Toro 3806 User manual

FormNo.3375-301RevC
Reelmaster®6500-Dand6700-D
TractionUnit
ModelNo.03806—SerialNo.313000001andUp
ModelNo.03807—SerialNo.313000001andUp
ModelNo.03808—SerialNo.313000001andUp
ModelNo.03812—SerialNo.313000001andUp
ModelNo.03813—SerialNo.313000001andUp
ToregisteryourproductordownloadanOperator'sManualorPartsCatalogatnocharge,gotowww.Toro.com.OriginalInstructions(EN)

ThisproductcomplieswithallrelevantEuropean
directives,fordetailspleaseseetheseparateproduct
specicDeclarationofConformity(DOC)sheet.
WARNING
CALIFORNIA
Proposition65Warning
Dieselengineexhaustandsomeofits
constituentsareknowntotheStateof
Californiatocausecancer,birthdefects,
andotherreproductiveharm.
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ndingadealer,
ortoregisteryourproduct.
Wheneveryouneedservice,genuineToroparts,
oradditionalinformation,contactanAuthorized
ServiceDealerorToroCustomerServiceandhave
themodelandserialnumbersofyourproductready.
Figure1identiesthelocationofthemodelandserial
numbersontheproduct.Writethenumbersinthe
spaceprovided.
Figure1
1.Locationofthemodelandserialnumbers
ModelNo.
SerialNo.
Thismanualidentiespotentialhazardsandhassafety
messagesidentiedbythesafetyalertsymbol(Figure2),
whichsignalsahazardthatmaycauseseriousinjury
ordeathifyoudonotfollowtherecommended
precautions.
Figure2
1.Safetyalertsymbol.
Thismanualusestwootherwordstohighlight
information.Importantcallsattentiontospecial
mechanicalinformationandNoteemphasizesgeneral
informationworthyofspecialattention.
©2013—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN554202
Contactusatwww.Toro.com.
PrintedintheUSA.
AllRightsReserved

Contents
Introduction.................................................................2
Safety...........................................................................4
SafeOperatingPractices.......................................4
ToroMowerSafety...............................................5
SoundPowerLevel...............................................6
SoundPowerLevel...............................................6
SoundPressureLevel...........................................6
VibrationLevel....................................................6
SafetyandInstructionalDecals.............................7
Setup.........................................................................14
1CheckingFluidLevels......................................14
2InstallingCuttingUnitsModels03860,03861
and03862.......................................................14
3InstallingCuttingUnitsModels03863and
03864.............................................................16
4MakingAlternateCuttingUnit
Adjustments...................................................21
5AddingRearBallast..........................................21
6InstallingCEDecals........................................21
7ReadingtheManualsandStoringAdditional
Parts...............................................................21
ProductOverview......................................................22
Controls.............................................................22
Specications.....................................................25
Attachments/Accessories...................................25
Operation...................................................................26
CheckingtheEngineOil.....................................26
CheckingtheCoolingSystem..............................26
FillingtheFuelTank...........................................27
CheckingtheHydraulicFluid..............................29
CheckingtheTirePressure.................................30
CheckingtheReeltoBedknifeContact................30
StartingandStopping.........................................30
BleedingtheFuelSystem....................................30
PushingorTowingtheMachine..........................31
CheckingtheInterlockSwitches.........................31
FaultMemoryandRetrieval................................33
HydraulicSolenoidValveFunctions....................33
OperatingTips...................................................34
Maintenance...............................................................35
RecommendedMaintenanceSchedule(s)................35
ServiceIntervalChart.........................................36
DailyMaintenanceChecklist...............................37
Lubrication.............................................................38
GreasingtheBearingsandBushings....................38
EngineMaintenance...............................................40
ServicingtheAirCleaner....................................40
ServicingtheEngineOilandFilter......................41
AdjustingThrottle..............................................41
FuelSystemMaintenance.......................................42
FuelTank...........................................................42
FuelLinesandConnections................................42
FuelFilter/WaterSeparator................................42
BleedingAirFromInjectors...............................43
ElectricalSystemMaintenance................................43
BatteryCare.......................................................43
Fuses..................................................................44
OptionalLighting...............................................44
DriveSystemMaintenance.....................................46
CheckingtheTorqueoftheWheelNutsor
Bolts..............................................................46
CheckingthePlanetaryGearDrive
Oil..................................................................46
ChangingthePlanetaryGearDrive
Oil..................................................................46
CheckingtheRearAxleLubricant.......................47
ChangingtheRearAxleLubricant.......................47
RearWheelToe-In.............................................48
AdjustingtheTractionDriveforNeutral.............48
CoolingSystemMaintenance..................................49
RemovingDebris...............................................49
MaintainingtheCoolingSystem..........................49
BrakeMaintenance.................................................50
AdjustingtheServiceBrakes...............................50
BeltMaintenance....................................................50
CheckingtheAlternatorBelt...............................50
HydraulicSystemMaintenance...............................51
ChangingtheHydraulicFluid.............................51
ReplacingtheHydraulicFilter.............................51
CheckingtheHydraulicLinesandHoses.............51
HydraulicSystemTestPorts...............................52
CuttingUnitMaintenance.......................................53
CuttingUnitKickstandModels03863and
03864.............................................................53
Backlapping........................................................53
AdjustingtheCuttingUnitLoweringRate
......................................................................54
LiftedHeightofOuterFrontCuttingUnits
(EnablePosition)............................................55
AdjustingtheTraveloftheFrontThree
CuttingUnits..................................................56
Storage.......................................................................57
TractionUnit......................................................57
Engine...............................................................57
Schematics.................................................................58
3

