Toro Reelmaster 2000-D 03431 User manual

Operator’s Manual
English (EN, GB)
Form No. 3356–617 Rev A
Reelmaster)2000-D
Traction Unit
Model No. 03431—270000001 and Up

2
All Rights Reserved
Printed in the USA
W2006 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents
are known to the State of California to cause
cancer, birth defects, and other reproductive harm.
Warning
Contents
Page
Introduction 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe Operating Practices 3. . . . . . . . . . . . . . . . . . . .
Toro Riding Mower Safety 5. . . . . . . . . . . . . . . . . . .
Sound Power Level 6. . . . . . . . . . . . . . . . . . . . . . . .
Sound Pressure Level 6. . . . . . . . . . . . . . . . . . . . . . .
Vibration Level 6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals 7. . . . . . . . . . . . . . . . .
Specifications 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 11. . . . . . . . . . . . . . . . . . . . .
Measurements 12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Equipment 12. . . . . . . . . . . . . . . . . . . . . . . .
Setup 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loose Parts 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Rear Wheel 14. . . . . . . . . . . . . . . . . . . .
Adjusting the Rear Carrier Frame Height 14. . . . . . .
Mounting the Carrier Frames to the Cutting Units 14
Installing the Front Lift Arms 15. . . . . . . . . . . . . . . .
Mounting the Cutting Unit Drive Motors 16. . . . . . .
Mounting the Cutting Units 16. . . . . . . . . . . . . . . . . .
Installing the Counterbalance Springs 17. . . . . . . . . .
Adding Rear Ballast 19. . . . . . . . . . . . . . . . . . . . . . . .
Activating and Charging the Battery 19. . . . . . . . . . .
Before Operating 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Crankcase Oil 21. . . . . . . . . . . . . . . . . .
Filling the Fuel Tank 22. . . . . . . . . . . . . . . . . . . . . . .
Checking the Cooling System 22. . . . . . . . . . . . . . . .
Checking the Hydraulic System 23. . . . . . . . . . . . . . .
Checking the Tire Pressure 24. . . . . . . . . . . . . . . . . .
Checking the Reel to Bedknife Contact 24. . . . . . . . .
Checking the Torque of the Wheel Nuts 24. . . . . . . .
Operation 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controls 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting and Stopping the Engine 27. . . . . . . . . . . . . .
Bleeding the Fuel System 27. . . . . . . . . . . . . . . . . . . .
Checking the Operation of the Interlock Switches 28
Towing the Traction Unit 28. . . . . . . . . . . . . . . . . . . .
Operating Characteristics 29. . . . . . . . . . . . . . . . . . . .
Selecting the Clip Rate
(Reel Speed) 29. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Training Period 31. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before Mowing 31. . . . . . . . . . . . . . . . . . . . . . . . . . .
Transport Operation 31. . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Clean-Up After Mowing 31. . . . . . . .
Standard Control Module (SCM) 32. . . . . . . . . . . . . .
Maintenance 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Maintenance Schedule 34. . . . . . . . .
Daily Maintenance Checklist 35. . . . . . . . . . . . . . . . .
Service Interval Chart 36. . . . . . . . . . . . . . . . . . . . . .
Greasing the Bearings and Bushings 37. . . . . . . . . . .
Removing the Hood 38. . . . . . . . . . . . . . . . . . . . . . . .
General Air Cleaner Maintenance 38
. . . . . . . . . . . . .
Cleaning the Radiator and Screen 39. . . . . . . . . . . . .
Changing Engine Oil And Filter 39. . . . . . . . . . . . . .
Changing the Hydraulic System Fluid and Filter 39. .
Hydraulic System Test Ports 40. . . . . . . . . . . . . . . . .
Fuel System 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Traction Drive for Neutral 41. . . . . . . .
Adjusting Neutral Switch 42. . . . . . . . . . . . . . . . . . . .
Adjusting the Belts 42. . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Traction Pedal 42. . . . . . . . . . . . . . . . .
Adjusting the Traction Pedal Damper 43. . . . . . . . . .
Adjusting the Hand Brake 43. . . . . . . . . . . . . . . . . . .
Battery Care 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storing the Battery 44. . . . . . . . . . . . . . . . . . . . . . . . .
Fuses 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Backlapping 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Schematic 46. . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Schematic 47. . . . . . . . . . . . . . . . . . . . . . .
Evaporative Emission Control Warranty Statement 51. .
The Toro General Commercial Products Warranty 52. . .

