Toro 03806, 03808, 03813, reelmaster 6500-D, 03807 Operator's 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.T oro.com.OriginalInstructions(EN)

ThisproductcomplieswithallrelevantEuropean
directives,fordetailspleaseseetheseparateproduct
specicDeclarationofConformity(DOC)sheet.

WARNING

CALIFORNIA

Proposition65Warning

Dieselengineexhaustandsomeofits
constituentsareknowntotheStateof

Californiatocausecancer,birthdefects,

andotherreproductiveharm.

Figure1

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.

1.Locationofthemodelandserialnumbers

ModelNo.

SerialNo.

Thismanualidentiespotentialhazardsandhassafety
messagesidentiedbythesafetyalertsymbol(Figure2),
whichsignalsahazardthatmaycauseseriousinjury
ordeathifyoudonotfollowtherecommended
precautions.

Figure2

1.Safetyalertsymbol.

Thismanualusestwootherwordstohighlight
information.Importantcallsattentiontospecial
mechanicalinformationandNoteemphasizesgeneral
informationworthyofspecialattention.

Wheneveryouneedservice,genuineToroparts,
oradditionalinformation,contactanAuthorized
ServiceDealerorToroCustomerServiceandhave
themodelandserialnumbersofyourproductready.
Figure1identiesthelocationofthemodelandserial
numbersontheproduct.Writethenumbersinthe
spaceprovided.

©2013—TheT oro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420

Contactusatwww.Toro.com.

2

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

RearWheelT oe-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.

•Inspecttheareawheretheequipmentistobeused
andremoveallobjectssuchasrocks,toysandwire
whichcanbethrownbythemachine.

•Useextracarewhenhandlingdieselfuel.Itis
ammableandvaporsareexplosive.

Useonlyanapprovedcontainer.

•Neverremovegascaporaddfuelwithengine
running.Allowenginetocoolbeforerefueling.Do
notsmoke.

•Neverrefuelordrainthemachineindoors.

Improperuseormaintenancebytheoperatororowner
canresultininjury.Toreducethepotentialforinjury,
complywiththesesafetyinstructionsandalwayspay
attentiontothesafetyalert
CAUTION,WARNING,orDANGER-“personalsafety
instruction.”Failuretocomplywiththeinstructionmay
resultinpersonalinjuryordeath.

symbol,whichmeans

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.

•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.

Preparation

•Evaluatetheterraintodeterminewhataccessories
andattachmentsareneededtoproperlyand
safelyperformthejob.Onlyuseaccessoriesand
attachmentsapprovedbythemanufacturer.

•Wearappropriateclothingincludinghardhat,safety
glassesandearprotection.Longhair,looseclothing
orjewelrymaygettangledinmovingparts.

•Stopequipmentandinspectthemachineafter
strikingobjectsorifanabnormalvibrationoccurs.
Makenecessaryrepairsbeforeresumingoperations.

•Keephandsandfeetawayfromthecuttingunits.

•Lookbehindanddownbeforebackinguptobesure
ofaclearpath.

•Nevercarrypassengersandkeeppetsandbystanders
away.

4

•Slowdownandusecautionwhenmakingturns
andcrossingroadsandsidewalks.Stopreelsifnot
mowing.

•Donotoperatethemowerundertheinuenceof
alcoholordrugs.

•Lightningcancausesevereinjuryordeath.If
lightningisseenorthunderisheardinthearea,do
notoperatethemachine;seekshelter.

•Usecarewhenloadingorunloadingthemachine
intoatrailerortruck.

ToroMowerSafety

Thefollowinglistcontainssafetyinformationspecicto
Toroproductsorothersafetyinformationthatyoumust
knowthatisnotincludedintheANSIstandards.

Thisproductiscapableofamputatinghandsand
feetandthrowingobjects.Alwaysfollowallsafety
instructionstoavoidseriousinjuryordeath.

Useofthisproductforpurposesotherthanitsintended
usecouldprovedangeroustouserandbystanders.

•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.W earglovesand
usecautionwhenservicingthem.