Safety
ThismachinemeetsorexceedsCENstandard
EN836:1997,ISOstandard5395:1990,andANSI
B71.4-2004specicationsineffectatthetimeof
productionwhenballastisadded;refertoAdding
RearBallastinSetUpsection.
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
B71.4-2004.
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.Alwaysuseseatbelts
whenROPSisprovided.
•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.
•Lightningcancausesevereinjuryordeath.If
lightningisseenorthunderisheardinthearea,do
notoperatethemachine;seekshelter.
•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.
•Disconnectbatterybeforemakinganyrepairs.
Disconnectthenegativeterminalrstandthe
positivelast.Reconnectpositiverstandnegative
last.
•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.
•Usingthemachinedemandsattention.Toprevent
lossofcontrol:
–Donotdriveclosetosandtraps,ditches,creeks,
orotherhazards.
–Reducespeedwhenmakingsharpturns.Avoid
suddenstopsandstarts.
–Whennearorcrossingroads,alwaysyieldthe
right-of-way.
–Applytheservicebrakeswhengoingdownhillto
keepforwardspeedslowandtomaintaincontrol
ofthemachine.
•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
5

ordeath.AlwaysusetheseatbeltandRollOver
ProtectionSystem(ROPS)together.
•Iftheenginestallsorlosesheadwayandcannotmake
ittothetopofaslope,donotturnthemachine
around.Alwaysbackslowly,straightdowntheslope.
•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.
SoundPowerLevel
Reelmaster6500
Thisunithasaguaranteedsoundpowerlevelof101
dBA,whichincludesanUncertaintyValue(K)of1dBA.
Soundpowerlevelwasdeterminedaccordingtothe
proceduresoutlinedinEN11094.
SoundPowerLevel
Reelmaster6700
Thisunithasaguaranteedsoundpowerlevelof103
dBA,whichincludesanUncertaintyValue(K)of1dBA.
Soundpowerlevelwasdeterminedaccordingtothe
proceduresoutlinedinEN11094.
SoundPressureLevel
Thisunithasasoundpressurelevelattheoperator’s
earof90dBA,whichincludesanUncertaintyValue(K)
of1dBA.
Soundpressurelevelwasdeterminedaccordingtothe
proceduresoutlinedinEN836.
VibrationLevel
Hand-Arm
Measuredvibrationlevelforrighthand=0.69m/s2
Measuredvibrationlevelforlefthand=1.04m/s2
UncertaintyValue(K)=0.5m/s2
Measuredvaluesweredeterminedaccordingtothe
proceduresoutlinedinEN836.
WholeBody
Measuredvibrationlevel=0.55m/s2
UncertaintyValue(K)=0.5m/s2
Measuredvaluesweredeterminedaccordingtothe
proceduresoutlinedinEN836.
6

SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaof
potentialdanger.Replaceanydecalthatisdamagedorlost.
105-7506
1.ReadtheOperator's
Manual.
4.Engine—preheat
2.Engine—stop5.Engine—start
3.On
93-6693
1.Crushinghazardofhand—waitformovingpartstostop.
114–9600
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.
93-6687
1.Donotstephere.
7

93–6689
1.Danger—donotsitontheplasticshroud.
93–6681
1.Cutting/dismembermenthazard—stayawayfrommoving
parts.
115-2047
1.Warning—donottouchthehotsurface.
104-9298
1.ReadtheOperator'sManual.
93-1263
93-1263
1.ReadtheOperator'sManual.
2.Toengagetheparkingbrake,connectthebrakepedals
withthelockingpin,pushdownonbothpedals,andpullthe
brakelatchout.
3.Toreleasetheparkingbrake,pressbothpedalsuntilthe
parkingbrakelatchretracts.
4.Danger—reelsenabled.
115-2048
1.ReadtheOperator'sManual.
8

105-0123
Model03808and03813
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
Models03806,03807and03812
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

106-6755
1.Enginecoolantunder
pressure.
3.Warning—donottouchthe
hotsurface.
2.Explosionhazard—read
theOperator'sManual.
4.Warning—readthe
Operator'sManual.
117–2718
115-2045
1.Warning—readtheOperator'sManual.
2.Cuttinghazardofhandorfoot—stayawayfrommovingparts;keepallguardsinplace.
3.Warning—donotoperatethismachineunlessyouaretrained.
4.Tippinghazard—lowerthecuttingunitwhendrivingdownslopes;slowmachinebeforeturning,donotturnathighspeeds.
5.Warning—weartheseatbeltwhenseatedintheoperator'sposition.
6.Warning—readtheOperator'sManual;donottowthemachine.
7.Thrownobjecthazard—keepbystandersasafedistancefromthemachine.
8.Warning—locktheparkingbrake,stoptheengineandremovetheignitionkeybeforeleavingthemachine.
10

115-2046
(Afxoverpartno.115–2045forCE*)
*ThissafetydecalincludesaslopewarningrequiredonthemachineforcompliancetotheEuropeanLawnMowerSafetyStandardEN836:1997.Theconservativemaximum
slopeanglesindicatedforoperationofthismachineareprescribedbyandrequiredbythisstandard.
1.Warning—readtheOperator'sManual.
2.Cuttinghazardofhandorfoot—stayawayfrommovingparts;keepallguardsinplace.
3.Warning—donotoperatethismachineunlessyouaretrained.
4.Tippinghazard—lowerthecuttingunitwhendrivingdownslopes;donotmowonslopesgreaterthan15degrees.
5.Warning—weartheseatbeltwhenseatedintheoperator'sposition.
6.Warning—readtheOperator'sManual;donottowthemachine.
7.Thrownobjecthazard—keepbystandersasafedistancefromthemachine.
8.Warning—locktheparkingbrake,stoptheengineandremovetheignitionkeybeforeleavingthemachine.
11

115-2049
Models03806,03807and03812
1.Reel—heightofcut4.Machinespeed
2.Reel—mowandbacklap5.Rearreelscircuitcontrols
3.ReadtheOperator's
Manual.
6.Frontreelscircuitcontrols
106-6754
1.Warning—donottouchthehotsurface.
2.Cutting/dismembermenthazard,fanandentanglement
hazard,belt—stayawayfrommovingparts.
93-6668
1.ReadtheOperator'sManualforinformationonchargingthe
battery;containslead;donotdiscard.
115-8000
Model03808and03813
1.Reel—heightofcut4.Machinespeed
2.Reel—mowandbacklap5.Rearreelscircuitcontrols
3.ReadtheOperator's
Manual.
6.Frontreelscircuitcontrols
12

