Twin-Drive REEL MOWER User manual

TWIN-DRIVE
REEL MOWER
OWNERS MANUAL

LIST OF CONTENTS
INTRODUCTION ..............................................................................................1
COMPLIANCE ..................................................................................................1
SAFETY PRECAUTIONS.....................................................................................2
SYMBOLS........................................................................................................4
OPERATING THE REEL MOWER........................................................................5
OPERATOR PRESENCE CONTROL (OPC) ............................................................. 5
IDENTIFICATION OF CONTROLS ......................................................................... 5
HANDLEBAR ADJUSTMENT................................................................................ 6
CUTTING HEIGHT ADJUSTMENT ........................................................................ 6
CUTTING CYLINDER TO BOTTOM BLADE ADJUSTMENT ..................................... 6
GRASS CATCHER ................................................................................................ 7
MAINTENANCE ...............................................................................................8
CLEANING AND STORAGE..............................................................................12
GRASS CUTTING FAULTS ...............................................................................13
TROUBLESHOOTING......................................................................................14
WARRANTY ..................................................................................................15
VER 6 : 4-12-08

-1-
INTRODUCTION
The ‘Twin-Drive’ Reel Mower is a precision built machine, designed for a high quality of
finish and long service life. The way in which the machine is operated and maintained will
have a profound effect on its performance and reliability.
This manual contains advice on the safe operation of your ‘Twin-Drive’ Reel Mower, which
is offered for the guidance and protection of all those operating and servicing the machine.
In the pursuit of continuous development and product improvement, the Supplier reserves
the right to alter specifications without notice.
COMPLIANCE
The Twin Drive Reel mowers have been tested for Noise Emission in accordance with Annex
H of UNI EN 836:2003
Test Results
400 B 2.4
500 B 2.4
500 Golf
660 B 4.0
500 H 5.5
500 Golf
660 H 5.5
B 4.0
H 5.5
95 db(A)
96 db(A)
97db(A)
97 db(A)
96 db(A)
97db(A)
97 db(A)
The Twin Drive Reel mowers have been tested for Vibration values in accordance with
EN 1033:1995
Test Results
400 B 2.4
500 B 2.4
500 Golf B 4.0
660 B 4.0
ahw,x = 3.12 m/s2
ahw,x = 4.04 m/s2
ahw,x = 3.93 m/s2
ahw,x = 5.25 m/s2
ahw,y = 3.73 m/s2
ahw,y = 1.52 m/s2
ahw,y = 0.61 m/s2
ahw,y = 1.19 m/s2
ahw,z = 3.74 m/s2
ahw,z = 2.17 m/s2
ahw,z = 2.25 m/s2
ahw,z = 2.34 m/s2
500 H 5.5
500 Golf H 5.5
660 H 5.5
ahw,x = 5.52 m/s2
ahw,x = 5.76 m/s2
ahw,x = 7.31 m/s2
ahw,y = 1.80 m/s2
ahw,y = 1.98 m/s2
ahw,y = 1.21 m/s2
ahw,z = 3.49 m/s2
ahw,z = 2.15 m/s2
ahw,z = 2.48 m/s2

-2-
SAFETY PRECAUTIONS
READ THIS MANUAL BEFORE USING THE REEL MOWER, IT IS ESSENTIAL THAT OPERATORS
STUDY IT FOR THEIR OWN SAFETY.
THE FOLLOWING PRECAUTIONS MUST BE TAKEN TO HELP PREVENT ACCIDENTS. A CAREFUL
OPERATOR WHO USES COMMON SENSE IS THE SAFEST OPERATOR.
1. Read the instructions carefully. Be familiar with the controls and use of the equipment.
2. Never allow children or people unfamiliar with these instructions to use the machine.
3. Never operate the machine while people or animals are nearby.
4. The operator or user is responsible for accidents or hazards occurring to other people or
property.
5. While mowing, always wear substantial footwear and long trousers. Do not operate the
mower when barefoot or wearing open sandals.
6. Thoroughly inspect the area where the mower is to be used and remove all stones, sticks,
wires, bones and any other foreign objects.
7. Check that the mower is in good working order before using. Always visually inspect to
see that the cutting blade, blade bolts and cutting cylinder are not worn or damaged and
regularly check that all nuts, bolts, linkages and connections are tight and secure. Repair or
replace excessively worn or damaged components with genuine TWIN DRIVE Spare Parts
only.
8. Always add fuel before you start mowing. Refuel and lubricate outdoors only. Never
remove the fuel cap or attempt to add fuel while the engine is running. Thoroughly clean
any fuel spillages before starting the engine. After refuelling or topping up with engine oil,
ensure that the filler caps are replaced securely.
9. Do not operate the mower in a confined space where dangerous carbon monoxide fumes
can collect.
10. Mow only in daylight hours or in good artificial light.
11. Replace worn or faulty silencers.