•Keephandsandfeetawayfrommovingparts.If
possible,donotmakeadjustmentswiththeengine
running.

•Chargebatteriesinanopenwellventilatedarea,
awayfromsparkandames.Unplugchargerbefore
connectingordisconnectingfrombattery.W ear
protectiveclothinganduseinsulatedtools.

•Keepallpartsingoodworkingconditionandall
hardwareandhydraulicttingstightened.Replaceall
wornordamageddecals.

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.

SoundPowerLevel

Reelmaster6500

Thisunithasaguaranteedsoundpowerlevelof101
dBA,whichincludesanUncertaintyValue(K)of1dBA.

•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.

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/s

Measuredvibrationlevelforlefthand=1.04m/s

UncertaintyValue(K)=0.5m/s

Measuredvaluesweredeterminedaccordingtothe
proceduresoutlinedinEN836.

WholeBody

Measuredvibrationlevel=0.55m/s

2

2

2

2

•Tomakesureofoptimumperformanceand
continuedsafetycerticationofthemachine,use
onlygenuineTororeplacementpartsandaccessories.
Replacementpartsandaccessoriesmadebyother
manufacturerscouldbedangerous,andsuchuse
couldvoidtheproductwarranty.

UncertaintyValue(K)=0.5m/s

Measuredvaluesweredeterminedaccordingtothe
proceduresoutlinedinEN836.

6

2

SafetyandInstructionalDecals

2

1

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaof
potentialdanger.Replaceanydecalthatisdamagedorlost.

105-7506

1.ReadtheOperator's

Manual.

2.Engine—stop5.Engine—start

3.On

4.Engine—preheat

93-6693

1.Crushinghazardofhand—waitformovingpartstostop.

114–9600

93-6699

1.Machinespeed

2.Slow

3.Continuousvariable
setting

4.Fast

93-9425

1.ReadtheOperator'sManual.

2.Hydraulichosesareunderpressure—stayawayfrom
movingparts.

1.Hydraulicoil

2.ReadtheOperator'sManual.

93-6696

1.Storedenergyhazard—readtheOperator'sManual.

93-6686

93-6687

1.Donotstephere.

7

93–6689

93-1263

1.Danger—donotsitontheplasticshroud.

93–6681

1.Cutting/dismembermenthazard—stayawayfrommoving
parts.

115-2047

1.Warning—donottouchthehotsurface.

93-1263

1.ReadtheOperator'sManual.

2.Toengagetheparkingbrake,connectthebrakepedals
withthelockingpin,pushdownonbothpedals,andpullthe
brakelatchout.

3.Toreleasetheparkingbrake,pressbothpedalsuntilthe
parkingbrakelatchretracts.

4.Danger—reelsenabled.

104-9298

1.ReadtheOperator'sManual.

1.ReadtheOperator'sManual.

115-2048

8

105-0123

Model03808and03813

1.Throttle—slow

2.Throttle—fast8.Headlights(optional)

3.Reelsraisedandoff9.Headlights—On

4.Reelsloweredandonwhenenabled—forwardandbacklap10.Headlights—Off

5.Reels—enabled

6.Reelsdisabled—liftonly

7.Reelsdisabled—liftandlower

11.ReadtheOperatorsManual.

104-9296

Models03806,03807and03812

1.Throttle—slow4.Reelsloweredandonwhen

2.Throttle—fast

3.Reelsraisedandoff6.Reelsdisabled—liftonly9.Headlights—On

enabled—forwardand
backlap

5.Reelsenabled

7.Reelsdisabled—liftand
lower

8.Headlights(optional)11.ReadtheOperator's

10.Headlights—Off

Manualforfurther
instructions.

9

117–2718

106-6755

1.Enginecoolantunder
pressure.

2.Explosionhazard—read
theOperator'sManual.

3.Warning—donottouchthe
hotsurface.

4.Warning—readthe

Operator'sManual.

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

93-6668

1.ReadtheOperator'sManualforinformationonchargingthe
battery;containslead;donotdiscard.

1.Reel—heightofcut

2.Reel—mowandbacklap5.Rearreelscircuitcontrols

3.ReadtheOperator's

Manual.

