Toro 3806 User manual

Form No. 3354-511 Rev B
Reelmaster® 6500-D and6700-D Traction UnitModel No. 03806 —Serial No. 260000001 and Up
Model No. 03807 —Serial No. 260000001 and Up
Model No. 03808 —Serial No. 260000001 and Up
Register your product at www.Toro.com Original Instructions (EN)

Warning
CALIFORNIA
Pr oposition 65 W ar ning
Diesel engine exhaust and some of its
constituents ar e kno wn to the State of
Calif or nia to cause cancer , bir th defects, and
other r epr oducti v e har m.
Important: T his engine is not equipped
with a spar k ar r ester muf fler . It is a
violation of Calif or nia Public R esource Code
Section 4442 to use or operate the engine
on an y f or est-co v er ed, br ush-co v er ed, or
g rass-co v er ed land. Other states or federal
ar eas may ha v e similar la ws.
Introduction
R ead this infor mation carefully to lear n ho w to
operate and maintain y our product properly and
to a v oid injur y and product damag e . Y ou are
responsible for operating the product properly
and safely .
Y ou ma y contact T oro directly at www .T oro .com
for product and accessor y infor mation, help
finding a dealer , or to register y our product.
W henev er y ou need ser vice , g en uine T oro par ts ,
or additional infor mation, contact an A uthorized
Ser vice Dealer or T oro Customer Ser vice and ha v e
the model and serial n umbers of y our product
ready . Figure 1 identifies the location of the model
and serial n umbers on the product. W rite the
n umbers in the space pro vided.
Figure 1
1. Location of the model and serial numbers
Model No.
Serial No.
T his man ual identifies potential hazards and has
safety messag es identified b y the safety aler t
symbol ( Figure 2 ), whic h signals a hazard that ma y
cause serious injur y or death if y ou do not follo w
the recommended precautions .
Figure 2
1. Safety alert symbol.
T his man ual uses tw o other w ords to highlight
infor mation. Impor tant calls attention to special
mec hanical infor mation and Note emphasizes
g eneral infor mation w or th y of special attention.
Contents
Introduction .......................................................2
Safety ..................................................................4
Safe Operating Practices . . . . . . . . . . . . . . . . . . . . . . 4
T oro Mo w er Safety ..............................5
Sound Pressure Lev el ...........................6
Vibration Lev el ....................................6
Safety and Instr uctional Decals . . . . . . . . . . . . 7
Setup ................................................................ 13
1 Chec king Fluid Lev els . . . . . . . . . . . . . . . . . . . . . 13
2 Installing the Cutting Units . . . . . . . . . . . . . . 13
3 Making Alter nate Cutting Unit
Adjustments ...................... 15
4 Adding R ear Ballast ......................... 16
5 Installing CE Decals ........................ 16
6 R eading the Man uals and Storing
Additional P ar ts . . . . . . . . . . . . . . . . . 16
Product Ov er view ............................................. 17
Controls ........................................... 17
Specifications ................................... 21
Operation .......................................................... 22
Chec king the Engine Oil . . . . . . . . . . . . . . . . . . . . 22
Chec king the Cooling System . . . . . . . . . . . . . 22
Filling the Fuel T ank .......................... 23
Chec king the Hy draulic Fluid . . . . . . . . . . . . . 24
Chec king the Tire Pressure . . . . . . . . . . . . . . . . . 25
Chec king the R eel to Bedknife
Contact ............................. 25
© 2005—The Toro® Company8111 Lyndale Avenue SouthBloomington, MN 55420
2
Contact us at www.Toro.com.
Printed in the USA.All Rights Reserved