3
Introduction
Read this manual carefully to learn how to operate and
maintain your product properly. The information in this
manual can help you and others avoid injury and product
damage. Although Toro designs and produces safe
products, you are responsible for operating the product
properly and safely.
Whenever you need service, genuine Toro parts, or
additional information, contact an Authorized Service
Dealer or Toro Customer Service and have the model and
serial numbers of your product ready. The two numbers are
stamped into a plate that is riveted to the frame of the
mower.
Write the product model and serial numbers in the space
below:
Model No.
Serial No.
This manual identifies potential hazards and has special
safety messages that help you and others avoid personal
injury and even death. Danger, Warning, and Caution are
signal words used to identify the level of hazard. However,
regardless of the hazard, be extremely careful.
Danger signals an extreme hazard that will cause serious
injury or death if you do not follow the recommended
precautions.
Warning signals a hazard that may cause serious injury or
death if you do not follow the recommended precautions.
Caution signals a hazard that may cause minor or moderate
injury if you do not follow the recommended precautions.
This manual uses two other words to highlight information.
Important calls attention to special mechanical
information and Note: emphasizes general information
worthy of special attention.
Safety
This machine meets or exceeds CEN standard EN
836:1997, ISO standard 5395:1990, and ANSI
B71.4-1999 specifications in effect at the time of
production when weights are installed according to
chart on page 20.
Improper use or maintenance by the operator or owner
can result in injury. To reduce the potential for injury,
comply with these safety instructions and always pay
attention to the safety alert symbol, which means
CAUTION, WARNING, or DANGER—“personal
safety instruction.” Failure to comply with the
instruction may result in personal injury or death.
Safe Operating Practices
The following instructions are from the CEN standard EN
836:1997, ISO standard 5395:1990, and ANSI B71.4-1999.
Training
•Read the operator’s manual and other training material
carefully. Be familiar with the controls, safety signs,
and the proper use of the equipment.
•Never allow children or people unfamiliar with these
instructions to use or service the mower. Local
regulations may restrict the age of the operator.
•Never mow while people, especially children, or pets
are nearby.
•Keep in mind that the operator or user is responsible for
accidents or hazards occurring to other people or their
property.
•Do not carry passengers.
•All drivers and mechanics should seek and obtain
professional and practical instruction. The owner is
responsible for training the users. Such instruction
should emphasize:
– the need for care and concentration when working
with ride-on machines;
– control of a ride-on machine sliding on a slope will
not be regained by the application of the brake. The
main reasons for loss of control are:
•insufficient wheel grip;
•being driven too fast;
•inadequate braking;
•the type of machine is unsuitable for its task;
•lack of awareness of the effect of ground
conditions, especially slopes;
•incorrect hitching and load distribution.
•The owner/user can prevent and is responsible for
accidents or injuries occurring to himself or herself,
other people, or property.

4
Preparation
•While mowing, always wear substantial footwear, long
trousers, hard hat, safety glasses, and ear protection.
Long hair, loose clothing, or jewelry may get tangled in
moving parts. Do not operate the equipment when
barefoot or wearing open sandals.
•Thoroughly inspect the area where the equipment is to
be used and remove all objects which may be thrown by
the machine.
•Warning—Fuel is highly flammable. Take the
following precautions:
– Store fuel in containers specifically designed for this
purpose.
– Refuel outdoors only and do not smoke while
refuelling.
– Add fuel before starting the engine. Never remove
the cap of the fuel tank or add fuel while the engine
is running or when the engine is hot.
– If fuel is spilled, do not attempt to start the engine
but move the machine away from the area of
spillage and avoid creating any source of ignition
until fuel vapors have dissipated.
– Replace all fuel tanks and container caps securely.
•Replace faulty silencers/mufflers.
•Evaluate the terrain to determine what accessories and
attachments are needed to properly and safely perform
the job. Only use accessories and attachments approved
by the manufacturer.
•Check that operator’s presence controls, safety switches
and shields are attached and functioning properly. Do
not operate unless they are functioning properly.
Operation
•Do not operate the engine in a confined space where
dangerous carbon monoxide fumes can collect.
•Mow only in daylight or in good artificial light.
•Before attempting to start the engine, disengage all
blade attachment clutches, shift into neutral, and engage
the parking brake.
•Remember there is no such thing as a safe slope. Travel
on grass slopes requires particular care. To guard
against overturning:
– do not stop or start suddenly when going up or
downhill;
– engage clutch slowly, always keep machine in gear,
especially when travelling downhill;
– machine speeds should be kept low on slopes and
during tight turns;
– stay alert for humps and hollows and other hidden
hazards;
– never mow across the face of the slope, unless the
mower is designed for this purpose.
•Stay alert for holes in the terrain and other hidden
hazards.
•Use care when pulling loads or using heavy equipment.
– Use only approved drawbar hitch points.
– Limit loads to those you can safely control.
– Do not turn sharply. Use care when reversing.
– Use counterweight(s) or wheel weights when
suggested in the operator’s manual.
•Watch out for traffic when crossing or near roadways.
•Stop the blades rotating before crossing surfaces other
than grass.
•When using any attachments, never direct discharge of
material toward bystanders nor allow anyone near the
machine while in operation.
•Never operate the machine with damaged guards,
shields, or without safety protective devices in place. Be
sure all interlocks are attached, adjusted properly, and
functioning properly.
•Do not change the engine governor settings or
overspeed the engine. Operating the engine at excessive
speed may increase the hazard of personal injury.
•Before leaving the operator’s position:
– stop on level ground;
– disengage the power take-off and lower the
attachments;
– change into neutral and set the parking brake;
– stop the engine and remove the key.
•Disengage drive to attachments when transporting or
not in use.
•Stop the engine and disengage drive to attachment
– before refuelling;
– before removing the grass catcher/catchers;
– before making height adjustment unless adjustment
can be made from the operator’s position.
– before clearing blockages;
– before checking, cleaning or working on the mower;
– after striking a foreign object or if an abnormal
vibration occurs. Inspect the mower for damage and
make repairs before restarting and operating the
equipment.

