Toro 03863 Reelmaster 6500, 03864 Reelmaster 6700 T, 03681 Operator's Manual

FormNo.3359-861RevA

8and11BladeDPACuttingUnits
with7inchReels

Reelmaster

ModelNo.03863—SerialNo.280000001andUp

ModelNo.03864—SerialNo.280000001andUp

®

6500&6700TractionUnits

Registeratwww.T oro.com.OriginalInstructions(EN)

Introduction

Readthisinformationcarefullytolearnhowtooperate
andmaintainyourproductproperlyandtoavoidinjury
andproductdamage.Youareresponsibleforoperating
theproductproperlyandsafely .

YoumaycontactTorodirectlyatwww .Toro.comfor
productandaccessoryinformation,helpndinga
dealer,ortoregisteryourproduct.

Wheneveryouneedservice,genuineT oroparts,or
additionalinformation,contactanAuthorizedService
DealerorToroCustomerServiceandhavethemodel
andserialnumbersofyourproductready .Figure1
identiesthelocationofthemodelandserialnumbers
ontheproduct.Writethenumbersinthespace
provided.

Figure1

1.Locationofthemodelandserialnumbers

Figure2

1.Safetyalertsymbol

Thismanualuses2otherwordstohighlightinformation.
Importantcallsattentiontospecialmechanical
informationandNoteemphasizesgeneralinformation
worthyofspecialattention.

Contents

Introduction.................................................................2

Safety...........................................................................3

SafetyandInstructionalDecals.............................3

Setup............................................................................4

1Inspection.........................................................5

2RemovingtheTipperAssemblies.......................5

3MounttheLiftBracketsandChains....................5

4CuttingUnitKickstand......................................6

5AdjustingtheRearShield...................................7

6MounttheCounterWeights...............................7

7InstallingtheCuttingUnits................................8

ProductOverview......................................................10

Specications.....................................................10

CuttingUnitAccessoriesandKits(seeparts

catalogforpartnumbers)................................11

Operation...................................................................12

Adjustments.......................................................12

HeightofCutChartTerms.................................13

HeightofCutChart............................................14

ServicingBedknife.............................................16

Maintenance...............................................................18

Lubrication.........................................................18

AdjustingtheReelBearings................................18

ServicingtheBedbar...........................................19

ServicingtheRoller............................................20

ModelNo.

SerialNo.

Thismanualidentiespotentialhazardsandhas
safetymessagesidentiedbythesafetyalertsymbol
(Figure2),whichsignalsahazardthatmaycauseserious
injuryordeathifyoudonotfollowtherecommended
precautions.

©2008—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420

Contactusatwww.Toro.com.

2

PrintedintheUSA.

AllRightsReserved

Safety

Hazardcontrolandaccidentpreventionare
dependentupontheawareness,concern,and
propertrainingofthepersonnelinvolvedinthe
operation,transport,maintenance,andstorageof
themachine.Improperuseormaintenanceofthe
machinecanresultininjuryordeath.Toreduce
thepotentialforinjuryordeath,complywiththe
followingsafetyinstructions.

•Read,understand,andfollowallinstructionsinthe
tractionunitoperatorsmanualbeforeoperatingthe
cuttingunit.

•Read,understand,andfollowallinstructionsinthis
operatorsmanualbeforeoperatingthecuttingunit.

•Neverallowchildrentooperatethetractionunitor
thecuttingunits.Donotallowadultstooperate
tractionunitorcuttingunitswithoutproper
instruction.Onlytrainedoperatorswhohaveread
thismanualshouldoperatethecuttingunits.

•Neveroperatethecuttingunitswhenunderthe
inuenceofdrugsoralcohol.

•Keepallshieldsandsafetydevicesinplace.Ifa
shield,safetydeviceordecalisillegibleordamaged,
repairorreplaceitbeforeoperationiscommenced.
Alsotightenanyloosenuts,bolts,andscrewsto
ensurecuttingunitisinsafeoperatingcondition.

•Alwayswearsubstantialshoes.Donotoperate
cuttingunitswhilewearingsandals,tennisshoes,
sneakersorshorts.Also,donotwearloosetting
clothingwhichcouldgetcaughtinmovingparts.
Alwayswearlongpantsandsubstantialshoes.

Wearingsafetyglasses,safetyshoesandahelmetis
advisableandrequiredbysomelocalordinancesand
insuranceregulations.