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.
13

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
OperatorTrainingMaterial1
DiagnosticACEdisplayoverlay1
Ignitionkeysonring1
Hoodlockkey1
Screw2
7
Wingnut2
Readthemanualsandviewthetraining
materialbeforeoperatingthemachine.
1
CheckingFluidLevels
NoPartsRequired
Procedure
Beforestartingtheengineforthersttime,checkthe
followinguidlevels:
•Engineoil
RefertoCheckingtheEngineOil.
•Enginecoolant
RefertoCheckingtheCoolingSystem.
•Hydraulicoil
RefertoCheckingtheHydraulicOil.
•Rearaxlelubricant
RefertoCheckingtheRearAxleLubricant.
14

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.
Figure3
1.Removecuttingunitsfromcartons.Assembleand
adjustperCuttingUnitOperator'sManual.
2.Removeprotectiveplugsfromeachendofcutting
unit.
3.LubricateandinstallalargeO-ringintobearing
housinggrooveoneachendofcuttingunit
(Figure4&Figure7).
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).
Figure5
1.Carrierframe4.Lynchpin
2.Pivotknuckle5.Steeringlockingpin
3.Liftarmsteeringplate
7.Insertthehorizontalshaftofthepivotknuckleinto
themountingtubeofthecarrierframe(Figure5).
8.Securepivotknuckletocarrierframewithathrust
washer,atwasherandaangeheadcapscrew
(Figure5).
9.Insertathrustwasherontoverticalshaftofpivot
knuckle(Figure5).
15

10.Ifremoved,inserttheverticalshaftofthepivot
knuckleintoliftarmpivothub(Figure5).Guide
thepivotknuckleinplacebetweenthetworubber
centeringbumpersintheundersideoftheliftarm
steeringplate.
11.Insertthelynchpinintothecrossholeonthepivot
knuckleshaft(Figure5).
12.Removenutsecuringturfcompensationspring
mountingbrackettocuttingunitstabilizerear
(Figure6).Inserttipperchainontocapscrewand
securewithnutremoved.
Figure6
1.Liftchain2.Cuttingunitstabilizerear
13.Mountthemotortothedriveendofthecuttingunit
andsecurewithtwocapscrewsprovided(Figure7).
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.
1.Tightenlocknutonrearofspringroduntilthegap
(C)betweenrearofspringbracketandfrontof
washeris1in.(25mm)(Figure8).
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.
16

3
InstallingCuttingUnits
Models03863and03864
Partsneededforthisprocedure:
5/7Liftchain
5/7Chainbracket
5/7U-bolt
10/14Nut
5/7Screw
5/7Washer
5/7Nut
5/7LargeO-ring
MounttheLiftBracketsandChains
MountachainbrackettoeachliftarmwithaU-boltand
2nuts.Positionthebracketsasfollows:
1.Onliftarms#1,#4and#5,positionthechain
bracketsandU-bolts15inchesbehindthecenter
lineofthepivotknuckle(Figure9).Onliftarms#1
and#5thebracketsshouldberotatedtotheright
10degreesfromvertical(Figure9).Onliftarm#4
thebracketshouldberotatedtotheleft10degrees
fromvertical(Figure9).
Figure9
2.Onliftarms#2and#3,positionthebracketsand
U-bolts15inchesbehindthecenterlineofthepivot
knuckle(Figure10).Rotatethebrackets45degrees
totheoutboardsideofthemachine.
Figure10
3.Onliftarms#6and#7,positionthebracketsand
U-bolts14.5inchesbehindthecenterlineofthe
pivotknuckle(Figure11).Rotatethebrackets10
degreestotheoutboardsideofthemachine.
Figure11
4.TightenalltheU-boltnutsto38–48ft-lbs.
5.Mountaliftchaintoeachchainbracketwithascrew,
washerandnut,positioningasshowninFigure12
17