Star ting and Stopping ........................ 25
Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . 25
Pushing or T o wing the
Mac hine ............................ 26
Chec king the Interloc k
Switc hes ............................ 27
F ault Memor y and R etriev al . . . . . . . . . . . . . . . 28
Hy draulic Solenoid V alv e
Functions .......................... 29
Operating Tips .................................. 29
Maintenance ...................................................... 31
R ecommended Maintenance
Sc hedule(s) ............................... 31
Ser vice Inter v al Char t . . . . . . . . . . . . . . . . . . . . . . . . 32
Daily Maintenance Chec klist . . . . . . . . . . . . . . 33
Lubrication ................................................ 33
Greasing the Bearings and
Bushings ........................... 33
Engine Maintenance .................................. 35
Ser vicing the Air Cleaner . . . . . . . . . . . . . . . . . . . 35
Ser vicing the Engine Oil and
Filter ................................. 37
Adjusting T hrottle ............................. 37
Fuel System Maintenance .......................... 37
Fuel T ank .......................................... 37
Fuel Lines and Connections . . . . . . . . . . . . . . . 38
Fuel Filter/W ater Se parator . . . . . . . . . . . . . . . 38
R e placing the Fuel Pre-Filter . . . . . . . . . . . . . . 38
Bleeding Air F rom Injectors . . . . . . . . . . . . . . . 39
Electrical System Maintenance . . . . . . . . . . . . . . . . . . . 39
Batter y Care ...................................... 39
Fuses ................................................. 40
Optional Lighting .............................. 40
Dri v e System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 41
Chec king the T or que of the W heel
Nuts or Bolts ..................... 41
Chec king the Planetar y Gear Dri v e
Oil ..................................... 41
Changing the Planetar y Gear Dri v e
Oil ..................................... 42
Chec king the R ear Axle
Lubricant .......................... 42
Changing the R ear Axle
Lubricant .......................... 43
R ear W heel T oe-In ............................. 43
Adjusting the T raction Dri v e for
Neutral .............................. 43
Cooling System Maintenance . . . . . . . . . . . . . . . . . . . . . 44
R emo ving Debris .............................. 44
Maintaining the Cooling
System ............................... 44
Brak e Maintenance .................................... 45
Adjusting the Ser vice Brak es . . . . . . . . . . . . . . 45
Belt Maintenance ....................................... 45
Chec king the Alter nator Belt . . . . . . . . . . . . . . 45
Hy draulic System Maintenance . . . . . . . . . . . . . . . . . . 45
Changing the Hy draulic Fluid . . . . . . . . . . . . . 45
R e placing the Hy draulic Filter . . . . . . . . . . . . 46
Chec king the Hy draulic Lines and
Hoses ................................ 46
Hy draulic System T est P or ts . . . . . . . . . . . . . . . 47
Cutting Unit Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Bac klapping ....................................... 48
Adjust T urf Compensation
Spring ............................... 49
Adjusting the Cutting Unit
Lo w ering Rate .................. 50
Lifted Height of Outer F ront
Cutting Units (Enable
P osition) ............................ 51
Adjusting the T ra v el of the
F ront T hree Cutting
Units ................................. 51
Storag e .............................................................. 53
T raction Unit ..................................... 53
Engine .............................................. 53
Sc hematics ........................................................ 54
3

Safety
T his machine meets or ex ceeds CEN standard
EN 836:1997, ISO standard 5395:1990, and
ANSI B71.4-1999 specifications in ef fect at the
time of pr oduction when, ballast is added;
r efer to Adding R ear Ballast in Setup , pa ge 13 .
Note: T he addition of attac hments made b y
other man ufacturers that do not meet American
National Standards Institute cer tification will cause
noncompliance of this mac hine .
Improper use or maintenance b y the operator or
o wner can result in injur y . T o reduce the potential
for injur y , comply with these safety instr uctions
and alw a ys pa y attention to the safety aler t
symbol, whic h means CA UTION , W ARNING , or
D ANGER-“personal safety instr uction. ” F ailure
to comply with the instr uction ma y result in
personal injur y or death.
Safe Operating Practices
T he follo wing instr uctions are from the CEN
standard EN 836:1997, ISO standard 5395:1990,
and ANSI B71.4-1999.
Training
•R ead the Operator’ s Man ual and other training
material. If the operator(s) or mec hanic(s) can
not read English it is the o wner’ s responsibility
to explain this material to them.
•Become familiar with the safe operation of the
equipment, operator controls , and safety signs .
•All operators and mec hanics should be trained.
T he o wner is responsible for training the users .
•Nev er let c hildren or untrained people operate
or ser vice the equipment. Local regulations
ma y restrict the ag e of the operator .
•T he o wner/user can prev ent and is responsible
for accidents or injuries occur ring to himself
or herself , other people or proper ty .
Preparation
•Ev aluate the ter rain to deter mine what
accessories and attac hments are needed to
properly and safely perfor m the job . Only use
accessories and attac hments appro v ed b y the
man ufacturer .
•W ear appropriate clothing including hard hat,
safety glasses and ear protection. Long hair ,
loose clothing or jew elr y ma y g et tangled in
mo ving par ts .
•Inspect the area where the equipment is to be
used and remo v e all objects suc h as roc ks , to ys
and wire whic h can be thro wn b y the mac hine .
•Use extra care when handling diesel fuel. It is
flammable and v apors are explosi v e .
Use only an appro v ed container .
•Nev er remo v e g as cap or add fuel with engine
r unning . Allo w engine to cool before refueling .
Do not smok e .
•Nev er refuel or drain the mac hine indoors .
•Chec k that operator’ s presence controls ,
safety switc hes and shields are attac hed and
functioning properly . Do not operate unless
they are functioning properly .
Operation
•Nev er r un an engine in an enclosed area.
•Only operate in g ood light, k ee ping a w a y from
holes and hidden hazards .
•Be sure all dri v es are in neutral and parking
brak e is eng ag ed before star ting engine . Only
star t engine from the operator’ s position. Use
seat belts if pro vided.
•Slo w do wn and use extra care on hillsides . Be
sure to tra v el in the recommended direction
on hillsides . T urf conditions can affect the
mac hine’ s stability . Use caution while operating
near drop-offs .
•Slo w do wn and use caution when making tur ns
and when c hanging directions on slopes .
•Nev er operate with guards not securely in
place . Be sure all interloc ks are attac hed,
adjusted properly , and functioning proper ty .
•Do not c hang e the engine g o v er nor setting or
o v erspeed the engine .
•Stop on lev el g round, raise the cutting units ,
diseng ag e dri v es , eng ag e parking brak e (if
pro vided), shut off engine before lea ving the
operator’ s position for any reason including
emptying the g rass bask ets .
•Stop equipment and inspect the mac hine after
striking objects or if an abnor mal vibration
4