5
•Reduce the throttle setting during engine run-out and, if
the engine is provided with a shut-off valve, turn the
fuel off at the conclusion of mowing.
•Keep hands and feet away from the cutting units.
•Look behind and down before backing up to be sure of
a clear path.
•Slow down and use caution when making turns and
crossing roads and sidewalks. Stop cylinders/reels if not
mowing.
•Do not operate the mower under the influence of
alcohol or drugs
•Use care when loading or unloading the machine into a
trailer or truck
•Use care when approaching blind corners, shrubs, trees,
or other objects that may obscure vision.
Maintenance and Storage
•Keep all nuts, bolts and screws tight to be sure the
equipment is in safe working condition.
•Never store the equipment with fuel in the tank inside a
building where fumes may reach an open flame or
spark.
•Allow the engine to cool before storing in any
enclosure.
•To reduce the fire hazard, keep the engine,
silencer/muffler, battery compartment and fuel storage
area free of grass, leaves, or excessive grease.
•Check the grass catcher frequently for wear or
deterioration.
•Keep all parts in good working condition and all
hardware and hydraulic fittings tightened. Replace all
worn or damaged parts and decals.
•If the fuel tank has to be drained, do this outdoors.
•Be careful during adjustment of the machine to prevent
entrapment of the fingers between moving blades and
fixed parts of the machine.
•On multi-cylinder/multi-reel machines, take care as
rotating one cylinder/reel can cause other
cylinders/reels to rotate.
•Disengage drives, lower the cutting units, set parking
brake, stop engine and remove key and disconnect spark
plug wire. Wait for all movement to stop before
adjusting, cleaning or repairing.
•Clean grass and debris from cutting units, drives,
silencers/mufflers, and engine to help prevent fires.
Clean up oil or fuel spillage.
•Use jack stands to support components when required.
•Carefully release pressure from components with stored
energy.
•Disconnect battery and remove spark plug wire before
making any repairs. Disconnect the negative terminal
first and the positive last. Reconnect positive first and
negative last.
•Use care when checking the cylinders/reels. Wear
gloves and use caution when servicing them.
•Keep hands and feet away from moving parts. If
possible, do not make adjustments with the engine
running.
•Charge batteries in an open well ventilated area, away
from spark and flames. Unplug charger before
connecting or disconnecting from battery. Wear
protective clothing and use insulated tools.
Toro Riding Mower Safety
The following list contains safety information specific to
Toro products or other safety information that you must
know that is not included in the CEN, ISO, or ANSI
standard.
This product is capable of amputating hands and feet and
throwing objects. Always follow all safety instructions to
avoid serious injury or death.
Use of this product for purposes other than its intended use
could prove dangerous to user and bystanders.
Engine exhaust contains carbon monoxide, which
is an odorless, deadly poison that can kill you.
Do not run engine indoors or in an enclosed area.
Warning
•Know how to stop the engine quickly.
•Do not operate the machine while wearing tennis shoes
or sneakers.
•Wearing safety shoes and long pants is advisable and
required by some local ordinances and insurance
regulations.
•Handle fuel carefully. Wipe up any spills.
•Check the safety interlock switches daily for proper
operation. If a switch should fail, replace the switch
before operating the machine. After every two years,
replace all four interlock switches in the safety system,
whether they are working properly or not.
•Before starting the engine, sit on the seat.
•Using the machine demands attention. To prevent loss
of control:

