420–1196. Use the Model and Serial Number when referring to your machine. If you have questions about this Service Manual, please contact: The Toro Company Commercial Service Department 8111 Lyndale Avenue South Minneapolis, Minnesota 55420. 2. Never allow children to operate the machine. Do not allow adults to operate machine without proper instruction. Only trained operators who have read this manual should operate this machine. 3. Never operate the machine when under the influence of drugs or alcohol. 4. Keep all shields, safety devices and decals in place. If a shield, safety device or decal is defective, illegible or damaged, repair or replace it before operating the machine. Also tighten any loose nuts, bolts or screws to en- sure machine is in safe operating condition. 5. Always wear substantial shoes. Do not operate machine while wearing sandals, tennis shoes, sneakers or when barefoot. Do not wear loose fitting clothing that could get caught in moving parts and possibly cause personal injury. Wearing safety glasses, safety shoes, long pants and a helmet is advisable and required by some local ordinances and insurance regulations. 6. Assure interlock switches are adjusted correctly so engine cannot be started unless traction pedal is in NEUTRAL and cutting units are DISENGAGED. Reelmaster 6500–D/6700–D Page 1 – 1 Rev. B Safety

7. Remove all debris or other objects that might be picked up and thrown by the reels or fast moving components from other attached implements. Keep all by- standers away from operating area. 8. Since diesel fuel is highly flammable, handle it carefully: A. Use an approved fuel container. B. Do not remove fuel tank cap while engine is hot or running. C. Do not smoke while handling fuel. D. Fill fuel tank outdoors and only to within an inch of the top of the tank, not the filler neck. Do not overfill. E. Wipe up any spilled fuel. While Operating 9. Sit on the seat when starting and operating the machine. 10. Before starting the engine: A. Engage the parking brake. B. Make sure traction pedal is in NEUTRAL, throttle is in SLOW and the ENABLE / DISABLE switch is in DISABLE. C. After engine is started, release parking brake and keep foot off traction pedal. Machine must not move. If movement is evident, the neutral return mechanism is adjusted incorrectly; therefore, shut engine off and adjust until machine does not move when traction pedal is released. 11. Seating capacity is one person. Therefore, never carry passengers. 12. Do not run engine in a confined area without ade- quate ventilation. Exhaust fumes are hazardous and could possibly be deadly. 13. Check interlock switches daily for proper operation. If a switch fails, replace it before operating the machine. The interlock system is for your protection, so do not by- pass it. Replace all interlock switches every two years. 14. Using the machine demands attention and to pre- vent loss of control: A. Operate only in daylight or when there is good ar- tificial light. B. Drive slowly C. Watch for holes or other hidden hazards. D. Look behind machine before backing up. E. Do not drive close to a sand trap, ditch, creek or other hazard. F. Reduce speed when making sharp turns and turning on a hillside. G. Avoid sudden stops and starts. 15. Traverse slopes carefully. Do not start or stop sud- denly when traveling uphill or downhill. 16. Operator must be skilled and trained in how to drive on hillsides. Failure to use caution on slopes or hills may cause loss of control and vehicle to tip or roll possibly resulting in personal injury or death. On 4 wheel drive model, always use the seat belt and ROPS together. 17. If engine stalls or loses power and cannot make it to the top of a slope, do not turn machine around. Always back slowly straight down the slope. 18. DON’T TAKE AN INJURY RISK! When a person or pet appears unexpectedly in or near the mowing area, STOP MOWING. Careless operation, combined with terrain angles, ricochets, or improperly positioned guards can lead to thrown object injuries. Do not resume mowing until area is cleared. 19. Do not touch engine, muffler or exhaust pipe while engine is running or soon after it is stopped. These areas could be hot enough to cause burns. 20. If cutting unit strikes a solid object or vibrates abnor- mally, stop cutting units immediately, turn engine off, set parking brake and wait for all motion to stop. Inspect for damage. If reel or bedknife is damaged, repair or replace it before operating. Do not attempt to free blocked cutting unit by reversing reel direction. Damage to reel may result. 21. Before getting off the seat: A. Move traction pedal to neutral. B. Set parking brake. C. Disengage cutting units and wait for reels to stop. D. Stop engine and remove key from switch. E. Do not park on slopes unless wheels are chocked or blocked. Safety Page 1 – 2 Rev. B Reelmaster 6500–D/6700–D