-3-
SAFETY PRECAUTIONS
12. Never cut grass while walking backwards.
13. Always wear suitable eye protection and ear muffs when operating the mower.
14. When mowing on slopes, only mow across the face, never up and down. Exercise
extreme caution when changing direction and do not attempt to mow excessively steep
gradients.
15. Never lift or carry the mower while the engine is running.
16. Keep hands and feet well clear of rotating blades and components.
17. Always stop the engine when you leave the mower unattended and disconnect the
cutting reel drive when crossing roads, pathways or gravel drives.
18. Always stop the engine and disconnect the spark plug before attempting to clean the
mower, un-block the cutting mechanisms, carry out maintenance or repairs, inspecting the
mower after abnormal vibrations or after striking a foreign object.
19. Do not adjust throttle or governor settings, as this will have a detrimental effect on the
mower’s cutting ability and ultimately shorten the mower’s working life.
20. Store fuel in a cool place away from direct sunlight in a suitable container.
21. Never operate the mower with defective guards, shields or without safety protection
devices in place and in good working order.
22. Disengage drive to the cutting reel when transporting or not in use
HEALTH & SAFETY AT WORK: This reel mower has been designed and constructed so that,
in so far as reasonably practical, it will not endanger the safety and health of those working
with it, This is however subject to the machine being properly used and maintained
according to the conditions stated in this manual and elsewhere, which have been found
necessary as a result of the research and testing of the Supplier.

-4-
SYMBOLS
MEANING OF THE SYMBOLS SHOWN ON THE MOWER
Warning
Read Operating Instructions before starting operations
Be careful of object thrown from the mower
Keep other people away from the danger zone
Disconnect spark plug before carrying out any maintenance
Attention –Danger Keep hands and feet away from cutting blades
Be careful of hot surfaces
Attention –Danger Do Not touch hot surfaces

-5-
OPERATING THE REEL MOWER
SAFETY NOTICE
WARNING: PREVENT ACCIDENTS
Before operating the mower it is essential that:-
The operator reads and understands this manual.
The daily maintenance checks have been properly carried out and the mower is in good
working order.
The operator should wear safety clothing and eye protection. Failure to do so could
result in damage and risk to health and safety.
OPERATOR PRESENCE CONTROL (OPC)
Drive to the cutting cylinder is only possible when the operator actuates the reel clutch
lever ‘Y. If the operator releases the lever, the drive to the cutting cylinder is disengaged.
IDENTIFICATION OF CONTROLS
Throttle Control Lever
The throttle control lever is located at the top the central handle tube. To start a cold
engine fitted with a choke system, push the throttle control lever forward and move the
choke lever situated on the carburettor to fully on position. After starting, slowly move the
choke lever to the run position. Do not use the choke when starting warm engine. Note
that the engine speed dictates the speed and operation of travel and cutting reel.
Reel Clutch Lever
The reel clutch lever ‘Y’ is located on the LH side of the upper
handlebar ‘Z’ and is sprung to the disengage position. Squeeze the
lever toward the handlebar to engage the drive to the cutting
cylinder. Release the lever to disengage the drive to the cutting
cylinder.
Roller Clutch Lever.
The roller clutch lever ‘X’ is located on the RH side of the upper handlebar ‘Z’ and is sprung
to the disengage position. Drive to the rear roller is engaged when the lever is squeezed
towards the upper handlebar. Releasing the lever disengages drive to the rear roller. When
the reel and rear roller clutch Levers are squeezed both levers ‘X’ and ‘Y’ are interlocked in
position. The levers remain engaged if any one of the levers is held squeezed. This enables
one hand operation of the mower. Both drives are disengaged with the release of the
levers.