occurs . Mak e necessar y re pairs before
resuming operations .
•K ee p hands and feet a w a y from the cutting
units .
•Look behind and do wn before bac king up to
be sure of a clear path.
•Nev er car r y passeng ers and k ee p pets and
b ystanders a w a y .
•Slo w do wn and use caution when making tur ns
and crossing roads and sidew alks . Stop reels if
not mo wing .
•Do not operate the mo w er under the influence
of alcohol or dr ugs .
•Use care when loading or unloading the
mac hine into a trailer or tr uc k.
•Use care when approac hing blind cor ners ,
shr ubs , trees , or other objects that ma y obscure
vision.
Maintenance and Storage
•Diseng ag e dri v es , raise the cutting units , set
parking brak e , stop engine and remo v e k ey .
W ait for all mo v ement to stop before adjusting,
cleaning or re pairing .
•Clean g rass and debris from cutting units ,
dri v es , m ufflers , and engine to help prev ent
fires . Clean up oil or fuel spillag e .
•Let engine cool before storing and do not store
near flame .
•Shut off fuel while storing or transpor ting . Do
not store fuel near flames or drain indoors .
•P ark mac hine on lev el g round. Nev er allo w
untrained personnel to ser vice mac hine .
•Use jac k stands to suppor t components when
required.
•Carefully release pressure from components
with stored energ y .
•Disconnect batter y and remo v e spark plug
wire before making any re pairs . Disconnect
the neg ati v e ter minal first and the positi v e last.
R econnect positi v e first and neg ati v e last.
•Use care when c hec king the reels . W ear glo v es
and use caution when ser vicing them.
•K ee p hands and feet a w a y from mo ving par ts .
If possible , do not mak e adjustments with the
engine r unning .
•Charg e batteries in an open w ell v entilated
area, a w a y from spark and flames . Unplug
c harg er before connecting or disconnecting
from batter y . W ear protecti v e clothing and use
insulated tools .
•K ee p all par ts in g ood w orking condition and
all hardw are and h y draulic fittings tightened.
R e place all w or n or damag ed decals .
Toro Mower Safety
T he follo wing list contains safety infor mation
specific to T oro products or other safety
infor mation that y ou m ust kno w that is not
included in the ANSI standards .
T his product is capable of amputating hands and
feet and thro wing objects . Alw a ys follo w all safety
instr uctions to a v oid serious injur y or death.
Use of this product for pur poses other than its
intended use could pro v e dang erous to user and
b ystanders .
Operation
•Sit on the seat when star ting and operating the
mac hine .
•Alw a ys w ear substantial shoes . Do not operate
the mac hine while w earing sandals , tennis
shoes , or sneak ers .
•W earing safety shoes and long pants is advisable
and required b y some local ordinances and
insurance regulations .
•Handle fuel carefully . Wipe up any spills .
•Chec k the safety interloc k switc hes daily
for proper operation. If a switc h should
fail, re place the switc h before operating the
mac hine . After ev er y tw o years , re place all
three interloc k switc hes in the safety system,
reg ardless if they are w orking properly or not.
•Using the mac hine demands attention. T o
prev ent loss of control:
Do not dri v e close to sand traps , ditc hes ,
creeks , or other hazards .
•R educe speed when making shar p tur ns . A v oid
sudden stops and star ts .
•Do not touc h the engine , m uffler , or exhaust
pipe while the engine is r unning or soon after
5