6
– Do not drive close to sand traps, ditches, creeks, or
other hazards.
– Reduce speed when making sharp turns. Avoid
sudden stops and starts.
– When near or crossing roads, always yield the
right-of-way.
– Apply the service brakes when going downhill to
keep forward speed slow and to maintain control of
the machine.
•The grass baskets must be in place during operation of
the cylinders/reels or thatchers for maximum safety.
Shut the engine off before emptying the baskets.
•Raise the cutting units when driving from one work
area to another.
•Do not touch the engine, silencer/muffler, or exhaust
pipe while the engine is running or soon after it has
stopped because these areas could be hot enough to
cause burns.
•If the engine stalls or loses headway and cannot make it
to the top of a slope, do not turn the machine around.
Always back slowly, straight down the slope.
•When a person or pet appears unexpectedly in or near
the mowing area, stop mowing. Careless operation,
combined with terrain angles, ricochets, or improperly
positioned guards can lead to thrown object injuries. Do
not resume mowing until the area is cleared.
Maintenance and Storage
•Make sure all hydraulic line connectors are tight and all
hydraulic hoses and lines are in good condition before
applying pressure to the system.
•Keep your body and hands away from pin hole leaks or
nozzles that eject hydraulic fluid under high pressure.
Use paper or cardboard, not your hands, to search for
leaks. Hydraulic fluid escaping under pressure can have
sufficient force to penetrate the skin and cause serious
injury. Seek immediate medical attention if fluid is
injected into skin.
•Before disconnecting or performing any work on the
hydraulic system, all pressure in the system must be
relieved by stopping the engine and lowering the cutting
units and attachments to the ground.
•Check all fuel lines for tightness and wear on a regular
basis. Tighten or repair them as needed.
•If the engine must be running to perform a maintenance
adjustment, keep hands, feet, clothing, and any parts of
the body away from the cutting units, attachments, and
any moving parts, especially fans, belts or pulleys. Keep
everyone away.
•To ensure safety and accuracy, have an Authorized Toro
Distributor check the maximum engine speed with a
tachometer. Maximum governed engine speed should be
3200 RPM.
•If major repairs are ever needed or if assistance is
desired, contact an Authorized Toro Distributor.
•Use only Toro-approved attachments and replacement
parts. The warranty may be voided if used with
unapproved attachments.
Sound Power Level
This unit has a guaranteed sound power level of
105 dBA/1 pW, based on measurements of identical
machines per Directive 2000/14/EC and amendments.
Sound Pressure Level
This unit has an equivalent continuous A-weighted sound
pressure level at the operator ear of 87 dBA based on
measurements of identical machines per Directive
98/37/EC and amendments
Vibration Level
This unit does not exceed a vibration level of 2.50 m/s2at
the hands based on measurements of identical machines per
ISO 5349 procedures.
This unit does not exceed a vibration level of 0.50 m/s2at
the posterior based on measurements of identical machines
per ISO 2631 procedures.

7
Safety and Instruction Decals
Safety decals and instructions are easily visible to the operator and are located near any area
of potential danger. Replace any decal that is damaged or lost.
93-7267
1. Lock parking brake 2. Unlock parking brake
94-5056
1. Slow reel speed
2. Fast reel speed
3. Reel height
4. 5 Blade cutting unit
5. 8 Blade cutting unit
94-3353
1. Crushing of fingers or hands—stay a safe distance away.
93-7272
1. Cutting/dismemberment hazard—stay away from moving parts.
106-8120
1. Thrown object
hazard—keep bystanders
a safe distance from the
machine.
2. Cutting hazard of hand
and foot—stay away from
moving parts.
93-6696
1. Warning—spring loaded mechanism. Read the operator’s
manual.
67-5360
93-6668
1. The battery contains lead.
Do not dispose of in the
garbage.
2. Read the operator’s
manual before performing
any maintenance.
106-8119
1. Warning—read the
Operator’s Manual.
2. Tipping hazard—do not
drive the machine on a
slope greater than
15 degrees.
3. Thrown object
hazard—keep bystanders
a safe distance from the
machine.
4. Cutting hazard of hand
and foot—stay away from
moving parts.
5. Warning—lock the
parking brake, stop the
engine, and remove the
ignition key before leaving
the machine.

8
93-7276
1. Explosion hazard—wear eye protection.
2. Caustic liquid hazard—flush skin with water.
3. Fire hazard—sparks, flame, and smoking prohibited.
4. Poison—keep children away from the battery.
106-5976
1. Engine coolant under
pressure
2. Explosion hazard—read
the Operator’s Manual.
3. Warning—do not touch
the hot surface.
4. Warning—read the
Operator’s Manual.
106-8109

9
104-3991

10
104-3994
(Affix over decal part no. 104–3991 for CE)
1. Read the Operator’s Manual.
2. Warning—read the
Operator’s Manual. Do not
use starting fluid.
3. Raise and lower the reels.
4. Lower the reels.
5. Neutral
6. Raise the reels.
7. Power take-off (PTO)
8. Pull on
9. Push off
10. Engine—stop
11. Engine—run
12. Engine—start
13. Fast
14. Slow

