Toro 3431 User manual

FormNo.3363-235RevB
Reelmaster®2000TractionUnit
ModelNo.03431—SerialNo.310000001andUp
ToregisteryourproductordownloadanOperator'sManualorPartsCatalogatnocharge,gotowww.Toro.com.OriginalInstructions(EN)

Warning
CALIFORNIA
Proposition65Warning
Dieselengineexhaustandsomeofits
constituentsareknowntotheStateof
Californiatocausecancer,birthdefects,
andotherreproductiveharm.
ThissparkignitionsystemcomplieswithCanadian
ICES-002.
Important:Thisengineisnotequippedwitha
sparkarrestermufer.ItisaviolationofCalifornia
PublicResourceCodeSection4442touseoroperate
theengineonanyforest-covered,brush-covered,or
grass-coveredland.Otherstatesorfederalareas
mayhavesimilarlaws.
Introduction
Thismachineisaride-on,reel-bladelawnmower
intendedtobeusedbyprofessional,hiredoperatorsin
commercialapplications.Itisprimarilydesignedfor
cuttinggrassonwell-maintainedlawnsinparks,golf
courses,sportselds,andoncommercialgrounds.Itis
notdesignedforcuttingbrush,mowinggrassandother
growthalongsidehighways,orforagriculturaluses.
Readthisinformationcarefullytolearnhowtooperate
andmaintainyourproductproperlyandtoavoidinjury
andproductdamage.Youareresponsibleforoperating
theproductproperlyandsafely.
YoumaycontactTorodirectlyatwww.Toro.comfor
productandaccessoryinformation,helpndinga
dealer,ortoregisteryourproduct.
Wheneveryouneedservice,genuineToroparts,or
additionalinformation,contactanAuthorizedService
DealerorToroCustomerServiceandhavethemodel
andserialnumbersofyourproductready.Themodel
andserialnumbersarestampedintoaplatethatis
rivetedtotheframeofthemachine.Writethenumbers
inthespaceprovided.
ModelNo.
SerialNo.
Thismanualidentiespotentialhazardsandhas
safetymessagesidentiedbythesafetyalertsymbol
(Figure1),whichsignalsahazardthatmaycauseserious
injuryordeathifyoudonotfollowtherecommended
precautions.
Figure1
1.Safetyalertsymbol
Thismanualuses2otherwordstohighlightinformation.
Importantcallsattentiontospecialmechanical
informationandNoteemphasizesgeneralinformation
worthyofspecialattention.
©2010—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN554202
Contactusatwww.Toro.com.
PrintedintheUSA.
AllRightsReserved

Contents
Introduction.................................................................2
Safety...........................................................................4
SafeOperatingPractices.......................................4
ToroRidingMowerSafety....................................6
SoundPowerLevel...............................................7
SoundPressureLevel...........................................7
VibrationLevel....................................................7
SafetyandInstructionalDecals.............................7
Setup..........................................................................12
1InstallingtheRearWheel.................................13
2AdjustingtheRearCarrierFrame
Height............................................................13
3MountingtheCarrierFramestotheCutting
Units..............................................................14
4InstallingtheFrontLiftArms...........................14
5MountingtheCuttingUnitDrive
Motors...........................................................15
6MountingtheCuttingUnits.............................16
7InstallingtheCounterbalanceSprings...............16
8AddingRearBallast..........................................19
9ActivatingandChargingtheBattery..................20
10InstallingCECompliantDecals......................20
11Breaking-inaNewMachine............................21
ProductOverview......................................................21
Controls.............................................................21
Specications.....................................................23
Attachments/Accessories...................................23
Operation...................................................................24
CheckingtheEngineOilLevel............................24
AddingFuel.......................................................25
CheckingtheCoolingSystem..............................26
CheckingtheHydraulicFluid..............................27
CheckingtheTirePressure.................................28
CheckingtheReeltoBedknifeContact................28
ChecktheTorqueoftheWheelNuts...................28
BleedingtheFuelSystem....................................28
StartingandStoppingtheEngine........................29
CheckingtheOperationoftheInterlock
Switches.........................................................30
TowingtheTractionUnit....................................30
OperatingCharacteristics...................................30
SettingtheReelSpeed.........................................31
TrainingPeriod...................................................32
BeforeMowing..................................................32
TransportOperation..........................................32
InspectionandClean-UpAfterMowing..............32
StandardControlModule(SCM)........................32
Maintenance...............................................................35
RecommendedMaintenanceSchedule(s)................35
DailyMaintenanceChecklist...............................36
ServiceIntervalChart.........................................37
PremaintenanceProcedures....................................37
RemovingtheHood...........................................38
Lubrication.............................................................38
GreasingtheBearingsandBushings....................38
EngineMaintenance...............................................40
ServicingtheAirCleaner....................................40
ChangingtheEngineOilandFilter.....................40
FuelSystemMaintenance.......................................41
CheckingtheFuelLinesandConnections...........41
DrainingWaterfromtheWaterSeparator............41
ReplacingtheFuelFilterCanister........................42
BleedingAirfromtheFuelInjectors...................42
ElectricalSystemMaintenance................................43
ServicingtheBattery...........................................43
Fuses..................................................................43
DriveSystemMaintenance.....................................44
AdjustingtheTractionDriveforNeutral.............44
AdjustingtheNeutralSwitch..............................45
CoolingSystemMaintenance..................................45
RemovingDebrisfromtheCooling
System............................................................45
BrakeMaintenance.................................................46
AdjustingtheParkingBrake................................46
BeltMaintenance....................................................47
TensioningtheAlternatorBelt............................47
TensioningtheHydraulicPumpBelt...................47
ControlsSystemMaintenance.................................48
AdjustingtheTractionPedal...............................48
AdjustingtheTractionPedalDamper..................48
HydraulicSystemMaintenance...............................49
ChangingtheHydraulicFluid.............................49
HydraulicSystemTestPorts...............................50
CuttingUnitSystemMaintenance...........................50
BacklappingtheCuttingUnits............................50
Storage.......................................................................51
PreparingtheTractionUnit................................51
StoringtheBattery..............................................51
PreparingtheEngine..........................................51
Schematics.................................................................53
3