-6-
OPERATING THE REEL MOWER
Recoil Start Handle.
Refer to the engine manufacturer’s owners’ handbook for details.
HANDLEBAR ADJUSTMENT
The clutch cables and levers are factory fitted to the upper handle and mower. The upper
handle assembly is transported separated at the handlebar pivot point. On assembly,
remove the handle locking lever, position the upper handle assembly, and fit the handle
locking lever and clamp the upper handle in place. The height and position of the handlebar
may be changed to suit individual operators requirements by loosening the bolts retaining
the lower handlebar to the mower frame and pivoting it in the slot provided. The nuts and
bolts must be secured in the position required.
CUTTING HEIGHT ADJUSTMENT
The cutting height is gauged by the
position of the front and rear rollers.
It is variable between 7 - 30mm and
adjusted by means of a plastic
handwheel. The cutting height is
increased by rotating the handwheel
in a clockwise direction and vice-versa.
If a particular cutting height is
required it is necessary to bridge the
rear and front rollers and measure the
normal height to the cutting point of the bottom blade and adjusting the handwheel to
obtain the correct height of cut.
CUTTING CYLINDER TO BOTTOM BLADE ADJUSTMENT
It is essential that the relationship between the bottom blade
and cutting cylinder is kept in good adjustment and that
cutting edges are kept sharp to ensure good cutting
performance, minimum power consumption and prolonged
life for the cutting edges. Carry out the following procedures
before commencing work and re-check the settings every 2-3
hours of mowing or when the cutting performance is
noticeably reduced.

-7-
OPERATING THE REEL MOWER
Razor Cut System
Check that the cutting cylinder is correctly set in relation to the bottom blade by a piece of
2 thou (0.05 mm) shim between the cutting cylinder and the bottom blade. Carefully rotate
the cylinder by hand and check that the shim is being touched by points along the length of
the blade. Hold the shim flat on the bottom blade:-
If adjustment is necessary, proceed as follows:-
Turn adjusting screw ‘A’ in a clockwise direction each end alternatively, whilst rotating the
cutting cylinder, with the shim on the bottom blade and is in fleeting contact with the
cutting cylinder along its entire length. Re-check this procedure making marginal
adjustments to screw ‘A’ as necessary.
NOTE:
There should always be a clearance of 2 thou (0.05 mm) between the bottom blade and
cutting cylinder to create a scything cut for a better finish. This clearance also eliminates
the noise created by the blades. DO NOT over tighten the bearing housing retaining nyloc
nuts B and C.
When the grass is not being cut cleanly it will be necessary to regrind the front of the
bottom blade. This procedure must be carried out by your authorised service agent on a
quality, well maintained bottom blade grinding machine. If the wearing is excessive both
the cutting cylinder and bottom blade will need regrinding.
GRASS CATCHER
Always shut off the engine whilst fitting or removing the grass catcher. The Twin Drive Reel
Mower can be operated with the grass catcher fitted or removed. Generally the quality of
sward will be improved with the grass catcher removed, hence re-clipping the grass. To fit
the grass catcher, position the catcher in front of the mower and support the catcher by its
front handle and its top edge. Lift the catcher into position engaging the hooks over the
catcher studs at each end of the mower frame. Finally lower the catcher into place,
ensuring it is sitting level on the mower. Reverse this procedure to remove the catcher.

