Toro 3806 User manual

FormNo.3358-628RevA
Reelmaster®6500-Dand6700-D
TractionUnit
ModelNo.03806—SerialNo.270000001andUp
ModelNo.03807—SerialNo.270000001andUp
ModelNo.03808—SerialNo.270000001andUp
Registeratwww.Toro.com.OriginalInstructions(EN)

Warning
CALIFORNIA
Proposition65Warning
Dieselengineexhaustandsomeofits
constituentsareknowntotheStateof
Californiatocausecancer,birthdefects,
andotherreproductiveharm.
Important:Thisengineisnotequippedwitha
sparkarrestermufer.ItisaviolationofCalifornia
PublicResourceCodeSection4442touseoroperate
theengineonanyforest-covered,brush-covered,or
grass-coveredland.Otherstatesorfederalareas
mayhavesimilarlaws.
Introduction
Readthisinformationcarefullytolearnhowtooperate
andmaintainyourproductproperlyandtoavoidinjury
andproductdamage.Youareresponsibleforoperating
theproductproperlyandsafely.
YoumaycontactTorodirectlyatwww.Toro.comfor
productandaccessoryinformation,helpndinga
dealer,ortoregisteryourproduct.
Wheneveryouneedservice,genuineToroparts,
oradditionalinformation,contactanAuthorized
ServiceDealerorToroCustomerServiceandhave
themodelandserialnumbersofyourproductready.
Figure1identiesthelocationofthemodelandserial
numbersontheproduct.Writethenumbersinthe
spaceprovided.
Figure1
1.Locationofthemodelandserialnumbers
ModelNo.
SerialNo.
Thismanualidentiespotentialhazardsandhas
safetymessagesidentiedbythesafetyalertsymbol
(Figure2),whichsignalsahazardthatmaycauseserious
injuryordeathifyoudonotfollowtherecommended
precautions.
Figure2
1.Safetyalertsymbol.
Thismanualusestwootherwordstohighlight
information.Importantcallsattentiontospecial
mechanicalinformationandNoteemphasizesgeneral
informationworthyofspecialattention.
©2007—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN554202
Contactusatwww.Toro.com.
PrintedintheUSA.
AllRightsReserved

Contents
Introduction.................................................................2
Safety...........................................................................4
SafeOperatingPractices.......................................4
ToroMowerSafety...............................................5
SoundPressureLevel...........................................6
VibrationLevel.....................................................6
SafetyandInstructionalDecals.............................7
Setup..........................................................................12
1CheckingFluidLevels......................................12
2InstallingCuttingUnitsModels03860,03861
and03862.......................................................12
3InstallingCuttingUnitsModels03863and
03864.............................................................14
4MakingAlternateCuttingUnit
Adjustments...................................................18
5AddingRearBallast..........................................19
6InstallingCEDecals........................................19
7ReadingtheManualsandStoringAdditional
Parts...............................................................19
ProductOverview......................................................20
Controls.............................................................20
Specications.....................................................24
Attachments/Accessories...................................24
Operation...................................................................24
CheckingtheEngineOil.....................................24
CheckingtheCoolingSystem..............................25
FillingtheFuelTank...........................................26
CheckingtheHydraulicFluid..............................26
CheckingtheTirePressure.................................27
CheckingtheReeltoBedknifeContact................27
StartingandStopping.........................................27
BleedingtheFuelSystem....................................27
PushingorTowingtheMachine..........................28
CheckingtheInterlockSwitches.........................29
FaultMemoryandRetrieval................................30
HydraulicSolenoidValveFunctions....................31
OperatingTips...................................................31
Maintenance...............................................................33
RecommendedMaintenanceSchedule(s)................33
ServiceIntervalChart.........................................34
DailyMaintenanceChecklist...............................34
Lubrication.............................................................35
GreasingtheBearingsandBushings....................35
EngineMaintenance...............................................37
ServicingtheAirCleaner....................................37
ServicingtheEngineOilandFilter......................38
AdjustingThrottle..............................................38
FuelSystemMaintenance.......................................39
FuelTank...........................................................39
FuelLinesandConnections................................39
FuelFilter/WaterSeparator................................39
ReplacingtheFuelPre-Filter...............................39
BleedingAirFromInjectors...............................40
ElectricalSystemMaintenance................................41
BatteryCare.......................................................41
Fuses..................................................................41
OptionalLighting...............................................42
DriveSystemMaintenance.....................................43
CheckingtheTorqueoftheWheelNutsor
Bolts..............................................................43
CheckingthePlanetaryGearDrive
Oil..................................................................43
ChangingthePlanetaryGearDrive
Oil..................................................................43
CheckingtheRearAxleLubricant.......................44
ChangingtheRearAxleLubricant.......................44
RearWheelToe-In.............................................45
AdjustingtheTractionDriveforNeutral.............45
CoolingSystemMaintenance..................................46
RemovingDebris...............................................46
MaintainingtheCoolingSystem..........................46
BrakeMaintenance.................................................47
AdjustingtheServiceBrakes...............................47
BeltMaintenance....................................................47
CheckingtheAlternatorBelt...............................47
HydraulicSystemMaintenance...............................48
ChangingtheHydraulicFluid.............................48
ReplacingtheHydraulicFilter.............................48
CheckingtheHydraulicLinesandHoses.............48
HydraulicSystemTestPorts...............................49
CuttingUnitMaintenance.......................................50
CuttingUnitKickstandModels03863and
03864.............................................................50
Backlapping........................................................50
AdjustingtheCuttingUnitLoweringRate
......................................................................52
LiftedHeightofOuterFrontCuttingUnits
(EnablePosition)............................................53
AdjustingtheTraveloftheFrontThree
CuttingUnits..................................................53
Storage.......................................................................55
TractionUnit......................................................55
Engine...............................................................55
Schematics.................................................................56
3