Safety
ThismachinemeetsorexceedsCENstandard
EN836:1997,ISOstandard5395:1990,andANSI
B71.4-2004specicationsineffectattimeof
production,whenequippedwithrearweight.Refer
tothesectioninthismanualonInstallingRear
Weight.
Improperuseormaintenancebytheoperator
orownercanresultininjury.Toreducethe
potentialforinjury,complywiththesesafety
instructionsandalwayspayattentiontothesafety
alertsymbol,whichmeansCaution,Warning,or
Danger—personalsafetyinstruction.Failureto
complywiththeinstructionmayresultinpersonal
injuryordeath.
SafeOperatingPractices
ThefollowinginstructionsarefromtheCENstandard
EN836:1997,ISOstandard5395:1990,andANSI
B71.4-2004.
Training
•Readtheoperator’smanualandothertraining
materialcarefully.Befamiliarwiththecontrols,
safetysigns,andtheproperuseoftheequipment.
•Neverallowchildrenorpeopleunfamiliarwiththese
instructionstouseorservicethemower.Local
regulationsmayrestricttheageoftheoperator.
•Nevermowwhilepeople,especiallychildren,orpets
arenearby.
•Keepinmindthattheoperatororuserisresponsible
foraccidentsorhazardsoccurringtootherpeopleor
theirproperty.
•Donotcarrypassengers.
•Alldriversandmechanicsshouldseekandobtain
professionalandpracticalinstruction.Theowneris
responsiblefortrainingtheusers.Suchinstruction
shouldemphasizethefollowing:
–Theneedforcareandconcentrationwhen
workingwithride-onmachines
–Controlofaride-onmachineslidingonaslope
willnotberegainedbytheapplicationofthe
brake.Themainreasonsforlossofcontrolare
asfollows:
◊Insufcientwheelgrip
◊Beingdriventoofast
◊Inadequatebraking
◊Thetypeofmachineisunsuitableforitstask
◊Lackofawarenessoftheeffectofground
conditions,especiallyslopes
◊Incorrecthitchingandloaddistribution
•Theowner/usercanpreventandisresponsiblefor
accidentsorinjuriesoccurringtohimselforherself,
otherpeople,orproperty.
Preparation
•Whilemowing,alwayswearsubstantialfootwear,
longtrousers,hardhat,safetyglasses,andear
protection.Longhair,looseclothing,orjewelrymay
gettangledinmovingparts.Donotoperatethe
equipmentwhenbarefootorwearingopensandals.
•Thoroughlyinspecttheareawheretheequipment
istobeusedandremoveallobjectswhichmaybe
thrownbythemachine.
•Warning—Fuelishighlyammable.Takethe
followingprecautions:
–Storefuelincontainersspecicallydesignedfor
thispurpose.
–Refueloutdoorsonlyanddonotsmokewhile
refuelling.
–Addfuelbeforestartingtheengine.Never
removethecapofthefueltankoraddfuelwhile
theengineisrunningorwhentheengineishot.
–Iffuelisspilled,donotattempttostartthe
enginebutmovethemachineawayfromthe
areaofspillageandavoidcreatinganysourceof
ignitionuntilfuelvaporshavedissipated.
–Replaceallfueltanksandcontainercapssecurely.
•Replacefaultysilencers/mufers.
•Evaluatetheterraintodeterminewhataccessories
andattachmentsareneededtoproperlyand
safelyperformthejob.Onlyuseaccessoriesand
attachmentsapprovedbythemanufacturer.
•Checkthattheoperator’spresencecontrols,safety
switches,andshieldsareattachedandfunctioning
properly.Donotoperateunlesstheyarefunctioning
properly.
Operation
•Donotoperatetheengineinaconnedspacewhere
dangerouscarbonmonoxidefumescancollect.
•Mowonlyindaylightoringoodarticiallight.
•Beforeattemptingtostarttheengine,disengageall
bladeattachmentclutches,shiftintoneutral,and
engagetheparkingbrake.
•Rememberthereisnosuchthingasasafeslope.
Travelongrassslopesrequiresparticularcare.To
guardagainstoverturning:
4