11
Specifications
Note: Specifications and design subject to change without notice.
General Specifications
Configuration Tricycle vehicle with 2-wheel traction drive and rear wheel steering.
Engine
Briggs & Stratton–Daihatsu, 4-cycle, 3-cylinder, liquid cooled, vertical OHV, diesel
engine with centrifugal water pump. 18.4 hp (13.7 kW); governed to a maximum
speed of 3200 RPM. 51.9 cu. in. (850 cc) displacement. Forced lubrication gear
pump. Mechanical centrifugal governor. Mechanical fuel transfer pump. Fuel
filter/water separator with replaceable filter element. 12 volt (1 kW) starter. Heavy
duty remote mounted air cleaner spin-on oil filter.
Radiator Side mounted industrial radiator, 7 fins per inch. Approx. 5 quart (4.7 liter) capacity.
Electrical
12 volt Group 55, 450 cold cranking amps at 0°F (–18°C) ,75 minute reserve
capacity at 80°F (27°C). 40 amp alternator with regulator/rectifier. Seat switch,
PTO, parking brake, and traction interlock switches. Indicator light when cutting
units are running.
Fuel Capacity 6.5 gallons
Traction Drive High torque hydraulic wheel motors. 2-wheel drive. Oil cooler and shuttle valve
provide positive closed-loop cooling. Optional 3–wheel drive kit.
Hydraulic Oil
Capacity/Filter
Remote mounted, 2.3 gallon (8.7 liter) oil reservoir. 25 micron remote mounted spin
on filter.
Ground Speed
Infinitely variable speed selection in forward and reverse
Mowing speed: 0–5 mph (0–8 km/h)
Transport speed: 0–8 mph (0–13 km/h)
Reverse speed: 0–3 mph (0–4.8 km/h).
Tires/Wheels
Two front traction drive tires, 20 x 10-8 tubeless, 4-ply rating. Rear steering tire and
tube; 20 x 8-8, 4-ply rating. Demountable front rims. Recommended tire pressure:
16–20 psi front and rear tires.
Frame Frame consists of formed steel, welded steel, and steel tubing components.
Steering Pinion and sector gear with solid drag link to rear steer wheel arm
Brakes
Service braking accomplished through dynamic characteristics of hydrostat.
Parking or emergency brake is actuated by ratchet hand lever on the operator’s
left-hand side.
Controls
Foot operated traction pedal and traction pedal stop. Hand operated throttle,
ignition switch, reel engagement switch, reel unit lift lever, parking brake, and seat
adjustment.
Gauges and Protective
Systems
Hour meter. Warning lights: oil pressure, water temperature, amps, glow plug and
reel engagement light. High water temperature shut-down. Engine preheat
incorporated into ignition switch.
Seat Adjustable to operator weight, fore and aft, w/removeable fold-up armrests
Cutting Unit Lift Hydraulic lift with automatic reel shut-off

12
Measurements
Wheel tread width 54-1/2 in. (138 cm)
Wheel base 55 in. (140 cm)
Width 76-1/2 in. (194 cm)
Transport width
with 27″cutting units
with 32″cutting units
72 in. (183 cm)
85 in. (216 cm)
Length 96 in. (244 cm)
Height w/o seat 44 in. (112 cm)
Weight
Traction Unit without
cutting units
1066 lb. (484 kg)
Model 03210—27″5
blade cutting unit
136 lb. (62 kg)
Model 03211—27″8
blade cutting unit
143 lb. (65 kg)
Model 03214—27″11
blade cutting unit
149 lb. (68 kg)
Model 03212—32″5
blade cutting unit
158 lb. (72 kg)
Model 03213—32″8
blade cutting unit
167 lb. (76 kg)
Optional Equipment
3–Wheel Drive Kit Model No. 03429
Weight Kit Part No. 94-3698
Rear Weight Kit Part No. 83-9370
Rear Weight Part No. 83-9390
27” Lift Arm Kit Model No. 03471
5 Blade Cutting Unit Model No. 03210
8 Blade Cutting Unit Model No. 03211
11 Blade Cutting Unit Model No. 03214
Basket Kit Model No. 03227
32” Lift Arm Kit Model No. 03472
5 Blade Cutting Unit Model No. 03212
8 Blade Cutting Unit Model No. 03213

13
Setup
Note: Determine the left and right sides of the machine from the normal operating position.
Loose Parts
Note: Use this chart as a checklist to ensure that all parts necessary for assembly have been received. Without these parts,
total setup cannot be completed. Some parts may have already been assembled at the factory.
Description Qty. Use
Wheel assembly
Lug nut
1
4Installing the rear wheel
Flat washer
Capscrew
Locknut
3
3
3
Mounting the carrier frames to the cutting units.
Lift arm
Pivot rod
Capscrew, 5/16 x 7/8 in.
Lock washer
Lift chain
Clevis pin
Cotter pin
2
2
2
2
2
4
4
Installing the front lift arms (supplied with the
Lift Arm Kit)
Thrust washer
Flat washer
Flange head capscrew
3
3
3
Mounting the cutting units to the lift arms
(supplied with the Lift Arm Kit)
Spring
Vinyl sleeve
Spring shackle
Clevis pin
Cotter pin
3
1
3
6
6
Installing the counterbalance springs (supplied
with the Lift Arm Kit)
Shackle
Spring anchor
Capscrew, 1/4 x 3/4 in.
Locknut
2
2
4
4
Installing the counterbalance springs (supplied
with the 32” Cutting Unit Lift Arm Kit only)
Key 2
Hydraulic reservoir plug 1
Danger decal 1Affix to inside of right hand panel housing for
European compliance.
Warning decal 1Affix to skirt for European compliance.
Danger decal 1Affix to battery for European compliance.
Instrument panel decal 1Affix to instrument panel for European
compliance.