-8-
MAINTENANCE
IMPORTANT PREVENT DAMAGE: Regular maintenance is essential for the continued safe
operation of the machine. Correct servicing will prolong the working life of the machine
and safeguard the Twin Drive Warranty. Always fit genuine ‘Twin Drive Service Parts’ as
these are accurately matched to the required duty.
Engine
Refer to the manufacturer’s operators’ manual for engine maintenance information.
Fuel
If the fuel has to be drained for maintenance or any other reason, this should be done
outdoors.
Check engine oil level
Before the first use, every Twin Drive mower will require the addition of engine oil, as they
leave the factory in a ‘dry’ condition. Engine oil requires changing after the initial first five
hours of use, and then every 50 hours of normal use and 25 hours of heavy use thereafter.
With the mower in a level position, remove the oil dipstick, if the engine oil level is below
the minimum mark on the dipstick, top up with the correct grade of engine oil to the full
mark on the dipstick. DO NOT OVER FILL. Then screw the dipstick securely back into place.
Clean the air cleaner
Remove and clean the air filter cartridge at three monthly intervals or every 25 hours of
use. The air filter cartridge may require servicing more often under dusty operating
conditions. To service the air cleaner cartridge, follow the procedures. Loosen the screws
and remove the cartridge. Blow a gentle air line through the cartridge in the opposite
direction to normal engine operation. If the cartridge is excessively dirty, it should be
replaced.
Check spark plug
Clean and reset the spark plug gap every 100 hours of operation. Remember, in small
engines, difficult starting and erratic running is most often attributable to a dirty, oily or
carbonated spark plug. Do not file or sand blast the spark plug electrode but clean by
scraping or wire brushing, then cleaning with a commercial solvent.
Rotating screen
Through prolonged operation, the rotating screen may become clogged with grass and
debris. Clean the screen in line with the engine manufacturer’s recommendations to avoid
over heating and possible engine damage.

-9-
MAINTENANCE
Throttle control
Lubricate the throttle cable by applying a light oil to the top of the inner wire and allowing it
to gravity drain down the inside. The throttle control lever quadrant should have a medium
grease smeared over it to protect it from corrosion and to give a smooth operation.
Clutch cables and pivots
Lubricate the clutch cable by applying a light oil to the top of the inner wire and allowing it
to gravity drain down the inside. The cable pivot also requires occasional lubrication to
allow free movement of the mechanisms.
Fasteners and linkages
Check that all nuts, bolts, pins and linkages are secured correctly in place and are in good
condition.
Drive chain tension
It will be necessary after the initial 5 hours and every 25 hours of use thereafter to check
and adjust the tension of the drive chains. The chain guard must be removed from the
mower frame to get access to the transmission system. Wear in the reel drive chain is
compensated for by the sprung chain tensioner shoe. As the motor / clutch and clutch /
roller chains stretch, the clutch assembly must be moved in order to obtain the correct slack
in each chain. The nut at the bottom of the clutch mount plate must be slackened and the
clutch assembly moved forward and down to take out the excess slack. There should be
approximately 3 - 5mm of slack in each chain for correct adjustment. It would be
worthwhile at this stage to inspect the bearings and sprockets for excessive wear. Replace
worn or damaged parts before further use.
Flexible coupling
Remove the drive shaft cover and inspect the flexible coupling ‘spider’ for signs of wear
every 50 hours of operation.
General Lubrication
Grease nipples are provided in the cutting cylinder bearings (and roller bearing housings on
Golf & Sports models) and should be greased every 25 hours. The drive chains should have
a small amount of grease applied to each one to prevent seizure and prolong the chain life.
Clutch cable adjustment
The Reel Mower operating levers feature a ‘Hold In’ interlatch that allows single handed
operation of the mower. After several hours of operation the clutch cables may require
adjustment to obtain the correct drive. This may be due to either the clutch cable

-10-
MAINTENANCE
stretching or the clutch plates wearing, therefore not allowing sufficient travel on the
clutches to engage the drives. There is adjustment in the cable assemblies to accommodate
the wear. The following procedures should be followed. Remove the shaft cover and put to
one side with the fasteners.
The Reel clutch can be adjusted, with the cable inline adjuster ‘D’. Firstly loosen the reel
clutch cable inline adjuster ‘D’, then tighten one turn at a time and re-check the roller
clutch engagement. Continue this procedure until the reel drive is fully engaged. When
the cable is correctly adjusted, the lever should engage the ‘hold in’ detent .
The Roller clutch can be adjusted, with the cable inline adjuster ‘E’ and also by the locknut
‘F’ fitted to the pull rod.
Firstly loosen the roller clutch cable inline
adjuster ‘E’, then tighten one turn at a time
and re-check the roller clutch engagement.
The correct engagement is achieved when the
lever engages the ‘hold in’ detent with full
clutch engagement. If this adjustment is not
attainable with this method it is necessary to
remove the ‘slack’ from the system by
tightening the locknut ‘F’ on the pull rod a
turn at a time until the required movement is
achieved.
Once the adjustments to the clutch cables have been made and the mower drive is correct,
finally replace the shaft cover.