Safety
ThismachinemeetsorexceedsCENstandard
EN836:1997,ISOstandard5395:1990,andANSI
B71.4-1999specicationsineffectatthetimeof
productionwhen,ballastisadded;refertoAdding
RearBallastinSetup,page12.
Note:Theadditionofattachmentsmadeby
othermanufacturersthatdonotmeetAmerican
NationalStandardsInstitutecerticationwillcause
noncomplianceofthismachine.
Improperuseormaintenancebytheoperatororowner
canresultininjury.Toreducethepotentialforinjury,
complywiththesesafetyinstructionsandalwayspay
attentiontothesafetyalertsymbol,whichmeans
CAUTION,WARNING,orDANGER-“personalsafety
instruction.”Failuretocomplywiththeinstructionmay
resultinpersonalinjuryordeath.
SafeOperatingPractices
ThefollowinginstructionsarefromtheCENstandard
EN836:1997,ISOstandard5395:1990,andANSI
B71.4-1999.
Training
•ReadtheOperator’sManualandothertraining
material.Iftheoperator(s)ormechanic(s)cannot
readEnglishitistheowner’sresponsibilitytoexplain
thismaterialtothem.
•Becomefamiliarwiththesafeoperationofthe
equipment,operatorcontrols,andsafetysigns.
•Alloperatorsandmechanicsshouldbetrained.The
ownerisresponsiblefortrainingtheusers.
•Neverletchildrenoruntrainedpeopleoperateor
servicetheequipment.Localregulationsmayrestrict
theageoftheoperator.
•Theowner/usercanpreventandisresponsiblefor
accidentsorinjuriesoccurringtohimselforherself,
otherpeopleorproperty.
Preparation
•Evaluatetheterraintodeterminewhataccessories
andattachmentsareneededtoproperlyand
safelyperformthejob.Onlyuseaccessoriesand
attachmentsapprovedbythemanufacturer.
•Wearappropriateclothingincludinghardhat,safety
glassesandearprotection.Longhair,looseclothing
orjewelrymaygettangledinmovingparts.
•Inspecttheareawheretheequipmentistobeused
andremoveallobjectssuchasrocks,toysandwire
whichcanbethrownbythemachine.
•Useextracarewhenhandlingdieselfuel.Itis
ammableandvaporsareexplosive.
Useonlyanapprovedcontainer.
•Neverremovegascaporaddfuelwithengine
running.Allowenginetocoolbeforerefueling.Do
notsmoke.
•Neverrefuelordrainthemachineindoors.
•Checkthatoperator’spresencecontrols,safety
switchesandshieldsareattachedandfunctioning
properly.Donotoperateunlesstheyarefunctioning
properly.
Operation
•Neverrunanengineinanenclosedarea.
•Onlyoperateingoodlight,keepingawayfromholes
andhiddenhazards.
•Besurealldrivesareinneutralandparkingbrakeis
engagedbeforestartingengine.Onlystartengine
fromtheoperator’sposition.Useseatbeltsif
provided.
•Slowdownanduseextracareonhillsides.Besure
totravelintherecommendeddirectiononhillsides.
Turfconditionscanaffectthemachine’sstability.
Usecautionwhileoperatingneardrop-offs.
•Slowdownandusecautionwhenmakingturnsand
whenchangingdirectionsonslopes.
•Neveroperatewithguardsnotsecurelyinplace.Be
sureallinterlocksareattached,adjustedproperly,
andfunctioningproperty.
•Donotchangetheenginegovernorsettingor
overspeedtheengine.
•Stoponlevelground,raisethecuttingunits,
disengagedrives,engageparkingbrake(ifprovided),
shutoffenginebeforeleavingtheoperator’sposition
foranyreasonincludingemptyingthegrassbaskets.
•Stopequipmentandinspectthemachineafter
strikingobjectsorifanabnormalvibrationoccurs.
Makenecessaryrepairsbeforeresumingoperations.
•Keephandsandfeetawayfromthecuttingunits.
•Lookbehindanddownbeforebackinguptobesure
ofaclearpath.
•Nevercarrypassengersandkeeppetsandbystanders
away.
4