4.Machinespeed

6.Frontreelscircuitcontrols

106-6754

1.Warning—donottouchthehotsurface.

2.Cutting/dismembermenthazard,fanandentanglement
hazard,belt—stayawayfrommovingparts.

115-8000

Model03808and03813

1.Reel—heightofcut

2.Reel—mowandbacklap5.Rearreelscircuitcontrols

3.ReadtheOperator's

Manual.

4.Machinespeed

6.Frontreelscircuitcontrols

12

BatterySymbols

Someorallofthesesymbolsareonyourbattery

1.Explosionhazard

2.Nore,opename,or
smoking.

3.Causticliquid/chemical
burnhazard

4.Weareyeprotection9.Flusheyesimmediately

5.ReadtheOperator's

Manual.

6.Keepbystandersasafe

7.Weareyeprotection;

8.Batteryacidcancause

10.Containslead;donot

distancefromthebattery .

explosivegasescan
causeblindnessandother
injuries

blindnessorsevereburns.

withwaterandgetmedical
helpfast.

discard.

13

Setup

LooseParts

Usethechartbelowtoverifythatallpartshavebeenshipped.

ProcedureDescription

1

2

3

4

5

6

7

Nopartsrequired

LargeO-ring14/10
Counterweight7/5
Steeringlockingpin7/5
Liftchain5/7
Chainbracket5/7
U-bolt
Nut
Screw5/7
Washer
Nut
LargeO-ring5/7

Nopartsrequired

Calciumchloride(obtainseparately)
Rearweightkit,partnumber104–1478

(obtainseparately)
CEdecals
CEcerticate
Operator'sManual
EngineOperator'sManual
PartsCatalog
OperatorTrainingMaterial
DiagnosticACEdisplayoverlay
Ignitionkeysonring1
Hoodlockkey1
Screw
Wingnut2

10/14

100lb

Qty.

5/7

5/7
5/7

Use

–

–

1

4
2
1
1
1
1
1

2

Checkuidlevels.

Installcuttingunits.

Installcuttingunits.

Makecuttingunitadjustmentsifneeded.

Addrearballast(ifrequired).

InstalltheCEdecals.

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.

Figure4

1.Bearinghousing

2.Largeo-ring

Note:Beforeinstallingcuttingunitmotorsor
counterweights,lubricateinternalsplinesofcutting
unitreelshaftswithgrease.

4.Installacounterweightontoappropriateendofeach
cuttingunitwithcapscrewsprovided(

5.Thoroughlygreasethecuttingunitreelbearingsprior
toinstallationonthetractionunit.Greaseshould
beevidentattheinboardreelseals;refertoCutting
UnitOperator'sManualforgreasingprocedure.

6.Insertathrustwasherontohorizontalshaftofpivot
knuckleasshownin(

3.Counterweight

Figure4).

Figure5).

Figure3

1.Removecuttingunitsfromcartons.Assembleand
adjustperCuttingUnitOperator'sManual.

2.Removeprotectiveplugsfromeachendofcutting
unit.

3.LubricateandinstallalargeO-ringintobearing
housinggrooveoneachendofcuttingunit

Figure4&Figure7).

(

Figure5

1.Carrierframe

2.Pivotknuckle

3.Liftarmsteeringplate

7.Insertthehorizontalshaftofthepivotknuckleinto
themountingtubeofthecarrierframe(Figure5).

8.Securepivotknuckletocarrierframewithathrust
washer,atwasherandaangeheadcapscrew
(Figure5).

9.Insertathrustwasherontoverticalshaftofpivot
knuckle(Figure5).

15

4.Lynchpin

5.Steeringlockingpin

10.Ifremoved,inserttheverticalshaftofthepivot
knuckleintoliftarmpivothub(Figure5).Guide
thepivotknuckleinplacebetweenthetworubber
centeringbumpersintheundersideoftheliftarm
steeringplate.

11.Insertthelynchpinintothecrossholeonthepivot
knuckleshaft(

Figure5).