14
Description UseQty.
Parts catalog
Certificate of compliance
1
1
Operator video 1View before operating the machine.
Operator’s manual
Engine operator’s manual
2
1Read before operating the machine.
Installing the Rear Wheel
1. Mount the wheel assembly onto the rear wheel hub
(Fig. 1).
1
2
3
Figure 1
1. Wheel assembly
2. Rear wheel hub
3. Lug nut
2. Install the lug nuts (Fig. 1) and tighten them to 45–65
ft.-lb. (3–5 N⋅m).
Adjusting the Rear Carrier
Frame Height
1. Slide the rear carrier frame onto the rear lift arm pivot
rod (Fig. 2). Do not install the carrier frame to the
cutting unit at this time.
2. Raise the lift arms and carrier frame fully.
3. Press down on one end of the carrier frame until the up
stop on the opposite end contacts the underside of the
foot step (Fig. 2). The distance between the up stop and
the underside of the foot step, on the end pressed down,
should be approximately 1/4 in. (6 mm). If the distance
is not 1/4 in. (6 mm), an adjustment to the lift cylinder
is required. If the distance is correct, remove the carrier
frame and proceed with the setup instructions.
1
3
3
2
4
Figure 2
1. Rear carrier frame
2. Pivot rod
3. Up stop
4. Lift cylinder
4. If an adjustment to the lift cylinder is required, proceed
as follows:
A. Remove the clevis pin securing the rod end of the
lift cylinder to the lift arm (Fig. 2).
B. Loosen the hex nut securing the clevis to the
cylinder rod.
C. Rotate the clevis end in or out until 1/4 in. (6 mm)
clearance is attained. Check the adjustment and
repeat steps 2–3 as required.
D. Tighten the hex nut and connect the cylinder rod end
to the lift arm (Fig. 2).
Mounting the Carrier Frames to
the Cutting Units
1. Remove the cutting units from the cartons. Adjust them
per the Cutting Unit Operator’s Manual.
2. Position a carrier frame onto each cutting unit, aligning
the mounting holes with the mounting links (Fig. 3).

15
3. Secure each mounting link to the carrier frame with a
capscrew (3/8 x 2-1/4 in.), 2 flat washers, and a locknut,
as shown in Figure 3. Position a washer on each side of
the link when mounting. Torque to 31 ft.-lb. (42 N⋅m).
1
3
2
Figure 3
1. Carrier frame
2. Mounting link
3. Bearing housing cover
Installing the Front Lift Arms
1. Insert a pivot rod into the left lift arm and align the
mounting holes (Fig. 4).
2. Secure the pivot rod to the lift arm with a capscrew
(5/16 x 7/8 in.) and lock washer.
1
2
Figure 4
1. Lift arm 2. Pivot rod
3. Loosen the top capscrew securing the left
counterbalance arm to the frame (Fig. 5).
1
2
3
4
5
8
6
7
Figure 5
1. Counterbalance arm
2. Top capscrew
3. Bottom capscrew
4. Lift arm pivot pin
5. Tipper chain
6. Lift chain
7. Cylinder pin
8. Lift arm tab
4. Remove the bottom capscrew and nut securing the left
counterbalance arm to the frame (Fig. 5).
5. Rotate the counterbalance arm outward, allowing
removal of the lift arm pivot pin and tipper chain
(Fig. 5).
6. Position the lift arm between the frame members, align
the mounting holes, and install the pivot pin (Fig. 5).
Insert the pivot pin so that the counterbalance arm fits
into the slot in the pin. Do not secure the counterbalance
arm at this time.
7. Secure one end of the lift chain to the lift cylinder pin
with a clevis pin and cotter pin.
8. Secure the other end of the lift chain to the hole in the
lift arm mounting tab with clevis pins and cotter pins.
Use the appropriate hole in the lift arm as designated in
Figure 6.
9. Repeat the procedure on the right-hand lift arm.
32” Cutting Unit
(Outer Hole)
27” Cutting Unit
(Inner Hole)
Figure 6

16
Mounting the Cutting Unit
Drive Motors
1. Position the cutting units in front of the pivot rods.
2. Remove the bearing housing cover (Fig. 3) from the
inside end of the right-hand cutting unit. Install the
cover and gasket (supplied with the cutting unit) on the
outside end. Locate the spider coupling (Fig. 7) shipped
in the bearing housing.
3. Insert the O-ring (supplied with the cutting unit) on the
flange of the drive motor (Fig. 7).
4. Mount the motor and the spider coupling to the drive
end of the cutting unit and secure them with 2
capscrews provided with the cutting unit (Fig. 7).
5. On the center and left-hand cutting units, remove the
bearing housing cover and install the gasket (supplied
with the cutting units).
1
2
3
Figure 7
1. Spider coupling
2. Reel motor
3. O-ring
Mounting the Cutting Units
1. Slide a thrust washer onto the lift arm pivot rod (Fig. 8).
2. Slide the cutting unit carrier frame onto the pivot rod
and secure it with a flat washer and flange head
capscrew (Fig. 8).
Note: On the rear cutting unit, position the thrust washer
between the rear of the carrier frame and the flat washer.
1
2
3
Figure 8
1. Thrust washer
2. Carrier frame
3. Flat washer and flange
head capscrew
3. Secure a tipper chain to the top of each 27” cutting unit
carrier frame and to the bottom of each 32” cutting unit
carrier frame with a capscrew, washer, and locknut
(Fig. 9).
1
2
3
Figure 9
1. Tipper chain (27” Cutting
Units)
2. Tipper chain (32” Cutting
Units)
3. Carrier frame
4. Grease all lift arm and carrier frame pivot points.