•Slowdownandusecautionwhenmakingturns
andcrossingroadsandsidewalks.Stopreelsifnot
mowing.
•Donotoperatethemowerundertheinuenceof
alcoholordrugs.
•Usecarewhenloadingorunloadingthemachine
intoatrailerortruck.
•Usecarewhenapproachingblindcorners,shrubs,
trees,orotherobjectsthatmayobscurevision.
MaintenanceandStorage
•Disengagedrives,raisethecuttingunits,setparking
brake,stopengineandremovekey.Waitforall
movementtostopbeforeadjusting,cleaningor
repairing.
•Cleangrassanddebrisfromcuttingunits,drives,
mufers,andenginetohelppreventres.Cleanup
oilorfuelspillage.
•Letenginecoolbeforestoringanddonotstorenear
ame.
•Shutofffuelwhilestoringortransporting.Donot
storefuelnearamesordrainindoors.
•Parkmachineonlevelground.Neverallowuntrained
personneltoservicemachine.
•Usejackstandstosupportcomponentswhen
required.
•Carefullyreleasepressurefromcomponentswith
storedenergy.
•Disconnectbatteryandremovesparkplugwire
beforemakinganyrepairs.Disconnectthenegative
terminalrstandthepositivelast.Reconnect
positiverstandnegativelast.
•Usecarewhencheckingthereels.Wearglovesand
usecautionwhenservicingthem.
•Keephandsandfeetawayfrommovingparts.If
possible,donotmakeadjustmentswiththeengine
running.
•Chargebatteriesinanopenwellventilatedarea,
awayfromsparkandames.Unplugchargerbefore
connectingordisconnectingfrombattery.Wear
protectiveclothinganduseinsulatedtools.
•Keepallpartsingoodworkingconditionandall
hardwareandhydraulicttingstightened.Replaceall
wornordamageddecals.
ToroMowerSafety
Thefollowinglistcontainssafetyinformationspecicto
Toroproductsorothersafetyinformationthatyoumust
knowthatisnotincludedintheANSIstandards.
Thisproductiscapableofamputatinghandsand
feetandthrowingobjects.Alwaysfollowallsafety
instructionstoavoidseriousinjuryordeath.
Useofthisproductforpurposesotherthanitsintended
usecouldprovedangeroustouserandbystanders.
Operation
•Sitontheseatwhenstartingandoperatingthe
machine.
•Alwayswearsubstantialshoes.Donotoperatethe
machinewhilewearingsandals,tennisshoes,or
sneakers.
•Wearingsafetyshoesandlongpantsisadvisableand
requiredbysomelocalordinancesandinsurance
regulations.
•Handlefuelcarefully.Wipeupanyspills.
•Checkthesafetyinterlockswitchesdailyforproper
operation.Ifaswitchshouldfail,replacetheswitch
beforeoperatingthemachine.Aftereverytwoyears,
replaceallthreeinterlockswitchesinthesafety
system,regardlessiftheyareworkingproperlyor
not.
•Usingthemachinedemandsattention.Toprevent
lossofcontrol:
Donotdriveclosetosandtraps,ditches,creeks,or
otherhazards.
•Reducespeedwhenmakingsharpturns.Avoid
suddenstopsandstarts.
•Donottouchtheengine,mufer,orexhaustpipe
whiletheengineisrunningorsoonafterithas
stoppedbecausetheseareascouldbehotenough
tocauseburns.
•Ifacuttingunitstrikesasolidobjectorvibrates
abnormally,stopimmediately,turntheengineoff,
waitforallmotiontostop,andinspectthemachine
fordamage.Adamagedreelorbedknifemustbe
repairedorreplacedbeforeoperationiscontinued.
•Traverseslopescarefully.Donotstartorstop
suddenlywhentravelinguphillordownhill.
•Theoperatormustbeskilledandtrainedinhowto
driveonhillsides.Failuretousecautiononslopesor
hillsmaycauselossofcontrolandcausethevehicle
totiporroll,possiblyresultinginpersonalinjury
ordeath.On4wheeldrivemodels,alwaysusethe
seatbeltandRollOverProtectionSystem(ROPS)
together.
•Iftheenginestallsorlosesheadwayandcannotmake
ittothetopofaslope,donotturnthemachine
around.Alwaysbackslowly,straightdowntheslope.
5