–Donotstoporstartsuddenlywhengoingupor
downhill.
–Machinespeedsshouldbekeptlowonslopes
andduringtightturns.
–Stayalertforhumpsandhollowsandother
hiddenhazards.
–Donotturnsharply.Usecarewhenreversing.
–Usecounterweight(s)orwheelweightswhen
suggestedintheoperator’smanual.
•Stayalertforholesintheterrainandotherhidden
hazards.
•Watchoutfortrafcwhencrossingornearroadways.
•Stopthebladesrotatingbeforecrossingsurfaces
otherthangrass.
•Whenusinganyattachments,neverdirectdischarge
ofmaterialtowardbystandersnorallowanyonenear
themachinewhileinoperation.
•Neveroperatethemachinewithdamagedguards,
shields,orwithoutsafetyprotectivedevicesinplace.
Besureallinterlocksareattached,adjustedproperly,
andfunctioningproperly.
•Donotchangetheenginegovernorsettingsor
over-speedtheengine.Operatingtheengineat
excessivespeedmayincreasethehazardofpersonal
injury.
•Beforeleavingtheoperator’sposition:
–Stoponlevelground.
–Disengagethepowertake-offandlowerthe
attachments.
–Changeintoneutralandsettheparkingbrake.
–Stoptheengineandremovethekey.
•Disengagedrivetoattachmentswhentransporting
ornotinuse.
•Stoptheengineanddisengagethedrivetothe
attachment:
–Beforerefuelling
–Beforeremovingthegrasscatcher/catchers
–Beforemakingheightadjustmentunless
adjustmentcanbemadefromtheoperator’s
position
–Beforeclearingblockages
–Beforechecking,cleaningorworkingonthe
mower
–Afterstrikingaforeignobjectorifanabnormal
vibrationoccurs.Inspectthemowerfordamage
andmakerepairsbeforerestartingandoperating
theequipment.
•Reducethethrottlesettingduringenginerun-out.If
theengineisprovidedwithafuelshut-offvalve,turn
thefueloffattheconclusionofmowing.
•Keephandsandfeetawayfromthecuttingunits.
•Lookbehindanddownbeforebackinguptobesure
ofaclearpath.
•Slowdownandusecautionwhenmakingturnsand
crossingroadsandsidewalks.Stopcylinders/reels
ifnotmowing.
•Donotoperatethemowerundertheinuenceof
alcoholordrugs.
•Lightningcancausesevereinjuryordeath.If
lightningisseenorthunderisheardinthearea,do
notoperatethemachine;seekshelter.
•Usecarewhenloadingorunloadingthemachine
intoatrailerortruck.
•Usecarewhenapproachingblindcorners,shrubs,
trees,orotherobjectsthatmayobscurevision.
MaintenanceandStorage
•Keepallnuts,boltsandscrewstighttobesurethe
equipmentisinsafeworkingcondition.
•Neverstoretheequipmentwithfuelinthetank
insideabuildingwherefumesmayreachanopen
ameorspark.
•Allowtheenginetocoolbeforestoringinany
enclosure.
•Toreducetherehazard,keeptheengine,
silencer/mufer,batterycompartment,andfuel
storageareafreeofgrass,leaves,orexcessivegrease.
•Checkthegrasscatcherfrequentlyforwearor
deterioration.
•Keepallpartsingoodworkingconditionandall
hardwareandhydraulicttingstightened.Replaceall
wornordamagedpartsanddecals.
•Ifthefueltankhastobedrained,dothisoutdoors.
•Becarefulduringadjustmentofthemachineto
prevententrapmentofthengersbetweenmoving
bladesandxedpartsofthemachine.
•Onmulti-cylinder/multi-reelmachines,takecare
asrotatingonecylinder/reelcancauseother
cylinders/reelstorotate.
•Disengagedrives,lowerthecuttingunits,setparking
brake,stopengine,andremovekeyfromignition.
Waitforallmovementtostopbeforeadjusting,
cleaning,orrepairing.
•Cleangrassanddebrisfromcuttingunits,drives,
silencers/mufers,andenginetohelppreventres.
Cleanupoilorfuelspillage.
5