Figure12
1.Liftchain2.Chainbracket
AdjusttheRearShield
Undermostconditions,bestdispersionisattained
whentherearshieldisclosed(frontdischarge).When
conditionsareheavyorwet,rearshieldmaybeopened.
Toopentherearshield(Figure13),loosenthecapscrew
securingtheshieldtotheleftsideplate,rotatetheshield
totheopenpositionandtightenthecapscrew .
Figure13
1.Rearshield2.Capscrew
MounttheCounterWeights
Allcuttingunitsareshippedwiththecounterweight
mountedtotheleftendofthecuttingunit.Usethe
followingdiagramtodeterminethepositionofthe
counterweightsandreelmotors.
Figure14
1.Onthe#2,#4and#6cuttingunits,removethe2
capscrewssecuringthecounterweighttotheleft
endofthecuttingunit.Removethecounterweight
(Figure15).
Figure15
1.Counterweight
2.Onrightendofcuttingunit,removetheplasticplug
fromthebearinghousing(Figure16).
3.Removethe2capscrewsfromtherightsideplate
(Figure16).
18

G003321
1
2
Figure16
1.Plasticplug2.Capscrew(2)
4.Installthecounterweighttotherightendofthe
cuttingunitwiththe2screwspreviouslyremoved.
5.Looselyinstallthe2reelmotormountingcapscrews
totheleftsideplateofthecuttingunit(Figure16).
MounttheCuttingUnits
1.Insertathrustwasherontohorizontalshaftofpivot
knuckleasshowninFigure17.
Figure17
1.Carrierframe4.Lynchpin
2.Pivotknuckle5.Steeringlockingpin
3.Liftarmsteeringplate
2.Insertthehorizontalshaftofthepivotknuckleinto
themountingtubeofthecarrierframe(Figure17).
3.Securepivotknuckletocarrierframewithathrust
washer,atwasherandaangeheadcapscrew
(Figure17).
4.Insertathrustwasherontoverticalshaftofpivot
knuckle(Figure17).
5.Ifremoved,inserttheverticalshaftofthepivot
knuckleintoliftarmpivothub(Figure17).Guide
thepivotknuckleinplacebetweenthetworubber
centeringbumpersintheundersideoftheliftarm
steeringplate.
6.Insertthelynchpinintothecrossholeonthepivot
knuckleshaft(Figure17).
7.Securetheliftarmchaintothecuttingunitchain
bracket(Figure18)withthesnapperpinasfollows:
A.Oncuttingunits#1,4,5,6and7,onlyuse6of
thechainlinks.
B.Oncuttingunits#2and3,useall7ofthechain
links.
Figure18
1.Liftchain2.Snapperpin
8.Coatthesplineofthereelmotorwithcleangrease.
9.OilthereelmotorO-ringandinstallitontothe
motorange.
10.Installthemotorbyrotatingitclockwisesothat
themotorangesclearthecapscrews(Figure19).
Rotatethemotorcounterclockwiseuntiltheanges
encirclethecapscrewsthentightenthecapscrews
Important:Makesurethereelmotorhoses
arenottwisted,kinkedorintheriskofbeing
pinched.
19

Figure19
1.Reeldrivemotor2.Capscrew
Note:Ifxedcuttingunitpositionisrequired,
insertsteeringlockingpinintopivotknuckle
mountinghole(Figure17).
11.Hookspringwirearoundbottomofsteeringlocking
pin(Figure17).
AdjusttheTurfCompensationSpring
Tractorsaresetupatthefactoryappropriatelyformost
fairwaymowingapplications.
Thefollowingadjustmentsareavailableforne-tuning
ofthemachinetotheapplication:
TheTurfCompensationSpring(Figure20)transfers
weightfromthefronttorearroller.Thishelpstoreduce
awavepatternintheturf,alsoknownasbobbing.
Important:Makespringadjustmentswithcutting
unitmountedtotractionunitandloweredtoshop
oor.
1.Tightenlocknutonrearofspringroduntilthegap
(C)betweenrearofspringbracketandfrontof
washeris2in.(51mm)(Figure20).
Figure20
2.Tightenhexnutsonfrontendofspringroduntil
thecompressedlength(A)ofspringis6.25in.(159
mm)(Figure20).
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(Figure20).
20