•Whenapersonorpetappearsunexpectedlyin
ornearthemowingarea,stopmowing.Careless
operation,combinedwithterrainangles,ricochets,
orimproperlypositionedguardscanleadtothrown
objectinjuries.Donotresumemowinguntilthe
areaiscleared.
•Donotparkonslopesunlessthewheelsarechocked
orblocked.
MaintenanceandStorage
•Makesureallhydrauliclineconnectorsaretightand
allhydraulichosesandlinesareingoodcondition
beforeapplyingpressuretothesystem.
•Keepyourbodyandhandsawayfrompinhole
leaksornozzlesthatejecthydraulicuidunderhigh
pressure.Usepaperorcardboard,notyourhands,
tosearchforleaks.Hydraulicuidescapingunder
pressurecanhavesufcientforcetopenetratethe
skinandcauseseriousinjury.
•Beforedisconnectingorperforminganyworkon
thehydraulicsystem,allpressureinthesystemmust
berelievedbystoppingtheengineandloweringthe
cuttingunitsandattachmentstotheground.
•Iftheenginemustberunningtoperforma
maintenanceadjustment,keephands,feet,clothing,
andanypartsofthebodyawayfromthecutting
units,attachmentsandanymovingparts.Keep
everyoneaway.
•Theenginemustbeshutoffbeforecheckingtheoil
oraddingoiltothecrankcase.
•Ifmajorrepairsareeverneededorifassistanceis
desired,contactanAuthorizedToroDistributor.
•Tomakesureofoptimumperformanceand
continuedsafetycerticationofthemachine,use
onlygenuineTororeplacementpartsandaccessories.
Replacementpartsandaccessoriesmadebyother
manufacturerscouldbedangerous,andsuchuse
couldvoidtheproductwarranty.
SoundPressureLevel
ThisunithasanequivalentcontinuousA-weighted
soundpressurelevelattheoperatorearof89dBA,
basedonmeasurementsofidenticalmachinesperEN
11094andEN836.
VibrationLevel
Thisunitdoesnotexceedavibrationlevelof2.5m/s²at
thehandsbasedonmeasurementsofidenticalmachines
perEN1033procedures.
Thisunitdoesnotexceedavibrationlevelof.5m/s²
attheposteriorbasedonmeasurementsofidentical
machinesperEN1032procedures.
6

SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaof
potentialdanger.Replaceanydecalthatisdamagedorlost.
104-5229
1.ReadtheOperator’s
Manual.
3.Fuseforheadlights
(optional)
2.Fuseforstarter
105-7506
1.ReadtheOperator’s
Manual.
4.Engine—preheat
2.Engine—stop5.Engine—start
3.On
93-6693
1.Crushinghazardofhand—waitformovingpartstostop.
93-6680
93-6686
1.Hydraulicoil
2.ReadtheOperator’sManual.
93-6699
1.Machinespeed3.Continuousvariable
setting
2.Slow4.Fast
2
1
93-9425
1.ReadtheOperator’sManual.
2.Hydraulichosesareunderpressure—stayawayfrom
movingparts.
93-6696
1.Storedenergyhazard—readtheOperator’sManual.
7

93-6687
1.Donotstephere.
93-6689
1.Warning—donotcarrypassengers.
93-6681
1.Cutting/dismemberment—hazard,fan-stayawayfrom
movingparts..
93-1265
1.Hotsurface/burnhazard—stayasafedistancefromthe
hotsurface.
104-9298
1.ReadtheOperator’sManual.
93-1263
93-1263
1.ReadtheOperator’sManual.
2.Toengagetheparkingbrake,connectthebrakepedalswith
thelockingpin,pushdownonbothpedals,andpullthe
brakelatchout.
3.Toreleasetheparkingbrake,pressbothpedalsuntilthe
parkingbrakelatchretracts.
4.Danger—reelsenabled.
108-6708
8

106-6754
1.Warning—donottouchthehotsurface.
2.Cutting/dismembermenthazard,fanandentanglement
hazard,belt—stayawayfrommovingparts.
67-7960
105-0123
Model03807
1.Throttle—slow7.Reelsdisabled—liftandlower
2.Throttle—fast8.Headlights(optional)
3.Reelsraisedandoff9.Headlights—On
4.Reelsloweredandonwhenenabled—forwardandbacklap10.Headlights—Off
5.Reels—enabled11.ReadtheOperatorsManual.
6.Reelsdisabled—liftonly
104-9296
Models03806and03807
1.Throttle—slow4.Reelsloweredandonwhen
enabled—forwardand
backlap
7.Reelsdisabled—liftand
lower
10.Headlights—Off
2.Throttle—fast5.Reelsenabled8.Headlights(optional)11.ReadtheOperator’s
Manualforfurther
instructions.
3.Reelsraisedandoff6.Reelsdisabled—liftonly9.Headlights—On
9