•Usejackstandstosupportcomponentswhen
required.
•Carefullyreleasepressurefromcomponentswith
storedenergy.
•Disconnectbatterybeforemakinganyrepairs.
Disconnectthenegativeterminalrstandthe
positivelast.Reconnectpositiverstandnegative
last.
•Usecarewhencheckingthecylinders/reels.Wear
glovesandusecautionwhenservicingthem.
•Keephandsandfeetawayfrommovingparts.If
possible,donotmakeadjustmentswiththeengine
running.
•Chargebatteriesinanopenwellventilatedarea,
awayfromsparkandames.Unplugchargerbefore
connectingordisconnectingfrombattery.Wear
protectiveclothinganduseinsulatedtools.
ToroRidingMowerSafety
Thefollowinglistcontainssafetyinformationspecic
toToroproductsorothersafetyinformationthatyou
mustknowthatisnotincludedintheCEN,ISO,or
ANSIstandards.
Thisproductiscapableofamputatinghandsand
feetandthrowingobjects.Alwaysfollowallsafety
instructionstoavoidseriousinjuryordeath.
Useofthisproductforpurposesotherthanitsintended
usecouldprovedangeroustouserandbystanders.
Engineexhaustcontainscarbonmonoxide,
whichisanodorless,deadlypoisonthatcan
killyou.
Donotrunengineindoorsorinanenclosed
area.
•Knowhowtostoptheenginequickly.
•Donotoperatethemachinewhilewearingtennis
shoesorsneakers.
•Wearingsafetyshoesandlongpantsisadvisableand
requiredbysomelocalordinancesandinsurance
regulations.
•Handlefuelcarefully.Wipeupanyspills.
•Checkthesafetyinterlockswitchesdailyforproper
operation.Ifaswitchshouldfail,replacetheswitch
beforeoperatingthemachine.
•Beforestartingtheengine,sitontheseat.
•Usingthemachinedemandsattention.Toprevent
lossofcontrol:
–Donotdriveclosetosandtraps,ditches,creeks,
orotherhazards.
–Reducespeedwhenmakingsharpturns.Avoid
suddenstopsandstarts.
–Whennearorcrossingroads,alwaysyieldthe
right-of-way.
–Applytheservicebrakeswhengoingdownhillto
keepforwardspeedslowandtomaintaincontrol
ofthemachine.
•Raisethecuttingunitswhendrivingfromonework
areatoanother.
•Donottouchtheengine,silencer/mufer,or
exhaustpipewhiletheengineisrunningorsoon
afterithasstoppedbecausetheseareascouldbehot
enoughtocauseburns.
•Iftheenginestallsorlosesheadwayandcannotmake
ittothetopofaslope,donotturnthemachine
around.Alwaysbackslowly,straightdowntheslope.
•Whenapersonorpetappearsunexpectedlyin
ornearthemowingarea,stopmowing.Careless
operation,combinedwithterrainangles,ricochets,
orimproperlypositionedguardscanleadtothrown
objectinjuries.Donotresumemowinguntilthe
areaiscleared.
MaintenanceandStorage
•Makesureallhydrauliclineconnectorsaretightand
allhydraulichosesandlinesareingoodcondition
beforeapplyingpressuretothesystem.
•Keepyourbodyandhandsawayfrompinhole
leaksornozzlesthatejecthydraulicuidunder
highpressure.Usepaperorcardboard,notyour
hands,tosearchforleaks.Hydraulicuidescaping
underpressurecanhavesufcientforcetopenetrate
theskinandcauseseriousinjury.Seekimmediate
medicalattentionifuidisinjectedintoskin.
•Beforedisconnectingorperforminganyworkon
thehydraulicsystem,allpressureinthesystemmust
berelievedbystoppingtheengineandloweringthe
cuttingunitsandattachmentstotheground.
•Checkallfuellinesfortightnessandwearona
regularbasis.Tightenorrepairthemasneeded.
•Iftheenginemustberunningtoperforma
maintenanceadjustment,keephands,feet,clothing,
andanypartsofthebodyawayfromthecutting
units,attachments,andanymovingparts.Keep
everyoneaway.
6

•Toensuresafetyandaccuracy,haveanAuthorized
ToroDistributorcheckthemaximumenginespeed
withatachometer.Maximumgovernedenginespeed
shouldbe3200RPM.
•Ifmajorrepairsareeverneededorifassistanceis
desired,contactanAuthorizedToroDistributor.
•UseonlyToro-approvedattachmentsand
replacementparts.Thewarrantymaybevoidedif
usedwithunapprovedattachments.
SoundPowerLevel
Thisunithasaguaranteedsoundpowerlevelof100
dBA,whichincludesanUncertaintyValue(K)of1dBA.
Soundpowerlevelwasdeterminedaccordingtothe
proceduresoutlinedinEN11094.
SoundPressureLevel
Thisunithasasoundpressurelevelattheoperator’s
earof87dBA,whichincludesanUncertaintyValue(K)
of1dBA.
Soundpressurelevelwasdeterminedaccordingtothe
proceduresoutlinedinEN836.
VibrationLevel
Hand-Arm
Measuredvibrationlevelforrighthand=1.54m/s2
Measuredvibrationlevelforlefthand=1.04m/s2
UncertaintyValue(K)=0.5m/s2
Measuredvaluesweredeterminedaccordingtothe
proceduresoutlinedinEN836.
WholeBody
Measuredvibrationlevel=6.22m/s2
UncertaintyValue(K)=0.4m/s2
Measuredvaluesweredeterminedaccordingtothe
proceduresoutlinedinEN836.
SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaof
potentialdanger.Replaceanydecalthatisdamagedorlost.
67-5360
93-6696
1.Storedenergyhazard—readtheOperator’sManual.
93-7267
1.Parkingbrake3.Unlocked
2.Locked
93-7272
1.Cutting/dismembermenthazard;fan—stayawayfrom
movingparts.
94-5056
1.Reelspeed—slow4.5Bladecuttingunit
2.Reelspeed—fast5.8Bladecuttingunit
3.Reelheight
7