it has stopped because these areas could be hot
enough to cause bur ns .
•If a cutting unit strik es a solid object or vibrates
abnor mally , stop immediately , tur n the engine
off , w ait for all motion to stop , and inspect
the mac hine for damag e . A damag ed reel or
bedknife m ust be re paired or re placed before
operation is contin ued.
•T ra v erse slopes carefully . Do not star t or stop
suddenly when tra v eling uphill or do wnhill.
•T he operator m ust be skilled and trained in
ho w to dri v e on hillsides . F ailure to use caution
on slopes or hills ma y cause loss of control
and cause the v ehicle to tip or roll, possibly
resulting in personal injur y or death. On 4
wheel dri v e models , alw a ys use the seat belt and
R oll Ov er Protection System (R OPS) tog ether .
•If the engine stalls or loses headw a y and cannot
mak e it to the top of a slope , do not tur n the
mac hine around. Alw a ys bac k slo wly , straight
do wn the slope .
•W hen a person or pet appears unexpectedly
in or near the mo wing area, stop mo wing .
Careless operation, combined with ter rain
angles , ricoc hets , or improperly positioned
guards can lead to thro wn object injuries . Do
not resume mo wing until the area is cleared.
•Do not park on slopes unless the wheels are
c hoc k ed or bloc k ed.
Maintenance and Storage
•Mak e sure all h y draulic line connectors are
tight and all h y draulic hoses and lines are in
g ood condition before applying pressure to the
system.
•K ee p y our body and hands a w a y from pin hole
leaks or nozzles that eject h y draulic fluid under
high pressure . Use paper or cardboard, not
y our hands , to searc h for leaks . Hy draulic fluid
escaping under pressure can ha v e sufficient
force to penetrate the skin and cause serious
injur y .
•Before disconnecting or perfor ming any w ork
on the h y draulic system, all pressure in the
system m ust be reliev ed b y stopping the engine
and lo w ering the cutting units and attac hments
to the g round.
•If the engine m ust be r unning to perfor m a
maintenance adjustment, k ee p hands , feet,
clothing, and any par ts of the body a w a y from
the cutting units , attac hments and any mo ving
par ts . K ee p ev er y one a w a y .
•T he engine m ust be shut off before c hec king
the oil or adding oil to the crankcase .
•If major re pairs are ev er needed or if assistance
is desired, contact an A uthorized T oro
Distributor .
•T o mak e sure of optim um perfor mance and
contin ued safety cer tification of the mac hine ,
use only g en uine T oro re placement par ts
and accessories . R e placement par ts and
accessories made b y other man ufacturers could
be dang erous , and suc h use could v oid the
product w ar ranty .
Sound Pressure Level
T his unit has an equi v alent contin uous A-w eighted
sound pressure at the operator ear of: 86 dB(A),
based on measurements of identical mac hines per
Directi v e 98/37/EC and amendments .
Vibration Level
T his unit does not ex ceed a vibration lev el of
2.5 m/s² at the hands based on measurements of
identical mac hines per ISO 5349 procedures .
T his unit does not ex ceed a vibration lev el of
.5 m/s² at the posterior based on measurements of
identical mac hines per ISO 2631 procedures .
6

Safety and Instructional
Decals
Safety decals and instr uctions are easily visible to the operator and are located near any
area of potential dang er . R e place any decal that is damag ed or lost.
104-5229
1. Read the Operator’s
Manual.
3. Fuse for headlights
(optional)2. Fuse for starter
105-7506
1. Read the Operator’s
Manual.
4. Engine—preheat
2. Engine—stop 5. Engine—start3. On
93-6693
1. Crushing hazard of hand—wait for moving parts to stop.
93-6680
93-6686
1. Hydraulic oil2. Read the Operator’s Manual.
93-6699
1. Machine speed 3. Continuous variable setting2. Slow
4. Fast
2
1
93-9425
1. Read the Operator’s Manual.2. Hydraulic hoses are under pressure—stay away from movingparts.
7