Maintenance and Service 22. Before servicing or making adjustments, stop engine and remove key from the switch. 23. When changing attachments, tires or performing other service, use the correct blocks, hoists and jacks. Always chock or block the wheels and use jack stands or solid wood blocks to support the raised machine. If the machine is not properly supported by blocks or jack stands, the machine may move or fall, resulting in personal injury. 24. Make sure machine is in safe operating condition by keeping all nuts, bolts and screws tight. 25. Make sure all hydraulic line connectors are tight, and all hydraulic hoses and lines are in good condition before applying pressure to the system. 26. Keep body and hands away from pin hole leaks in hydraulic lines that eject high pressure hydraulic fluid. Use cardboard or paper to find hydraulic leaks. Hydrau- lic fluid escaping under pressure can penetrate skin and cause injury. Fluid accidentally injected into the skin must be surgically removed within a few hours by a doc- tor familiar with this form of injury or gangrene may result. 26. Before disconnecting or performing any work on the hydraulic system, all pressure in system must be re- lieved by stopping engine and lowering cutting units to the ground. 28. If major repairs are ever needed or assistance is de- sired, contact an Authorized Toro Distributor. 29. To reduce potential fire hazard, keep engine area free of excessive grease, grass, leaves and dirt. Clean protective screen on front of engine frequently. 30. If engine must be running to perform maintenance or an adjustment, keep hands, feet, clothing and other parts of the body away from cutting units and other moving parts. Keep everyone away. 31. Do not overspeed the engine by changing governor setting. To assure safety and accuracy, have an Autho- rized Toro Distributor check maximum engine speed. 32. Shut engine off before checking or adding oil to the crankcase. 33. Disconnect battery before servicing the machine. If battery voltage is required for troubleshooting or test procedures, temporarily connect the battery. 34. At the time of manufacture, the machine conformed to the safety standards for riding mowers. To assure op- timum performance and continued safety certification of the machine, use genuine Toro replacement parts and accessories. Replacement parts and accessories made by other manufacturers may result in non-conformance with the safety standards, and the warranty may be voided. Safety3 Reelmaster 6500–D/6700–D Page 1 – 3 Rev. B Safety

Safety and Instruction Decals The following safety and instruction decals are affixed to the traction unit. If any decal becomes illegible or damaged, install a new decal. Part numbers are listed below and in your Parts Catalog. UNDER FLOOR PLATE (Part No. 93–6693) WARNING: Moving Parts under floor plate IN TOOL BOX (Part No. 93–3728) Quick Reference Aid ON LEFT FENDER (Part No. 93–6680) Diesel Fuel Only INSIDE CONTROL BOX (Part No. 93–1268) Operating Instructions ON RIGHT FENDER (Part No. 93–6686) Hydraulic Oil Only H.O.C. Selector INSIDE CONTROL BOX (Part No. 94–6349) Fuse Locations UNDER SEAT PLATE ON TOP OF STEERING TOWER (Part No. 98–8110) (Part No. 93–1263) Selecting Clip Rate & Solenoid Brake Operation & reel Control Lamp Wire Identification Safety Page 1 – 4 Rev. B Reelmaster 6500–D/6700–D

ON TOOL BOX (Part No. 93–1262) WARNING: Read Operating & Safety Instructions ON BACKLAP BRACKET (Part No. 93–1264) WARNING: Read Backlap, Operating & Safety Instructions ON LIFT ARMS (Part No. 93–6687) Do Not Step ON TOWER (Part No. 93–6699) Mowing Speed Control ON CONSOLES ON ROLL BAR ROOF (Part No. 93–6689) (Part No. 93–8050) WARNING: No Riders (Model 03804 only) WARNING: Fasten Seat Belt ON FRAME UNDER MUFFLER (Part No. 93–1265) WARNING: Hot Surface Do Not Touch! ON UNDERSIDE OF SEAT PLATE (Part No. 98–8108) Solenoid Wire Identification ON UNDERSIDE OF SEAT PLATE (Part No. 98–8109) ON ROLL BAR Solenoid Wire Identification (Part No. 92–7540) (Model 03804 only) ROPS Serial Tag Safety3 Reelmaster 6500–D/6700–D Page 1 – 5 Rev. B Safety

Safety Page 1 – 6 Reelmaster 6500–D/6700–D

Toro Reelmaster 6500-D 6700-D (Peugeot Engine) Mower Service Repair Workshop Manual

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