104-9294
1.ReadtheOperator’s
Manual.
3.Warning—Readthe
Operator’sManual.
5.Warning—keepbystanders
asafedistancefromthe
machine.
7.Warning—usearollover
protectionsystemandwear
theseatbelt.
2.Donottowthemachine.4.Cuttinghazardofhand
orfoot—stayawayfrom
movingparts.
6.Warning—locktheparking
brake,stoptheengine,and
removetheignitionkey
beforeleavingthemachine.
8.Tippinghazard—lowerthe
cuttingunitwhendriving
downslopes.
104-9295
Replaces104–9294forCE
1.ReadtheOperator’s
Manual.
3.Warning—Readthe
Operator’sManual.
5.Warning—keepbystanders
asafedistancefromthe
machine.
7.Warning—usearollover
protectionsystemandwear
theseatbelt.
2.Donottowthemachine.4.Cuttinghazardofhand
orfoot—stayawayfrom
movingparts.
6.Warning—locktheparking
brake,stoptheengine,and
removetheignitionkey
beforeleavingthemachine.
8.Tippinghazard—lowerthe
cuttingunitwhendriving
downslopesanddonot
driveacrossordownslopes
greaterthan15degrees.
10

112-6555
Models03806and03807
Partno.112–6556forModel03808
1.Reel—heightofcut4.Machinespeed
2.Reel—mowandbacklap5.Rearreelscircuitcontrols
3.ReadtheOperator’s
Manual.
6.Frontreelscircuitcontrols
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.
11

Setup
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
1Nopartsrequired–Checkuidlevels.
LargeO-ring14/10
Counterweight7/5
2Steeringlockingpin7/5
Installcuttingunits.
Liftchain5/7
Chainbracket5/7
U-bolt5/7
Nut10/14
Screw5/7
Washer5/7
Nut5/7
3
LargeO-ring5/7
Installcuttingunits.
4Nopartsrequired–Makecuttingunitadjustmentsifneeded.
Calciumchloride(obtainseparately)100lb
5Rearweightkit,partnumber104–1478
(obtainseparately)1Addrearballast(ifrequired).
CEdecals4
6CEcerticate2InstalltheCEdecals.
Operator’sManual1
EngineOperator’sManual1
PartsCatalog1
DiagnosticACEdisplayoverlay1
Ignitionkeysonring1
Hoodlockkey1
Gaugebar1
Screw2
7
Wingnut2
Readthemanualsandwatchthevideo
beforeoperatingthemachine.
1
CheckingFluidLevels
NoPartsRequired
Procedure
Beforestartingtheengineforthersttime,checkthe
followinguidlevels:
•Engineoil
RefertoCheckingtheEngineOilinOperation,
page24.
•Enginecoolant
RefertoCheckingtheCoolingSystemOperation,
page24.
•Hydraulicoil
RefertoCheckingtheHydraulicOilinOperation,
page24.
•Rearaxlelubricant
RefertoCheckingtheRearAxleLubricantinDrive
SystemMaintenance,page43.
12

2
InstallingCuttingUnits
Models03860,03861and
03862
Partsneededforthisprocedure:
14/10LargeO-ring
7/5Counterweight
7/5Steeringlockingpin
MounttheCuttingUnits
Cuttingunitmodels03860,03861,and03862canbe
installedatanyofthemountinglocationsonthetraction
unit.Figure3showstheorientationofthehydraulic
drivemotorforeachofthelocations.Foranyofthe
locationsrequiringthemotortobemountedontheright
endofthecuttingunit,installacounterweightonthe
leftendofthecuttingunit.Forthelocationsrequiring
themotortobemountedontheleftend,installa
counterweightontherightendofthecuttingunit.
Note:Counterweightmountingcapscrewsareshipped
installedontherightbearinghousingofthecutting
units.Thecapscrewsonleftbearinghousingaretobe
usedforsecuringthehydraulicmotor.
Motor Weight
Motor Weight* Weight Motor
Weight* Motor Weight Motor
* With speed sensor
#1#4 #5
#3
#2
Motor Weight Weight Motor
#7
#6
G000810
Figure3
1.Removecuttingunitsfromcartons.Assembleand
adjustperCuttingUnitOperator’sManual.
2.Removeprotectiveplugsfromeachendofcutting
unit.
3.LubricateandinstallalargeO-ringintobearing
housinggrooveoneachendofcuttingunit
(Figure4&Figure7).
1
2
3
G000742
Figure4
1.Bearinghousing3.Counterweight
2.Largeo-ring
Note:Beforeinstallingcuttingunitmotorsor
counterweights,lubricateinternalsplinesofcutting
unitreelshaftswithgrease.
4.Installacounterweightontoappropriateendofeach
cuttingunitwithcapscrewsprovided(Figure4).
5.Thoroughlygreasethecuttingunitreelbearingsprior
toinstallationonthetractionunit.Greaseshould
beevidentattheinboardreelseals;refertoCutting
UnitOperator’sManualforgreasingprocedure.
6.Insertathrustwasherontohorizontalshaftofpivot
knuckleasshownin(Figure5).
1
2
3
4
5
G000749
Figure5
1.Carrierframe4.Lynchpin
2.Pivotknuckle5.Steeringlockingpin
3.Liftarmsteeringplate
7.Insertthehorizontalshaftofthepivotknuckleinto
themountingtubeofthecarrierframe(Figure5).
8.Securepivotknuckletocarrierframewithathrust
washer,atwasherandaangeheadcapscrew
(Figure5).
9.Insertathrustwasherontoverticalshaftofpivot
knuckle(Figure5).
13