93-6696
1. Stored energy hazard—read the Operator’s Manual .
93-6687
1. Do not step here.
93-6689
1. Warning—do not carry passengers.
93-6681
1. Cutting/dismemberment—hazard, fan-stay away frommoving parts..
93-1265
1. Hot surface/burn hazard—stay a safe distance from the hotsurface.
104-9298
1. Read the Operator’s Manual .
4
3
2
1
93-1263
1. Read the Operator’s Manual.2. To engage the parking brake, connect the brake pedals withthe locking pin, push down on both pedals, and pull thebrake latch out.3. To release the parking brake, press both pedals until theparking brake latch retracts.4. Danger—reels enabled.
8

108-6708
105-0123
Model 03807
1. Throttle—slow 7. Reels disabled—lift and lower2. Throttle—fast
8. Headlights (optional)3. Reels raised and off 9. Headlights—On4. Reels lowered and on when enabled—forward and backlap 10. Headlights—Off5. Reels—enabled 11. Read the Operators Manual .6. Reels disabled—lift only
9

104-9296
Models 03806 and 03807
1. Throttle—slow 4. Reels lowered and on whenenabled—forward andbacklap 7. Reels disabled—lift and lower 10. Headlights—Off
2. Throttle—fast 5. Reels enabled
8. Headlights (optional) 11. Read the Operator’s Manualfor further instructions.3. Reels raised and off 6. Reels disabled—lift only 9. Headlights—On
104-9294
1. Read the Operator’s Manual .
3. Warning—Read theOperator’s Manual . 5. Warning—keep bystandersa safe distance from themachine. 7. Warning—use a rolloverprotection system and wearthe seat belt.2. Do not tow the machine. 4. Cutting hazard of handor foot—stay away frommoving parts.
6. Warning—lock the parkingbrake, stop the engine, andremove the ignition keybefore leaving the machine. 8. Tipping hazard—lower thecutting unit when drivingdown slopes.
10

104-9295
Replaces 104–9294 for CE
1. Read the Operator’s Manual .
3. Warning—Read theOperator’s Manual . 5. Warning—keep bystandersa safe distance from themachine. 7. Warning—use a rolloverprotection system and wearthe seat belt.2. Do not tow the machine. 4. Cutting hazard of handor foot—stay away frommoving parts.
6. Warning—lock the parkingbrake, stop the engine, andremove the ignition keybefore leaving the machine. 8. Tipping hazard—lower thecutting unit when drivingdown slopes and do notdrive across or down slopesgreater than 15 degrees.
11

105-9268
1. Reel—height of cut 4. Machine speed2. Reel—mow and backlap 5. Rear reels circuit controls3. Read the Operator’s
Manual.
6. Front reels circuit controls
Battery Symbols
Some or all of these symbols are on your battery
1. Explosion hazard 6. Keep bystanders a safedistance from the battery.2. No re, open ame, orsmoking.
7. Wear eye protection;
explosive gases can causeblindness and other injuries3. Caustic liquid/chemical
burn hazard
8. Battery acid can causeblindness or severe burns.4. Wear eye protection
9. Flush eyes immediately
with water and get medicalhelp fast.5. Read the Operator’s
Manual.
10. Contains lead; do notdiscard.
106-6754
1. Warning—do not touch the hot surface.2. Cutting/dismemberment hazard, fan and entanglementhazard, belt—stay away from moving parts.
67-7960
12

Setup
Loose Parts
Use the chart below to verify that all parts have been shipped.
Step
Description
Qty.
Use
1
No parts required
–
Check uid levels.
Large O-ring
14/10
Counter weight 7/52
Steering locking pin 7/5
Install the cutting units.
3
No parts required
–
Make cutting unit adjustments ifneeded.
Calcium chloride (obtainseparately)
100lb
4
Rear weight kit, part number104–1478 (obtain separately)
1
Add rear ballast (if required).
CE decals
45
CE certicate
2
Install the CE decals.
Operator’s Manual
1
Engine Operator’s Manual
1
Parts Catalog
1
Diagnostic ACE display overlay
1
Ignition keys on ring
1
Hood lock key
1
Gauge bar
1
Screw 2
6
Wing nut
2
Read the manuals and watchthe video before operating themachine.
Step
1
Checking Fluid Levels
No Parts Required
Procedure
Before star ting the engine for the first time , c hec k
the follo wing fluid lev els:
•Engine oil
R efer to Chec king the Engine Oil in Operation ,
pag e 22 .
•Engine coolant
R efer to Chec king the Cooling System
Operation , pag e 22 .
•Hy draulic oil
R efer to Chec king the Hy draulic Oil in
Operation , pag e 22 .
•R ear axle lubricant
R efer to Chec king the R ear Axle Lubricant in
Dri v e System Maintenance , pag e 41 .
13