98-4387
1.Warning—wearhearingprotection.
106-5976
1.Enginecoolantunder
pressure
3.Warning—donottouch
thehotsurface.
2.Explosionhazard—read
theOperator’sManual.
4.Warning—readthe
Operator’sManual.
106-8119
(Afxoverdecalpartno.104–4096forCE)
*Thissafetydecalincludesaslopewarningrequiredonthemachineforcompliance
totheEuropeanLawnMowerSafetyStandardEN836:1997.Theconservative
maximumslopeanglesindicatedforoperationofthismachineareprescribedby
andrequiredbythisstandard.
1.Warning—readtheOperator’sManual.
2.Tippinghazard—donotdrivethemachineonaslope
greaterthan15degrees.
3.Thrownobjecthazard—keepbystandersasafedistance
fromthemachine.
4.Cuttinghazardofhandandfoot—stayawayfrommoving
parts,keepallguardsandshieldsinplace.
5.Warning—locktheparkingbrake,stoptheengine,and
removetheignitionkeybeforeleavingthemachine.
106-8120
1.Thrownobjecthazard—keepbystandersasafedistance
fromthemachine.
2.Cuttinghazardofhandandfoot—stayawayfrommoving
parts.
BatterySymbols
Someorallofthesesymbolsareonyourbattery
1.Explosionhazard6.Keepbystandersasafe
distancefromthebattery.
2.Nore,opename,or
smoking.
7.Weareyeprotection;
explosivegasescan
causeblindnessandother
injuries
3.Causticliquid/chemical
burnhazard
8.Batteryacidcancause
blindnessorsevereburns.
4.Weareyeprotection9.Flusheyesimmediately
withwaterandgetmedical
helpfast.
5.ReadtheOperator’s
Manual.
10.Containslead;donot
discard.
8

104-3991
9

104-3994
(Afxoverdecalpartno.104–3991forCE)
1.ReadtheOperator’s
Manual.
5.Neutral9.Pushoff13.Fast
2.Warning—readthe
Operator’sManual,do
notusestartinguid.
6.Raisethereels.10.Engine—stop14.Slow
3.Raiseandlowerthereels.7.Powertake-off(PTO)11.Engine—run
4.Lowerthereels.8.Pullon12.Engine—start
104-4096
10

115–3037
11

Setup
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
Wheelassembly1
1Lugnut4Installtherearwheel.
2Rearcarrierframe1Adjusttherearcarrierframeheight.
Washer6
Bolt(3/8x2-1/4inches)3
3Locknut(3/8inch)3
Mountthecarrierframestothecutting
units.
Liftarm2
Pivotrod2
Bolt(5/16x7/8inch)2
Lockwasher2
Liftchain2
Clevispin4
4
Cotterpin4
Installthefrontliftarms(suppliedinthe
LiftArmKit).
5Nopartsrequired–Mountthecuttingunitdrivemotors
(suppliedintheLiftArmKit).
Trustwasher3
Flatwasher3
6Flange-headbolt3
Mountthecuttingunits.
Spring3
Vinylsleeve1
Springshackle3
Clevispin6
Cotterpin6
Shackle(32inchcuttingunitonly)2
Springanchor(32inchcuttingunitonly)2
Bolt(1/4x3/4inch)(32inchcuttingunit
only)4
7
Locknut(32inchcuttingunitonly)4
Installthecounterbalancesprings
(suppliedintheliftarmkit).
8Rearweightkit(s)VariesAddrearballast(orderfromyourT oro
Distributor).
9Nopartsrequired–ActivateandChargetheBattery
Decal104–39941
10Decal106–81191InstallCECompliantDecals(CEOnly)
11Nopartsrequired–Break-inanewmachine
MediaandAdditionalParts
DescriptionQty.Use
Key2Startthemachine
Hydraulicreserviorplug1Pluggingthehydraulicreservoirduringalterchange.
12

DescriptionQty.Use
Operator’sManual1
EngineOperator’sManual1Readbeforeoperatingthemachine.
Operatortrainingmaterial1Viewbeforeoperatingthemachine.
PartsCatalog1Viewandorderparts.
Certicateofcompliance1CEcertication
Note:Determinetheleftandrightsidesofthemachine
fromthenormaloperatingposition.
1
InstallingtheRearWheel
Partsneededforthisprocedure:
1Wheelassembly
4Lugnut
Procedure
1.Mountthewheelassemblyontotherearwheelhub
(Figure2).
G009850
1
2
3
Figure2
1.Wheelassembly3.Lugnut
2.Rearwheelhub
2.Installthelugnuts(Figure2)andtightenthemto45
to65ft-lb(3to5N-m).
2
AdjustingtheRearCarrier
FrameHeight
Partsneededforthisprocedure:
1Rearcarrierframe
Procedure
1.Slidetherearcarrierframeontotherearliftarm
pivotrod(Figure3).Donotinstallthecarrierframe
tothecuttingunitatthistime.
G009851
1
3
3
2
4
Figure3
1.Rearcarrierframe3.Upstop
2.Pivotrod4.Liftcylinder
2.Raisetheliftarmsandcarrierframefully.
3.Pressdownononeendofthecarrierframeuntilthe
upstopontheoppositeendcontactstheunderside
ofthefootstep(Figure3).
Thedistancebetweentheupstopandtheunderside
ofthefootstep,ontheendpresseddown,shouldbe
approximately1/4inch(6mm).
13