•Removealldebrisorotherobjectsthatmightbe
pickedupandthrownbythecuttingunitreelblades.
Keepallbystandersawayfromtheworkingarea.

•Ifthecuttingbladesstrikeasolidobjectortheunit
vibratesabnormally,stopandshuttheengineoff.
Checkcuttingunitfordamagedparts.Repairany
damagebeforerestartingandoperatingthecutting
unit.

•Lowerthecuttingunitstothegroundandremove
keyfromignitionswitchwhenevermachineisleft
unattended.

•Besurecuttingunitsareinsafeoperatingcondition
bykeepingnuts,boltsandscrewstight.

•Removekeyfromignitionswitchtoprevent
accidentalstartingoftheenginewhenservicing,
adjustingorstoringthemachine.

•Performonlythosemaintenanceinstructions
describedinthismanual.Ifmajorrepairsare
everneededorassistanceisdesired,contactan
AuthorizedT oroDistributor.

•Toensureoptimumperformanceandsafety,always
purchasegenuineTororeplacementpartsand
accessoriestokeeptheToroallTORO.Neveruse

"will-t"replacementpartsandaccessories
madebyothermanufacturers.Lookforthe

Torologotoassuregenuineness.Usingunapproved
replacementpartsandaccessoriescouldvoidthe
warrantyofTheToroCompany.

SafetyandInstructionalDecals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaof
potentialdanger.Replaceanydecalthatisdamagedorlost.

93-6688

1.Warning—readthe
instructionsbefore
servicingorperforming
maintenance.

2.Cuttinghazardofhandor
foot—stoptheengineand
waitformovingpartsto
stop.

3

Setup

LooseParts

Usethechartbelowtoverifythatallpartshavebeenshipped.

ProcedureDescription

1
2

3

4

5
6
7

Cuttingunit

Nopartsrequired

Liftchain5/7
Chainbracket5/7
U-bolt
Nut
Screw5/7
Washer
Nut

Kickstand(suppliedwithtractionunit)

Nopartsrequired

Nopartsrequired

LargeO-ring5/7

Qty.

1Inspectthecuttingunit

–

5/7

10/14

5/7
5/7

1

–

–

Removethetipperassemblies

Mountliftbracketsandchains

Usethekickstandwhentippingthe
cuttingunit

Adjusttherearshield

Mountthecounterweights

Installthecuttingunits.

Use

MediaandAdditionalParts

Description

Partscatalog1
Operator’sManual
CerticateofCompliance

Note:Determinetheleftandrightsidesofthemachine
fromthenormaloperatingposition.

Qty.

Use

1
1

Reviewthematerialandsaveinanappropriateplace:

4

1

Inspection

Partsneededforthisprocedure:

1

Cuttingunit

Procedure

Afterthecuttingunitisremovedfromthebox,inspect
thefollowing:

1.Checkeachendofthereelforgrease.Greaseshould
bevisiblyevidentinthereelbearingsandinternal
splinesofthereelshaft.

2.Ensurethatallnutsandboltsaresecurelytightened.

3.Makesurethecarrierframesuspensionoperates
freelyanddoesnotbindwhenmovedbackandforth.

2

RemovingtheTipper
Assemblies

NoPartsRequired

Procedure

Thetipperassembliesmustberemovedfromthe#1,#2
and#3liftarmstoavoidinterferencewiththecutting
unitcarrierframes.

1.Removethelocknutandwashersecuringthepivot
rodtothe#2liftarm(Figure3).Removethe
pivotrodandspringfromtheliftarm.Repeatthe
procedureonthe#1and#3liftarms.

Figure3

1.Pivotrod2.Tippersupportbracket

Note:Thetipperbracketw/rollerandthetipper
supportbracketsarenotrequiredwhenoperating
theDPAcuttingunits(Figure3).Theymaybe
removedifdesired.

2.Disconnecttheliftchainsfromthecuttingunits,if
attached.

w/roller

3

MounttheLiftBracketsand
Chains

Partsneededforthisprocedure:

5/7Liftchain

5/7Chainbracket

U-bolt

5/7

10/14

Procedure

Nut

5/7Screw

Washer

5/7

Nut

5/7

MountachainbrackettoeachliftarmwithaU-boltand
2nuts.Positionthebracketsasfollows:

Note:RefertoFigure10todeterminetheliftarm
numberbeingdescribed.