Step
2
Installing the Cutting Units
Parts needed for this step:
14/10
Large O-ring
7/5 Counter weight
7/5 Steering locking pin
Procedure
Cutting unit models 03860, 03861, and 03862 can
be installed at any of the mounting locations on
the traction unit. Figure 3 sho ws the orientation of
the h y draulic dri v e motor for eac h of the locations .
F or any of the locations requiring the motor to
be mounted on the right end of the cutting unit,
install a counter w eight on the left end of the
cutting unit. F or the locations requiring the motor
to be mounted on the left end, install a counter
w eight on the right end of the cutting unit.
Note: Counterw eight mounting capscrews are
shipped installed on the right bearing housing of
the cutting units . T he capscrews on left bearing
housing are to be used for securing the h y draulic
motor .
Figure 3
1. R emo v e cutting units from car tons . Assemble
and adjust per Cutting Unit Operator’ s Manual .
2. R emo v e protecti v e plugs from eac h end of
cutting unit.
3. Lubricate and install a larg e O-ring into bearing
housing g roo v e on eac h end of cutting unit
( Figure 4 & Figure 7 ).
Figure 4
1. Bearing housing 3. Counterweight2. Large o-ring
Note: Before installing cutting unit motors
or counterw eights , lubricate inter nal splines of
cutting unit reel shafts with g rease .
4. Install a counter w eight onto appropriate end
of eac h cutting unit with capscrews pro vided
( Figure 4 ).
5. T horoughly g rease the cutting unit reel
bearings prior to installation on the traction
unit. Grease should be evident at the inboard
reel seals; refer to Cutting Unit Operator’ s
Manual for g reasing procedure .
6. Inser t a thr ust w asher onto horizontal shaft of
pi v ot kn uc kle as sho wn in Figure 5 .
Figure 5
1. Carrier frame 4. Lynch pin2. Pivot knuckle 5. Steering locking pin3. Lift arm steering plate
14

7. Inser t the horizontal shaft of the pi v ot kn uc kle
into the mounting tube of the car rier frame
( Figure 5 ).
8. Secure pi v ot kn uc kle to car rier frame with a
thr ust w asher , flat w asher and a flang e head
capscrew ( Figure 5 ).
9. Inser t a thr ust w asher onto v er tical shaft of
pi v ot kn uc kle ( Figure 5 ).
10. If remo v ed, inser t the v er tical shaft of the
pi v ot kn uc kle into lift ar m pi v ot hub ( Figure 5 ).
Guide the pi v ot kn uc kle in place betw een the
tw o r ubber centering bumpers in the under
side of the lift ar m steering plate .
11. Inser t the lync h pin into the cross hole on the
pi v ot kn uc kle shaft ( Figure 5 ).
12. R emo v e n ut securing turf compensation spring
mounting brac k et to cutting unit stabilizer ear
( Figure 6 ). Inser t tipper c hain onto capscrew
and secure with n ut remo v ed.
Figure 6
1. Lift chain 2. Cutting unit stabilizer ear
13. Mount the motor to the dri v e end of the
cutting unit and secure with tw o capscrews
pro vided ( Figure 7 ).
Figure 7
1. Motor
2. O-ring
Note: If fix ed cutting unit position is
required, inser t steering loc king pin into pi v ot
kn uc kle mounting hole ( Figure 5 ).
14. Hook spring wire around bottom of steering
loc king pin ( Figure 5 ).
Step
3
Making Alternate CuttingUnit Adjustments
No Parts Required
Procedure
T he factor y sets the tractor appropriately for
most fairw a y mo wing applications . Sev eral
adjustments for fine-tuning the mac hine
for par ticular applications are included in
Cutting Unit Maintenance , pag e 48 , as follo ws:
•Adjusting the turf compensation spring
Adjusts the amount of fore and aft rotation
a v ailable , the amount of g round clearance in
transpor t, and transfers the w eight from the
front to rear roller , reducing bobbing (a w a v e
patter n in the turf).
•Adjusting the cutting unit lo w ering rate
Adjusts the speed at whic h the cutting units
lo w er .
15