•Ifthedistanceiscorrect,removethecarrier
frameandproceedwiththesetupinstructions.
•Ifthedistanceisnot1/4inch(6mm),adjustthe
liftcylinderasfollows:
A.Removetheclevispinsecuringtherodend
oftheliftcylindertotheliftarm(Figure3).
B.Loosenthehexnutsecuringtheclevistothe
cylinderrod.
C.Rotatetheclevisendinoroutuntilyou
attain1/4inch(6mm)clearance.Checkthe
adjustmentandrepeatsteps2through3as
required.
D.Tightenthehexnutandconnectthecylinder
rodendtotheliftarm(Figure3).
3
MountingtheCarrierFrames
totheCuttingUnits
Partsneededforthisprocedure:
6Washer
3Bolt(3/8x2-1/4inches)
3Locknut(3/8inch)
Procedure
1.Removethecuttingunitsfromthecartons.Adjust
thempertheCuttingUnitOperator’sManual.
2.Positionacarrierframeontoeachcuttingunit,
aligningthemountingholeswiththemountinglinks
(Figure4).
G009852
1
3
2
Figure4
1.Carrierframe3.Bearinghousingcover
2.Mountinglink
3.Secureeachmountinglinktothecarrierframewith
abolt(3/8x2-1/4inches),2washers,andalocknut,
asshowninFigure4.Positionawasheroneach
sideofthelinkwhenmounting.Torqueto31ft-lb
(42N-m).
4
InstallingtheFrontLiftArms
Partsneededforthisprocedure:
2Liftarm
2Pivotrod
2Bolt(5/16x7/8inch)
2Lockwasher
2Liftchain
4Clevispin
4Cotterpin
Procedure
1.Insertapivotrodintotheleftliftarmandalignthe
mountingholes(Figure5).
14

G009853
1
2
Figure5
1.Liftarm2.Pivotrod
2.Securethepivotrodtotheliftarmwithabolt(5/16
x7/8inch)andlockwasher.
3.Loosenthetopboltsecuringtheleftcounterbalance
armtotheframe(Figure6).
G009854
1
2
3
4
5
8
6
7
Figure6
1.Counterbalancearm5.Tipperchain
2.Topbolt6.Liftchain
3.Bottombolt7.Cylinderpin
4.Liftarmpivotpin8.Liftarmtab
4.Removethebottomboltandnutsecuringtheleft
counterbalancearmtotheframe(Figure6).
5.Rotatethecounterbalancearmoutwardandremove
theliftarmpivotpinandtipperchain(Figure6).
6.Positiontheliftarmbetweentheframemembers,
alignthemountingholes,andinstallthepivot
pin(Figure6).Insertthepivotpinsothatthe
counterbalancearmtsintotheslotinthepin.Do
notsecurethecounterbalancearmatthistime.
7.Secureoneendoftheliftchaintotheliftcylinder
pinwithaclevispinandcotterpin.
8.Securetheotherendoftheliftchaintothehole
intheliftarmmountingtabwithclevispinsand
cotterpins.Usetheappropriateholeintheliftarm
asdesignatedinFigure7.
G009855
2
1
Figure7
1.27inchcuttingunit(inner
hole)
2.32inchcuttingunit(outer
hole)
9.Repeattheprocedureontheright-handliftarm.
5
MountingtheCuttingUnit
DriveMotors
NoPartsRequired
Procedure
1.Positionthecuttingunitsinfrontofthepivotrods.
2.Removethebearinghousingcover(Figure4)from
theinsideendoftheright-handcuttingunit.Install
thecoverandgasket(suppliedwiththecuttingunit)
ontheoutsideend.Locatethespidercoupling
(Figure8)shippedinthebearinghousing.
15

G009856
1
2
3
Figure8
1.Spidercoupling3.O-ring
2.Reelmotor
3.InserttheO-ring(suppliedwiththecuttingunit)on
theangeofthedrivemotor(Figure8).
4.Mountthemotorandthespidercouplingtothe
driveendofthecuttingunitandsecurethemwith2
boltsprovidedwiththecuttingunit(Figure8).
5.Onthecenterandleft-handcuttingunits,remove
thebearinghousingcoverandinstallthegasket
(suppliedwiththecuttingunits).
6
MountingtheCuttingUnits
Partsneededforthisprocedure:
3Trustwasher
3Flatwasher
3Flange-headbolt
Procedure
1.Slideathrustwasherontotheliftarmpivotrod
(Figure9).
G009857
1
2
3
Figure9
1.Thrustwasher3.Flatwasherand
ange-headbolt
2.Carrierframe
2.Slidethecuttingunitcarrierframeontothepivot
rodandsecureitwithaatwasherandange-head
bolt(Figure9).
Note:Ontherearcuttingunit,positionthethrust
washerbetweentherearofthecarrierframeandthe
atwasher.
3.Secureatipperchaintothetopofeach27inch
cuttingunitcarrierframeandtothebottomofeach
32inchcuttingunitcarrierframewithabolt,washer,
andlocknut(Figure10).
G009858
1
2
3
Figure10
1.Tipperchain(27inch
cuttingunits)
3.Carrierframe
2.Tipperchain(32inch
cuttingunits)
4.Greaseallliftarmandcarrierframepivotpoints.
16