1.Onliftarms#1,#4and#5,positionthechain
bracketsandU-bolts15inchesbehindthecenter
lineofthepivotknuckle(Figure4).Onliftarms#1
and#5thebracketsshouldberotatedtotheright
10degreesfromvertical(Figure4).Onliftarm#4

5

thebracketshouldberotatedtotheleft10degrees
fromvertical(Figure4).

Figure6

4.TightenalltheU-boltnutsto38–48ft-lbs.

Figure4

2.Onliftarms#2and#3,positionthebracketsand
U-bolts15inchesbehindthecenterlineofthepivot
knuckle(Figure5).Rotatethebrackets45degreesto
theoutboardsideofthemachine.

5.Mountaliftchaintoeachchainbracketwithascrew,
washerandnut,positioningasshowninFigure7

Figure7

1.Liftchain2.Chainbracket

Figure5

3.Onliftarms#6and#7,positionthebracketsand
U-bolts14.5inchesbehindthecenterlineofthe
pivotknuckle(Figure6).Rotatethebrackets10
degreestotheoutboardsideofthemachine.

4

CuttingUnitKickstand

Partsneededforthisprocedure:

1

Kickstand(suppliedwithtractionunit)

Procedure

Wheneverthecuttingunithastobetippedtoexposethe
bedknife/reel,propuptherearofthecuttingunitwith
thekickstand(suppliedwiththetractionunit)tomake

6

surethenutsonthebackendofthebedbaradjusting
screwsarenotrestingontheworksurface(Figure8).

Figure8

1.Cuttingunitkickstand

1.Rearshield

Figure9

2.Capscrew

5

AdjustingtheRearShield

NoPartsRequired

Procedure

Undermostconditions,bestdispersionisattained
whentherearshieldisclosed(frontdischarge).When
conditionsareheavyorwet,rearshieldmaybeopened.

Toopentherearshield(Figure9),loosenthecapscrew
securingtheshieldtotheleftsideplate,rotatetheshield
totheopenpositionandtightenthecapscrew .

6

MounttheCounterWeights

NoPartsRequired

Procedure

Allcuttingunitsareshippedwiththecounterweight
mountedtotheleftendofthecuttingunit.Usethe
followingdiagramtodeterminethepositionofthe
counterweightsandreelmotors.

Figure10

1.Onthe#2,#4and#6cuttingunits,removethe2
capscrewssecuringthecounterweighttotheleft
endofthecuttingunit.Removethecounterweight
(Figure11).

7

Figure11

1.Counterweight

2.Onrightendofcuttingunit,removetheplasticplug
fromthebearinghousing(Figure12).

3.Removethe2capscrewsfromtherightsideplate
(Figure12).

7

InstallingtheCuttingUnits

Partsneededforthisprocedure:

5/7LargeO-ring

Procedure

1.Insertathrustwasherontohorizontalshaftofpivot
knuckleasshowninFigure13.

Figure12

1.Plasticplug

4.Installthecounterweighttotherightendofthe
cuttingunitwiththe2screwspreviouslyremoved.

5.Looselyinstallthe2reelmotormountingcapscrews
totheleftsideplateofthecuttingunit(Figure12).

2.Capscrew(2)

Figure13

1.Carrierframe

2.Pivotknuckle

3.Liftarmsteeringplate

2.Insertthehorizontalshaftofthepivotknuckleinto
themountingtubeofthecarrierframe(Figure13).

3.Securepivotknuckletocarrierframewithathrust
washer,atwasherandaangeheadcapscrew
(Figure13).

4.Insertathrustwasherontoverticalshaftofpivot
knuckle(Figure13).

5.Ifremoved,inserttheverticalshaftofthepivot
knuckleintoliftarmpivothub(Figure13).Guide
thepivotknuckleinplacebetweenthetworubber
centeringbumpersintheundersideoftheliftarm
steeringplate.

6.Insertthelynchpinintothecrossholeonthepivot
knuckleshaft(Figure13).

7.Securetheliftarmchaintothecuttingunitchain
bracket(Figure14)withthesnapperpinasfollows:

4.Lynchpin

5.Steeringlockingpin

A.Oncuttingunits#1,4,5,6and7,onlyuse6of

thechainlinks.

B.Oncuttingunits#2and3,useall7ofthechain

links.

8