•Adjusting the lifted height of the outer front
cutting units
Adjusts the tur naround height of the outer
front cutting units to pro vide g reater clearance
on contoured fairw a ys .
•Adjusting the tra v el of the front three cutting
units
Adjusts the do wnw ard tra v el of the front three
cutting units to allo w for highly contoured
fairw a ys .
Step
4
Adding Rear Ballast
Parts needed for this step:
100lb
Calcium chloride (obtain separately)
1
Rear weight kit, part number 104–1478 (obtainseparately)
Procedure
T o comply with CEN standard EN 836:1997, ISO
standard 5395:1990, and the ANSI B71.4-1999
Standard, add 100 lb (45 kg) of calcium c hloride
ballast is to the rear wheels and install the rear
w eight kit (P ar t Number 104-1478).
Important: If a punctur e occur s in a tir e
with calcium chloride, r emo v e unit fr om
turf ar ea as quickl y as possible. T o pr ev ent
possible dama ge to turf, immediatel y soak
af fected ar ea with w ater .
Step
5
Installing CE Decals
Parts needed for this step:
4
CE decals
2
CE certicate
Procedure
If y ou will be using the mac hine in a CE
countr y , install the supplied CE decals o v er the
cor responding ANSI decals on the product. Store
the CE cer tificates in a safe location.
Step
6
Reading the Manuals andStoring Additional Parts
Parts needed for this step:
1
Operator’s Manual
1
Engine Operator’s Manual
1
Parts Catalog
1
Diagnostic ACE display overlay
1
Ignition keys on ring
1
Hood lock key
1
Gauge bar
2 Screw
2
Wing nut
Procedure
1. R ead the man uals .
2. View the Operator video .
3. T he diagnostic A CE displa y o v erla y is for
diagnosing mac hine malfunctions . Store it in a
safe location.
4. T he g aug e bar , screws , and wing n ut are for
use in setting the cutting units (refer to the
cutting unit Operator’ s Manual ). Store them in a
safe location.
16

Product Overview
Figure 8
1. Steering wheel
3. Cutting unit
5. Manual tube 7. Roll over protection system(ROPS)2. Brake pedals 4. Traction pedal 6. Hood
Controls
Traction Pedal
T he traction pedal ( Figure 9 ) controls forw ard and
rev erse operation. De press top of pedal to mo v e
forw ard and bottom to mo v e bac kw ard. Ground
speed de pends on ho w far pedal is de pressed. F or
no load, maxim um g round speed, fully de press
pedal while throttle is in F AST .
T o stop , reduce foot pressure on traction pedal
and allo w it to retur n to center position.
17

Figure 9
1. Traction pedal 6. Parking brake latch2. Forward speed limiter 7. Locking pin3. Red diagnostic light 8. Reverse speed limiter4. Speedometer 9. Key switch5. Brake pedals
Forward Speed Limiter
Preset the forw ard speed limiter ( Figure 9 ) to limit
the amount the traction pedal can be de pressed
in the forw ard direction to maintain a constant
mo wing speed.
Red Diagnostic Light
T he red diagnostic light ( Figure 9 ), located on
steering to w er , is used to con v ey sev eral different
messag es . W hile star ting the mac hine , the light
will illuminate when the glo w plugs are on.
If the light blinks during operation, it ma y indicate
any of the follo wing:
•T he mac hine is being operated faster than the
maxim um speed v alue initially prog rammed
into the ECU .
•An electrical malfunction has been detected
(open or shor ted output.
•A h y draulic leak has been detected (Only if
T urfdefender leak detector is installed on
mac hine)
•A comm unications er ror has been detected
(Only if T urfdefender leak detector is installed
on mac hine)
Key Switch
T he k ey switc h ( Figure 9 ) has three positions:
OFF , ON/Preheat and ST AR T .
Speedometer
T he speedometer ( Figure 9 ) indicates g round
speed at whic h mac hine is tra v eling .
Brake Pedals
T w o brak e pedals ( Figure 9 ) operate indi vidual
wheel brak es for tur ning assistance , parking,
and to aid in obtaining better sidehill traction.
Loc king pin connects the pedals for parking brak e
operation and transpor t.
Parking Brake Latch
A knob on the left side of console actuates parking
brak e loc k ( Figure 9 ). T o eng ag e parking brak e ,
connect pedals with loc king pin, push do wn on
both pedals and pull parking brak e latc h out. T o
release parking brak e , de press both pedals until
parking brak e latc h retracts .
Reverse Speed Limiter
Adjust the screw ( Figure 9 ) to limit the amount the
traction pedal can be de pressed in the rearw ard
direction to limit speed.
Lower Mow/Raise Control Lever(Joystick)
T he lev er ( Figure 10 and Figure 11 ) raises and
lo w ers the cutting units and also star ts and stops
the reels .
18