7
InstallingtheCounterbalance
Springs
Partsneededforthisprocedure:
3Spring
1Vinylsleeve
3Springshackle
6Clevispin
6Cotterpin
2Shackle(32inchcuttingunitonly)
2Springanchor(32inchcuttingunitonly)
4Bolt(1/4x3/4inch)(32inchcuttingunitonly)
4Locknut(32inchcuttingunitonly)
PrecautionsandSettingsforthe
CounterbalanceSprings
Usecautionwhentensioningthespringsas
theyareunderheavyload.
Thecounterbalancespringshelpbalancethecutting
unitstoallowequalamountsofweight(downpressure)
tobedistributedtoeachendofthecuttingunit.The
springsalsotransferweightfromthecuttingunitstothe
tractionunit,thereforeincreasingtraction.
Thesettingsrecommendedinthefollowingprocedures
mayberequireminorchangestoachieveoptimum
performanceforyourturfconditions.Theweight,at
eachendofthecuttingunit,canbecheckedeasilywitha
springscale.
•Increasingthespringtensionreducestheweight
oninboardendofthecuttingunitandincreases
theweightontheoutboardend.
•Decreasingthespringtensionincreasestheweight
ontheinboardendofthecuttingunitandreduces
theweightonoutboardend.
InstallingtheCounterbalanceSprings
on27InchCuttingUnits
1.Hookthespringintothethirdholefromthetopon
theinboardsideofbothfrontcuttingunitlifttabs
andontherearcuttingunitlifttab(Figure11).
Note:Selectingthe#4holeposition(increasing
thespringtension)willreducetheweightonthe
inboardendofthecuttingunit,increasetheweight
ontheoutboardendofthecuttingunit,andincrease
traction.Selectingthe#2holepositionhasthe
oppositeaffect.
G009859
1
Figure11
1.Cuttingunitlifttab
2.Securetheotherendofthespringtotheappropriate
hole(seebelow)onthefrontandrearcounterbalance
arms(Figure12andFigure13)withthespring
shackle,clevispin,andcotterpin.
•5bladereels—fourthholefromthetop
•8bladereels—thirdholefromthetop
•Reelswithbaskets—tophole
Note:Ontherearcounterbalancespring,installthe
vinylcoveroverthespringbeforeinstalling.
Note:Increasingthespringtensionwillreduce
theweightontheinboardendofthecuttingunit,
increasetheweightontheoutboardendofthe
cuttingunit,andincreasetraction.Decreasingthe
springtensionhastheoppositeeffect.
17

Figure12
1.Counterbalancearm4.Springshackle
2.Topbolt5.Clevispinandcotterpin
3.Bottombolt
Figure13
1.Rearcounterbalance
spring
3.Springshackle
2.Vinylcover
3.Insertthebreakerbarintothesquareholeinthe
counterbalancearmandpivotthearmbacktoits
originalposition,aligningthemountingholes.
4.Securethebottomofthecounterbalancearmtothe
framewiththeboltandnutpreviouslyremoved.
Tightenthetopbolt(Figure12).
5.Totensionthecounterbalancesprings,proceedas
follows:
A.Removethecotterpinandclevispinsecuringthe
springshackletothecounterbalancearm.Do
notremovetheotherclevispin.
B.Movetheshackleupordownonthe
counterbalancearmuntilitisalignedwiththe
desiredholeonthearm.Installtheclevispin
andcotterpin.
InstallingtheCounterbalanceSprings
on32InchCuttingUnits
1.Mountaspringanchortotherearinboardsideof
eachfrontcuttingunitlifttabwith2bolts(1/4x3/4
inch)andlocknuts,asshowninFigure14.
G009862
1
2
Figure14
1.Cuttingunitlifttab2.Springanchor
2.Onthefrontcuttingunits,hookthespringintothe
secondholefromthebottom(#3position)inthe
springanchor(Figure14).
Note:Selectingthe#4holeposition(increasing
thespringtension)willreducetheweightonthe
inboardendofthecuttingunit,increasetheweight
ontheoutboardendofthecuttingunit,andincrease
traction.Selectingthe#2holepositionhasthe
oppositeaffect.
3.Ontherearcuttingunit,hookthespringintothetop
holeontherearcuttingunitlifttab.
Note:Increasingthespringtensionwillreduce
theweightontheinboardendofthecuttingunit,
increasetheweightontheoutboardendofthe
cuttingunit,andincreasetraction.Decreasingthe
springtensionhastheoppositeaffect.
4.Securetheotherendofthespringtotheappropriate
hole(seebelow)onthefrontandrearcounterbalance
arms(Figure15andFigure16)withthespring
shacklewiththechain,clevis,clevispin,andcotter
pin.
•5bladereels—thirdholefromthetop
•8bladereels—secondholefromthetop
•Reelswithbaskets—tophole
Note:Onrearcounterbalancespring,installthe
vinylcoveroverthespringbeforeinstalling.
18