17
Installing the Counterbalance
Springs
Use caution when tensioning the springs as they
are under heavy load.
Warning
The counterbalance springs help balance the cutting units to
allow equal amounts of weight (down pressure) to be
distributed to each end of the cutting unit. The springs also
transfer weight from the cutting units to the traction unit
therefore, increasing traction.
The following are recommended settings for the
counterbalance springs. Minor changes may be required to
achieve optimum performance for your turf conditions. The
weight, at each end of the cutting unit, can be checked
easily with a spring scale.
•Increasing the spring tension reduces the weight on
inboard end of the cutting unit and increases the
weight on the outboard end.
•Decreasing the spring tension increases the weight on
the inboard end of the cutting unit and reduces the
weight on outboard end.
27” Cutting Units
1. Hook the spring into the third hole from the top on the
inboard side of both front cutting unit lift tabs and on
the rear cutting unit lift tab (Fig. 10).
Note: Selecting the #4 hole position (increasing the spring
tension) will reduce the weight on the inboard end of the
cutting unit, increase the weight on the outboard end of the
cutting unit, and increase traction. Selecting the #2 hole
position has the opposite affect.
1
Figure 10
1. Cutting unit lift tab
2. Secure the other end of the spring to the appropriate
hole (see below) on the front and rear counterbalance
arms (Fig. 11 & 12) with the spring shackle, clevis pin,
and cotter pin.
•Fourth hole from the top for 5 blade reels
•Third hole from the top for 8 blade reels
•Top hole for reels with baskets
Note: On the rear counterbalance spring, install the vinyl
cover over the spring before installing.
Note: Increasing the spring tension will reduce the weight
on the inboard end of the cutting unit, increase the weight
on the outboard end of the cutting unit, and increase
traction. Decreasing the spring tension has the opposite
affect.
1
4
2
35
Figure 11
1. Counterbalance arm
2. Top capscrew
3. Bottom capscrew
4. Spring shackle
5. Clevis pin and cotter pin
1 23
Figure 12
1. Rear counterbalance
spring
2. Vinyl cover
3. Spring shackle
3. Insert the breaker bar into the square hole in the
counterbalance arm and pivot the arm back to its
original position, aligning the mounting holes.
4. Secure the bottom of the counterbalance arm to the
frame with the capscrew and nut previously removed.
Tighten the top capscrew (Fig. 11).

18
5. To tension the counterbalance springs, proceed as
follows:
A. Remove the cotter pin and clevis pin securing the
spring shackle to the counterbalance arm. Do not
remove the other clevis pin.
B. Move the shackle up or down on the counterbalance
arm until it is aligned with the desired hole on the
arm. Install the clevis pin and cotter pin.
32” Cutting Units
1. Mount a spring anchor to the rear inboard side of each
front cutting unit lift tab with 2 capscrews (1/4 x 3/4 in.)
and locknuts, as shown in Figure 13.
1
2
Figure 13
1. Cutting unit lift tab 2. Spring anchor
2. On the front cutting units, hook the spring into the
second hole from the bottom (#3 position) in the spring
anchor (Fig. 13).
Note: Selecting the #4 hole position (increasing the spring
tension) will reduce the weight on the inboard end of the
cutting unit, increase the weight on the outboard end of the
cutting unit, and increase traction. Selecting the #2 hole
position has the opposite affect.
3. On the rear cutting unit, hook the spring into the top
hole on the rear cutting unit lift tab.
Note: Increasing the spring tension will reduce the weight
on the inboard end of the cutting unit, increase the weight
on the outboard end of the cutting unit, and increase
traction. Decreasing the spring tension has the opposite
affect.
4. Secure the other end of the spring to the appropriate
hole (see below) on the front and rear counterbalance
arms (Fig. 14 & 15) with the spring shackle with the
chain, clevis, clevis pin, and cotter pin.
•Third hole from the top for 5 blade reels
•Second hole from the top for 8 blade reels
•Top hole for reels with baskets
Note: On rear counterbalance spring, install vinyl cover
over spring before installing.
5. Secure the other end of the spring to the second hole
from the top with the spring shackle with the chain,
clevis, clevis pin, and cotter pin (Fig. 14).
14
2
3
5
Figure 14
1. Counterbalance arm
2. Top capscrew
3. Bottom capscrew
4. Spring shackle
5. Clevis pin and cotter pin
6. Chain, clevis, and clevis
pin
6. On the rear counterbalance arms, install the vinyl cover
over the spring before hooking the other end of the
spring into the spring shackle in the second hole from
the top (Fig. 15).
1 23
Figure 15
1. Rear counterbalance
spring
2. Vinyl cover
3. Spring shackle
7. Insert the breaker bar into the square hole in the
counterbalance arm and pivot the arm back to its
original position, aligning the mounting holes.
8. Secure the bottom of the counterbalance arm to the
frame with the capscrew and nut previously removed.
Tighten the top capscrew (Fig. 14).
9. To tension the counterbalance springs proceed as
follows:
A. Remove the cotter pin and clevis pin securing the
spring shackle to the counterbalance arm. Do not
remove the other clevis pin.