Figure 10
Model 03808
1. Lower mow/raise controllever 7. Charge indicator
2. Fuel gauge 8. Throttle control3. Engine coolanttemperature gauge
9. Enable/disable switch(Master)4. Engine oil pressure warninglight
10. Enable/disable switch (#7)right rear5. Engine coolanttemperature warninglight
11. Enable/disable switch (#6)left rear
6. Glow plug indicator light
Figure 11
Models 03806 and 03807
1. Lower mow/raise controllever 6. Glow plug indicator light
2. Fuel gauge 7. Charge indicator3. Engine coolanttemperature gauge
8. Throttle control
4. Engine oil pressure warninglight 9. Enable/disable switch(Master)5. Engine coolanttemperature warninglight
Fuel Gauge
T he fuel g aug e ( Figure 10 and Figure 11 ) indicates
lev el of fuel in tank.
Engine Oil Pressure Warning Light
T his light ( Figure 10 and Figure 11 ) indicates
dang erously lo w engine oil pressure .
Throttle Control
Mo v e the control ( Figure 10 and Figure 11 )
forw ard to increase engine speed, rearw ard to
decrease speed.
Engine Coolant Temperature WarningLight
T he light ( Figure 10 and Figure 11 ) illuminates and
the engine shuts do wn when the coolant reac hes
a dang erously high temperature .
Glow Plug Indicator Light
W hen the indicator light ( Figure 10 and Figure 11 )
is lit, indicates glo w plugs are on.
Charge Indicator
T he c harg e indicator ( Figure 10 and Figure 11 )
illuminates when system c harging circuit
malfunctions .
Enable/Disable Switches
T he enable/disable switc hes ( Figure 10 and
Figure 11 ) are used in conjunction with the lo w er
mo w/raise control lev er (J o ystic k) to operate reels .
R eels can be raised but not lo w ered when in mid
position.
Hour Meter
T he hour meter ( Figure 12 ) sho ws total hours that
mac hine has been operated.
19

Figure 12
1. Hour meter
Backlap Knobs
T he bac klap knobs ( Figure 13 ) are used in
conjunction with lo w er mo w/raise control lev er
for bac klapping operation. R efer to Bac klapping
in Cutting Unit Maintenance , pag e 48 .
Figure 13
1. Reel control knobs 2. Backlap knobs
Reel Speed Controls
Controls RPM of front and rear cutting units
( Figure 13 ). #1 position is for bac klapping .
R emaining settings are for mo wing operations . See
decal under seat for proper settings .
Seat
T he seat adjusting lev er ( Figure 14 ) allo ws 4 inc h
fore and aft adjustment. T he seat adjusting knob
( Figure 14 ) adjusts seat for operators w eight. T o
adjust seat fore and aft, pull lev er on left side
of seat assembly outw ard. After mo ving seat to
desired location, release lev er to loc k seat into
position. T o adjust for operators w eight, tur n
spring tension knob; cloc kwise to increase tension,
countercloc kwise to decrease spring tension.
Figure 14
1. Seat adjusting lever 2. Seat adjusting knob
Green Diagnostic Light
T he mac hine is equipped with a diagnostic light
whic h indicates if the electronic controller is
functioning cor rectly . T he g reen diagnostic light
( Figure 15 ) is located under the control panel,
next to the fuse bloc k. W hen the electronic
controller is functioning cor rectly and the k ey
switc h is mo v ed to the ON position, the controller
diagnostic light will be illuminated. T he light will
blink if the controller detects a malfunction in the
electrical system. T he light will stop blinking and
automatically reset when the k ey switc h is tur ned
to the OFF position.
Figure 15
1. Green diagnostic light
W hen the controller diagnostic light blinks , one of
the follo wing problems has been detected b y the
controller :
20