10.Ifremoved,inserttheverticalshaftofthepivot
knuckleintoliftarmpivothub(Figure5).Guide
thepivotknuckleinplacebetweenthetworubber
centeringbumpersintheundersideoftheliftarm
steeringplate.
11.Insertthelynchpinintothecrossholeonthepivot
knuckleshaft(Figure5).
12.Removenutsecuringturfcompensationspring
mountingbrackettocuttingunitstabilizerear
(Figure6).Inserttipperchainontocapscrewand
securewithnutremoved.
1
2
G000758
Figure6
1.Liftchain2.Cuttingunitstabilizerear
13.Mountthemotortothedriveendofthecuttingunit
andsecurewithtwocapscrewsprovided(Figure7).
1
2
G000769
Figure7
1.Motor2.O-ring
Note:Ifxedcuttingunitpositionisrequired,
insertsteeringlockingpinintopivotknuckle
mountinghole(Figure5).
14.Hookspringwirearoundbottomofsteeringlocking
pin(Figure5).
AdjustTurfCompensationSpring
Tractorsaresetupatthefactoryappropriatelyformost
fairwaymowingapplications.Thefollowingadjustment
isforne-tuningthemachinetotheapplication:
TheTurfCompensationSpring(Figure8),connecting
carrierframetocuttingunit,controlstheamountof
fore-aftrotationavailable,aswellastheamountof
groundclearanceintransportandturnaround.
TheTurfCompensationSpringalsotransfersweight
fromthefronttorearroller.Thishelpstoreduceawave
patternintheturf,alsoknownasbobbing.
Important:Makespringadjustmentswithcutting
unitmountedtotractionunitandloweredtoshop
oor.RefertoSetup,page12,formounting
instructions.
1.Tightenlocknutonrearofspringroduntilthe
gap(C)betweenrearofspringbracketandfrontof
washeris1in.(25mm)(Figure8).
ˆC"
ˆA"
ˆB"
G000780
Figure8
2.Tightenhexnutsonfrontendofspringroduntilthe
compressedlength(A)ofspringis8in.(203mm)
(Figure8).
Note:Whencuttingroughorundulatingturf,
increasecompressedlength(A)ofspringto8-1/2in.
(216mm)andgap(C)betweenrearofspringbracket
andfrontofwasherto1-1/2in.(38mm)(Figure8).
Note:Ascompressedspringlength(A)decreases,
weighttransferfromfrontrollertorearroller
increasesandcarrierframe/cuttingunitrotation
angle(B)decreases.
Note:Asgap(C)betweenspringbracketand
washerincreases,cuttingunitgroundclearance
decreasesandcarrierframe/cuttingunitrotation
angle(B)increases.
14

3
InstallingCuttingUnits
Models03863and03864
Partsneededforthisprocedure:
5/7Liftchain
5/7Chainbracket
5/7U-bolt
10/14Nut
5/7Screw
5/7Washer
5/7Nut
5/7LargeO-ring
RemovetheTipperAssemblies
Thetipperassembliesmustberemovedfromthe#1,#2
and#3liftarmstoavoidinterferencewiththecutting
unitcarrierframes.
1.Removethelocknutandwashersecuringthepivot
rodtothe#2liftarm(Figure9).Removethe
pivotrodandspringfromtheliftarm.Repeatthe
procedureonthe#1and#3liftarms.
Figure9
1.Pivotrod2.Tippersupportbracket
w/roller
Note:Thetipperbracketw/rollerandthetipper
supportbracketsarenotrequiredwhenoperating
theDPAcuttingunits(Figure9).Theymaybe
removedifdesired.
2.Disconnecttheliftchainsfromthecuttingunits,if
attached.
MounttheLiftBracketsandChains
MountachainbrackettoeachliftarmwithaU-boltand
2nuts.Positionthebracketsasfollows:
1.Onliftarms#1,#4and#5,positionthechain
bracketsandU-bolts15inchesbehindthecenterline
ofthepivotknuckle(Figure10).Onliftarms#1
and#5thebracketsshouldberotatedtotheright10
degreesfromvertical(Figure10).Onliftarm#4
thebracketshouldberotatedtotheleft10degrees
fromvertical(Figure10).
Figure10
2.Onliftarms#2and#3,positionthebracketsand
U-bolts15inchesbehindthecenterlineofthepivot
knuckle(Figure11).Rotatethebrackets45degrees
totheoutboardsideofthemachine.
Figure11
15