19
B. Move the shackle up or down on the counterbalance
arm until it is aligned with the desired hole on the
arm. Install the clevis pin and cotter pin.
Adding Rear Ballast
This unit complies with ANSl B71.4–1999 Standard and all
applicable European requirements when equipped with rear
ballast. Use the following chart to determine the weight or
combinations of weights needed.
Cutting Unit
Configuration Weight Kits Required
Standard machine with
27” cutting units
(1) 83-9370
(2) 83-9390
Standard machine with
27” cutting units &
baskets
(1) 83-9370
(3) 83-9390
(2) 94-3698
Standard machine with
three wheel drive kit &
27” cutting units
(1) 83-9390,
(1) 83–9370
Standard machine with
three wheel drive kit, 27”
cutting units & baskets
(2) 83-9390
(2) 94-3698
(1) 83–9370
Standard machine with
32” cutting units
(3) 83-9390
(2) 94-3698
(1) 83–9370
Standard machine with
32” cutting units & three
wheel drive kit
(1) 83-9370
(2) 83-9390
(1) 94–3698
Note: All configurations require calcium chloride in the
rear tire. Tires should be filled to approximately 75%
capacity (valve level with valve at the top) (60 lb. fluid or
74 lb. tire and fluid).
Important If a puncture occurs in a tire with calcium
chloride, remove the unit from the turf area as quickly as
possible. To prevent possible damage to the turf,
immediately soak the affected area with water.
Either Type 1 (77%) or Type 2 (94%) commercial calcium
chloride flake may be used.
Plain water freezes solid at 32°F (0°C). The 3-1/2 lb.
(1.6 kg) calcium chloride to 1 gallon (3.8 l) of water
solution is slush free to –12°F (–24°C) and will freeze solid
at –52°F (–46°C). The 5 lb. (2.3 kg) per gallon (liter)
solution is slush free to –50°F (–45°C) and will freeze
solid at –62°F (–52°C).
Activating and Charging the
Battery
CALIFORNIA
Proposition 65 Warning
Battery posts, terminals, and related accessories
contain lead and lead compounds, chemicals
known to the State of California to cause cancer
and reproductive harm. Wash hands after
handling.
Warning
If the battery is not filled with electrolyte or activated, bulk
electrolyte with 1.260 specific gravity must be purchased
from a local battery supply outlet and added to the battery.
1. Remove the filler caps from the battery and slowly fill
each cell until the electrolyte is just above the plates.
Danger
Battery electrolyte contains sulfuric acid which is a
deadly poison and causes severe burns.
•Do not drink electrolyte and avoid contact with
skin, eyes or clothing. Wear safety glasses to
shield your eyes and rubber gloves to protect
your hands.
•Fill the battery where clean water is always
available for flushing the skin.
2. Replace the filler caps with the vents pointing to the
rear (toward the fuel tank) and connect a 3 to 4 amp
battery charger to the battery posts. Charge the battery
at a rate of 3 to 4 amperes for 4 to 8 hours.
Charging the battery produces gasses that can
explode.
Never smoke near the battery and keep sparks and
flames away from battery.
Warning
3. When the battery is charged, disconnect the charger
from the electrical outlet and battery posts.
4. Remove the filler caps. Slowly add electrolyte to each
cell until the level is up to the fill ring. Install the filler
caps.

20
Important Do not overfill the battery. Electrolyte will
overflow onto other parts of the machine and severe
corrosion and deterioration will result.
5. Install the positive cable (red) to the positive (+)
terminal and the negative cable (black) to the negative
(—) terminal of the battery (Fig. 16) and secure them
with capscrews and nuts. Slide the rubber boot over the
positive terminal to prevent a possible short from
occurring.
Incorrect battery cable routing could damage the
machine and cables causing sparks. Sparks can
cause the battery gasses to explode, resulting in
personal injury.
•Always disconnect the negative (black) battery
cable before disconnecting the positive (red)
cable.
•Always connect the positive (red) battery cable
before connecting the negative (black) cable.
Warning
2
3
1
Figure 16
1. Battery
2. Positive (+) batter cable
3. Negative (–) battery cable