-11-
MAINTENANCE
Grass thrower adjustment
The grass thrower will require adjustment in
certain grass conditions or after prolonged use of
the mower as the cutting edges wear. This will be
noticeable by the reduced efficiency to catch grass
and to fill the catcher. The closer that the grass
thrower is to the periphery of the cutting reel, the
better the catching ability and the harder the
grass is thrown.
First slacken the two retaining screws and pull the
grass thrower forward to reduce the gap between
it and the cutting cylinder without it touching as
this will create unnecessary noise and wear on the
cutting edges. A little trial and error will soon
achieve the optimum position. Re-tighten the
retaining screws while holding the grass thrower in position. If the grass throwing ability is
not improved by these adjustments it will be necessary to take the mower to an authorized
service agent for checking over and possible modification to the grass thrower plate.
Catcher
Check the grass catcher frequently for wear or deterioration.
Maintenance
Replace worn or damaged parts to keep the mower in a safe condition.
When carrying out any adjustment or maintenance, take care to prevent entrapment of
the fingers between moving blades and fixed parts of the mower.

-12-
CLEANING AND STORAGE
There is a direct relationship between the mower’s life and the care and attention given to
the mower both during and after operation. After use it is important that the mower is
thoroughly cleaned down and inspected so that it will be in good working order the next
time it is required. Disconnect the spark plug lead and thoroughly clean the engine,
underside of the chassis, rollers and grass catcher. Where water is used under pressure it
is important that all the grease and lubrication points are lubricated to force out the water
that can sit in the bottom of bearings and chains prior to storage. Do not use a water hose
around the engine as this may contaminate the fuel or enter the ignition system and result
in poor engine performance and starting problems.
Muffler
Always clean around the muffler area regularly to reduce the risk of fire and damaging the
mower. Brush the grass, dirt or combustible debris from the muffler.
Always store the mower on a flat, level surface.
End of Season storage:
After each mowing season or if the mower is not going to be used for 30 days or more, it is
recommended that the fuel shut off valve be closed off (where fitted) and the fuel tank be
drained as fuel has a shelf life of only about 30 days. The mower should then be started up
and run until all of the fuel left in the system is used. Run the engine until it is warm and
drain the engine oil and refill with the correct grade to the required level. Remove the
spark plug and pour 15cc of engine oil into the cylinder, crank slowly to distribute the oil
and replace the spark plug. Store the mower in a clean dry area away from direct sunlight
as this will have an aging effect on the plastic catcher assembly.
Adjust the cutting cylinder away from the bottom blade and apply a thin layer of grease to
the cutting edges to prevent corrosion through the storage period. If possible, spray the
mower with a thin film of light oil to protect it.
Safety:
To reduce the fire hazard keep the engine, muffler and petrol storage free of grass, leaves
or excessive grease. Never store the mower with petrol in the tank inside a building where
fumes can reach an open flame or spark.

-13-
GRASS CUTTING FAULTS
FAULT
POSSIBLE CAUSE
REMEDY
Ridge lines in the cut across
the direction of travel.
Forward speed too high.
Reduce engine rpm.
Cylinder speed too slow.
Reduce forward speed.
Height of cut too low.
Raise height of cut.
Some uncut or poorly cut
strands of grass.
Cutting cylinder is partially out of contact
with the bottom blade.
Re-adjust cutting cylinder to bottom
blade.
Cutting cylinder is in heavy contact with
the bottom blade.
Re-adjust cutting cylinder to bottom
blade.
Height of cut is too high.
Lower height of cut setting.
Cutting edges of cutting cylinder / bottom
blade are rounded.
Regrind cutting edges.
Lines of uncut or badly cut
grass in direction of travel.
Tramlining of cutting edges due to heavy
contact caused by poor cylinder / blade
adjustment.
Regrind cutting edges.
Bottom blade in ground contact.
Raise height of cut.
‘Nose down’ attitude of bottom blade.
Re-adjust height of cut.
Scalping.
Undulations too severe for height of cut
setting.
Raise height of cut.
Excessive bottom blade wear
Bottom blade in heavy ground contact.
Raise height of cut.
Cutting edges of cutting cylinder / bottom
blade are rounded.
Regrind cutting edges.
Cutting cylinder is in heavy contact with
the bottom blade.
Re-adjust cutting cylinder to bottom
blade.
Damaged cutting cylinder or bottom blade.
Regrind or replace as necessary.
If fault persists, consult your authorised Twin Drive Service Agent.