3.Onliftarms#6and#7,positionthebracketsand
U-bolts14.5inchesbehindthecenterlineofthe
pivotknuckle(Figure12).Rotatethebrackets10
degreestotheoutboardsideofthemachine.
Figure12
4.TightenalltheU-boltnutsto38–48ft-lbs.
5.Mountaliftchaintoeachchainbracketwithascrew,
washerandnut,positioningasshowninFigure13
Figure13
1.Liftchain2.Chainbracket
AdjusttheRearShield
Undermostconditions,bestdispersionisattained
whentherearshieldisclosed(frontdischarge).When
conditionsareheavyorwet,rearshieldmaybeopened.
Toopentherearshield(Figure14),loosenthecapscrew
securingtheshieldtotheleftsideplate,rotatetheshield
totheopenpositionandtightenthecapscrew .
Figure14
1.Rearshield2.Capscrew
MounttheCounterWeights
Allcuttingunitsareshippedwiththecounterweight
mountedtotheleftendofthecuttingunit.Usethe
followingdiagramtodeterminethepositionofthe
counterweightsandreelmotors.
Figure15
1.Onthe#2,#4and#6cuttingunits,removethe2
capscrewssecuringthecounterweighttotheleft
endofthecuttingunit.Removethecounterweight
(Figure16).
16

Figure16
1.Counterweight
2.Onrightendofcuttingunit,removetheplasticplug
fromthebearinghousing(Figure17).
3.Removethe2capscrewsfromtherightsideplate
(Figure17).
Figure17
1.Plasticplug2.Capscrew(2)
4.Installthecounterweighttotherightendofthe
cuttingunitwiththe2screwspreviouslyremoved.
5.Looselyinstallthe2reelmotormountingcapscrews
totheleftsideplateofthecuttingunit(Figure17).
MounttheCuttingUnits
1.Insertathrustwasherontohorizontalshaftofpivot
knuckleasshowninFigure18.
Figure18
1.Carrierframe4.Lynchpin
2.Pivotknuckle5.Steeringlockingpin
3.Liftarmsteeringplate
2.Insertthehorizontalshaftofthepivotknuckleinto
themountingtubeofthecarrierframe(Figure18).
3.Securepivotknuckletocarrierframewithathrust
washer,atwasherandaangeheadcapscrew
(Figure18).
4.Insertathrustwasherontoverticalshaftofpivot
knuckle(Figure18).
5.Ifremoved,inserttheverticalshaftofthepivot
knuckleintoliftarmpivothub(Figure18).Guide
thepivotknuckleinplacebetweenthetworubber
centeringbumpersintheundersideoftheliftarm
steeringplate.
6.Insertthelynchpinintothecrossholeonthepivot
knuckleshaft(Figure18).
7.Securetheliftarmchaintothecuttingunitchain
bracket(Figure19)withthesnapperpinasfollows:
A.Oncuttingunits#1,4,5,6and7,onlyuse6of
thechainlinks.
B.Oncuttingunits#2and3,useall7ofthechain
links.
17