Figure15
1.Counterbalancearm4.Springshackle
2.Topbolt5.Clevispinandcotterpin
3.Bottombolt6.Chain,clevis,andclevis
pin
Figure16
1.Rearcounterbalance
spring
3.Springshackle
2.Vinylcover
5.Securetheotherendofthespringtothesecondhole
fromthetopwiththespringshacklewiththechain,
clevis,clevispin,andcotterpin(Figure15).
6.Ontherearcounterbalancearms,installthevinyl
coveroverthespringbeforehookingtheotherend
ofthespringintothespringshackleinthesecond
holefromthetop(Figure16).
7.Insertthebreakerbarintothesquareholeinthe
counterbalancearmandpivotthearmbacktoits
originalposition,aligningthemountingholes.
8.Securethebottomofthecounterbalancearmtothe
framewiththeboltandnutpreviouslyremoved.
Tightenthetopbolt(Figure15).
9.Totensionthecounterbalancespringsproceedas
follows:
A.Removethecotterpinandclevispinsecuringthe
springshackletothecounterbalancearm.Do
notremovetheotherclevispin.
B.Movetheshackleupordownonthe
counterbalancearmuntilitisalignedwiththe
desiredholeonthearm.Installtheclevispin
andcotterpin.
8
AddingRearBallast
Partsneededforthisprocedure:
VariesRearweightkit(s)
Procedure
ThisunitcomplieswithANSlB71.4–2004Standardsand
allapplicableEuropeanrequirementswhenequipped
withrearballast.Usethefollowingcharttodetermine
theweightorcombinationsofweightsneeded.
CuttingUnitCongurationWeightKitsRequired
Standardmachinewith27inch
cuttingunits
(1)83-9370
(2)83-9390
Standardmachinewith27inch
cuttingunits&baskets
(1)83-9370(3)83-9390
(2)94-3698
Standardmachinewiththree
wheeldrivekit&27inch
cuttingunits
(1)83-9390
(1)83–9370
Standardmachinewiththree
wheeldrivekit,27inchcutting
units&baskets
(2)83-9390(2)94-3698
(1)83–9370
Standardmachinewith32inch
cuttingunits
(3)83-9390(2)94-3698
(1)83–9370
Standardmachinewith32inch
cuttingunits&threewheel
drivekit
(1)83-9370(2)83-9390
(1)94–3698
Note:Allcongurationsrequirecalciumchlorideinthe
reartire.Thetireshouldbelledtoapproximately75%
capacity(levelwiththevalveatthetop)(60lb(27kg)
uidor74lb(33.5kg)tireanduid).
Important:Ifapunctureoccursinatirewith
calciumchloride,removetheunitfromtheturfarea
asquicklyaspossible.Topreventpossibledamage
totheturf,immediatelysoaktheaffectedareawith
water.
EitherType1(77%)orType2(94%)commercial
calciumchlorideakemaybeused.
Plainwaterfreezessolidat32°F(0°C).The3-1/2lb.
(1.6kg)calciumchlorideto1gallon(3.8l)ofwater
19

solutionisslushfreeto-12°F(-24°C)andwillfreeze
solidat-52°F(-46°C).The5lb.(2.3kg)pergallon(liter)
solutionisslushfreeto-50°F(-45°C)andwillfreeze
solidat-62°F(-52°C).
9
ActivatingandChargingthe
Battery
NoPartsRequired
Procedure
Warning
CALIFORNIA
Proposition65Warning
Batteryposts,terminals,andrelated
accessoriescontainleadandleadcompounds,
chemicalsknowntotheStateofCalifornia
tocausecancerandreproductiveharm.
Washhandsafterhandling.
Ifthebatteryisnotlledwithelectrolyteoractivated,
bulkelectrolytewith1.260specicgravitymustbe
purchasedfromalocalbatterysupplyoutletandadded
tothebattery.
1.Removethellercapsfromthebatteryandslowlyll
eachcelluntiltheelectrolyteisjustabovetheplates.
Batteryelectrolytecontainssulfuricacidwhich
isadeadlypoisonandcausessevereburns.
•Donotdrinkelectrolyteandavoidcontact
withskin,eyesorclothing.Wearsafety
glassestoshieldyoureyesandrubbergloves
toprotectyourhands.
•Fillthebatterywherecleanwaterisalways
availableforushingtheskin.
2.Replacethellercapswiththeventspointingto
therear(towardthefueltank)andconnecta3to4
ampbatterychargertothebatteryposts.Chargethe
batteryatarateof3to4amperesfor4to8hours.
Chargingthebatteryproducesgassesthatcan
explode.
Neversmokenearthebatteryandkeepsparks
andamesawayfrombattery.
3.Whenthebatteryischarged,disconnectthecharger
fromtheelectricaloutletandbatteryposts.
4.Removethellercaps.Slowlyaddelectrolyteto
eachcelluntilthelevelisuptothellring.Install
thellercaps.
Important:Donotoverllthebattery.
Electrolytewilloverowontootherpartsofthe
machineandseverecorrosionanddeterioration
willresult.
5.Installthepositivecable(red)tothepositive(+)
terminalandthenegativecable(black)tothe
negative(-)terminalofthebatteryandsecurethem
withboltsandnuts.Slidetherubberbootoverthe
positiveterminaltopreventapossibleshortfrom
occurring.
Incorrectbatterycableroutingcoulddamage
themachineandcablescausingsparks.Sparks
cancausethebatterygassestoexplode,
resultinginpersonalinjury.
•Always
disconnect thenegative(black)
batterycablebeforedisconnectingthe
positive(red)cable.
•Always connect thepositive(red)battery
cablebeforeconnectingthenegative(black)
cable.
20