-14-
TROUBLESHOOTING
FAULT
POSSIBLE CAUSE
REMEDY
Engine does not start, runs
erratically or experiencing
power loss.
Throttle not in choke / start position.
Move throttle to choke / start position
Fuel tank empty or fuel shut off valve
closed.
Fill tank with recommended fuel grade
and open fuel shut-off valve.
Air cleaner element is dirty.
Service or replace air cleaner
Spark plug loose.
Tighten spark plug.
Spark plug cable disconnected.
Refit cable to spark plug.
Defective spark plug.
Replace damaged spark plug.
Spark plug gap incorrect.
Replace damaged spark plug. Refer to
Engine Manual.
Carburettor is flooded with fuel.
Move throttle to ‘stop’ position, pull the
starter cord 5 - 6 times, move throttle to
‘run’ and start engine.
Dirt, water or stale fuel in the tank.
Drain and clean fuel tank. Refill with
clean fresh fuel before starting.
Vent hole in the filler cap is blocked.
Clean or replace filler cap.
Spark plug gap too small.
Refer to engine manual.
Air cleaner is element dirty.
Service or replace air cleaner.
Engine skips at high speed.
Blocked engine cooling fins and air
passages.
Remove debris from around engine.
Engine idles poorly.
Cooling air flow restricted.
Remove debris from around engine.
Engine overheats.
Incorrect spark plug fitted.
Refer to Engine Manual.
Low engine oil level.
Check oil level and top up if necessary.
Excessive vibration and / or
noise.
Worn or damaged bearing(s).
Remove and inspect suspect bearings,
replace if necessary.
Worn or damaged drive chains and / or
sprockets.
Remove and inspect suspect chains and
sprockets, replace if necessary.
Worn or damaged cutting reel or bottom
blade.
Inspect cutting reel and bottom blade for
excessive wear or damage. Cutting edges
will require regrinding or replacement by
your authorised Twin Drive Service
Agent.
Oil leaks from muffler or air
cleaner.
Worn or damaged flexible coupling.
Inspect and replace worn ‘spider’if
necessary.
Engine oil sump over filled.
Check oil level and drain excessive oil.
Mower tipped or handled incorrectly.
Check oil level, air cleaner and spark plug
and correct as necessary.
If fault persists, consult your authorised Twin Drive Service Agent.

-15-
WARRANTY
The supplier warrants this Twin Drive Reel Mower to be free from defects in material and
workmanship.
Subject to the following conditions, the Supplier will meet the cost of repairing or replacing
any part(s) deemed to be defective when examined by an authorised Twin Drive Service
Agent.
1. This warranty does not include the engine and batteries (if fitted), which are covered by
separate manufacturers warranties.
2. For other items, this warranty will apply for a period of two years from the date of
purchase for the original purchaser only, with the exception of domestic mowers that
are used for commercial, institutional, industrial, rental or income producing purposes
which are limited to 90 days of warranty.
3. This warranty excludes normal wear and tear, misuse, neglect, accidental damage or
defects arising from failure to comply with the instructions as outlined in this Owner’s
Manual. Wearing parts such as reels, bottom blades and spark plugs which can be
subjected to use beyond their normal working capacity are also excluded.
4. This warranty is void if parts other than genuine Twin Drive have been used or repairs
carried out by other than authorised Twin Drive Service Agents.
5. This warranty does not cover the costs of transportation of any part(s) but does cover
the labour / part costs incurred in repairing or replacing any defective part(s).
6. The supplier reserves the right to inspect any faulty part(s) in order to determine the
validity of the warranty claim or for any other reason.
7. The supplier has no liability for any incidental, consequential or special damages and /
or expenses resulting from any defect in their product.
These conditions do not affect the purchasers’ statutory rights under the laws of the place,
state or country of purchase.
If warranty service is required, contact your nearest authorised Twin Drive Service Agent.