Figure19
1.Liftchain2.Snapperpin
8.Coatthesplineofthereelmotorwithcleangrease.
9.OilthereelmotorO-ringandinstallitontothe
motorange.
10.Installthemotorbyrotatingitclockwisesothat
themotorangesclearthecapscrews(Figure20).
Rotatethemotorcounterclockwiseuntiltheanges
encirclethecapscrewsthentightenthecapscrews
Important:Makesurethereelmotorhoses
arenottwisted,kinkedorintheriskofbeing
pinched.
Figure20
1.Reeldrivemotor2.Capscrew
Note:Ifxedcuttingunitpositionisrequired,
insertsteeringlockingpinintopivotknuckle
mountinghole(Figure18).
11.Hookspringwirearoundbottomofsteeringlocking
pin(Figure18).
AdjusttheTurfCompensationSpring
Tractorsaresetupatthefactoryappropriatelyformost
fairwaymowingapplications.
Thefollowingadjustmentsareavailableforne-tuning
ofthemachinetotheapplication:
TheTurfCompensationSpring(Figure21)transfers
weightfromthefronttorearroller.Thishelpstoreduce
awavepatternintheturf,alsoknownasbobbing.
Important:Makespringadjustmentswithcutting
unitmountedtotractionunitandloweredtoshop
oor.
1.Tightenlocknutonrearofspringroduntilthe
gap(C)betweenrearofspringbracketandfrontof
washeris2in.(51mm)(Figure21).
Figure21
2.Tightenhexnutsonfrontendofspringroduntil
thecompressedlength(A)ofspringis6.25in.(159
mm)(Figure21).
Note:Whenoperatingonroughterrain,decrease
thespringlengthby1/2inch.Groundfollowingwill
beslightlydecreased.
Note:Ascompressedspringlength(A)decreases,
weighttransferfromfrontrollertorearroller
increasesandcarrierframe/cuttingunitrotation
angle(B)decreases.
Note:Asgap(C)betweenspringbracketand
washerincreases,cuttingunitgroundclearance
decreasesandcarrierframe/cuttingunitrotation
angle(B)increases.
Note:Whencuttingundulatingturf,increasethe
compressedspringlength(A)andthegapwidth(C)
1/2inch(Figure21).
18

4
MakingAlternateCuttingUnit
Adjustments
NoPartsRequired
Procedure
Thefactorysetsthetractorappropriatelyformost
fairwaymowingapplications.Severaladjustmentsfor
ne-tuningthemachineforparticularapplicationsare
includedinCuttingUnitMaintenance,page50,asfollows:
•Adjustingthecuttingunitloweringrate
Adjuststhespeedatwhichthecuttingunitslower.
•Adjustingtheliftedheightoftheouterfrontcutting
units
Adjuststheturnaroundheightoftheouterfront
cuttingunitstoprovidegreaterclearanceon
contouredfairways.
•Adjustingthetravelofthefrontthreecuttingunits
Adjuststhedownwardtravelofthefrontthree
cuttingunitstoallowforhighlycontouredfairways.
5
AddingRearBallast
Partsneededforthisprocedure:
100lbCalciumchloride(obtainseparately)
1Rearweightkit,partnumber104–1478(obtain
separately)
Procedure
TocomplywithCENstandardEN836:1997,ISO
standard5395:1990,andtheANSIB71.4-1999
Standard,add100lb(45kg)ofcalciumchlorideballast
istotherearwheelsandinstalltherearweightkit
(PartNumber104-1478).
Important:Ifapunctureoccursinatirewith
calciumchloride,removeunitfromturfareaas
quicklyaspossible.Topreventpossibledamageto
turf,immediatelysoakaffectedareawithwater.
6
InstallingCEDecals
Partsneededforthisprocedure:
4CEdecals
2CEcerticate
Procedure
IfyouwillbeusingthemachineinaCEcountry,install
thesuppliedCEdecalsoverthecorrespondingANSI
decalsontheproduct.StoretheCEcerticatesinasafe
location.
7
ReadingtheManualsand
StoringAdditionalParts
Partsneededforthisprocedure:
1Operator’sManual
1EngineOperator’sManual
1PartsCatalog
1DiagnosticACEdisplayoverlay
1Ignitionkeysonring
1Hoodlockkey
1Gaugebar
2Screw
2Wingnut
Procedure
1.Readthemanuals.
2.ViewtheOperatorvideo.
3.ThediagnosticACEdisplayoverlayisfordiagnosing
machinemalfunctions.Storeitinasafelocation.
4.Thegaugebar,screws,andwingnutareforusein
settingthecuttingunits(refertothecuttingunit
Operator’sManual).Storetheminasafelocation.
19

ProductOverview
Figure22
1.Steeringwheel3.Cuttingunit5.Manualtube7.Rolloverprotectionsystem
(ROPS)
2.Brakepedals4.Tractionpedal6.Hood
Controls
TractionPedal
Thetractionpedal(Figure23)controlsforwardand
reverseoperation.Depresstopofpedaltomove
forwardandbottomtomovebackward.Groundspeed
dependsonhowfarpedalisdepressed.Fornoload,
maximumgroundspeed,fullydepresspedalwhile
throttleisinFAST.
Tostop,reducefootpressureontractionpedaland
allowittoreturntocenterposition.
Figure23
1.Tractionpedal6.Parkingbrakelatch
2.Forwardspeedlimiter7.Lockingpin
3.Reddiagnosticlight8.Reversespeedlimiter
4.Speedometer9.Keyswitch
5.Brakepedals
20