12.Removenutsecuringturfcompensationspring
mountingbrackettocuttingunitstabilizerear
(Figure6).Inserttipperchainontocapscrewand
securewithnutremoved.

Figure6

1.Liftchain2.Cuttingunitstabilizerear

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).

13.Mountthemotortothedriveendofthecuttingunit
andsecurewithtwocapscrewsprovided(

Figure7

1.Motor

2.O-ring

Figure7).

Note:Ifxedcuttingunitpositionisrequired,
insertsteeringlockingpinintopivotknuckle
mountinghole(Figure5).

14.Hookspringwirearoundbottomofsteeringlocking
pin(Figure5).

AdjustTurfCompensationSpring

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.

Tractorsaresetupatthefactoryappropriatelyformost
fairwaymowingapplications.Thefollowingadjustment
isforne-tuningthemachinetotheapplication:

16

3

InstallingCuttingUnits
Models03863and03864

Partsneededforthisprocedure:

5/7Liftchain

5/7Chainbracket

U-bolt

5/7

5/7Screw

5/7

5/7

5/7LargeO-ring

Nut

Washer

Nut

10/14

MounttheLiftBracketsandChains

knuckle(Figure10).Rotatethebrackets45degrees
totheoutboardsideofthemachine.

Figure10

MountachainbrackettoeachliftarmwithaU-boltand
2nuts.Positionthebracketsasfollows:

1.Onliftarms#1,#4and#5,positionthechain
bracketsandU-bolts15inchesbehindthecenter
lineofthepivotknuckle(
and#5thebracketsshouldberotatedtotheright
10degreesfromvertical(Figure9).Onliftarm#4
thebracketshouldberotatedtotheleft10degrees
fromvertical(Figure9).

Figure9).Onliftarms#1

3.Onliftarms#6and#7,positionthebracketsand
U-bolts14.5inchesbehindthecenterlineofthe
pivotknuckle(
degreestotheoutboardsideofthemachine.

4.TightenalltheU-boltnutsto38–48ft-lbs.

Figure11).Rotatethebrackets10

Figure11

Figure9

2.Onliftarms#2and#3,positionthebracketsand
U-bolts15inchesbehindthecenterlineofthepivot

5.Mountaliftchaintoeachchainbracketwithascrew ,
washerandnut,positioningasshowninFigure12

17

Figure12

1.Liftchain2.Chainbracket

AdjusttheRearShield

Undermostconditions,bestdispersionisattained
whentherearshieldisclosed(frontdischarge).When
conditionsareheavyorwet,rearshieldmaybeopened.

MounttheCounterWeights

Allcuttingunitsareshippedwiththecounterweight
mountedtotheleftendofthecuttingunit.Usethe
followingdiagramtodeterminethepositionofthe
counterweightsandreelmotors.

Figure14

1.Onthe#2,#4and#6cuttingunits,removethe2
capscrewssecuringthecounterweighttotheleft
endofthecuttingunit.Removethecounterweight

Figure15).

(

Toopentherearshield(

Figure13),loosenthecapscrew
securingtheshieldtotheleftsideplate,rotatetheshield
totheopenpositionandtightenthecapscrew .

Figure13

1.Rearshield

2.Capscrew

Figure15

1.Counterweight

2.Onrightendofcuttingunit,removetheplasticplug
fromthebearinghousing(Figure16).

3.Removethe2capscrewsfromtherightsideplate
(Figure16).

18

G003321

1

2

Figure16

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.

1.Plasticplug

2.Capscrew(2)

4.Installthecounterweighttotherightendofthe
cuttingunitwiththe2screwspreviouslyremoved.

5.Looselyinstallthe2reelmotormountingcapscrews
totheleftsideplateofthecuttingunit(Figure16).

MounttheCuttingUnits

1.Insertathrustwasherontohorizontalshaftofpivot
knuckleasshowninFigure17.

Figure17

Figure18

1.Liftchain2.Snapperpin

8.Coatthesplineofthereelmotorwithcleangrease.

9.OilthereelmotorO-ringandinstallitontothe
motorange.

10.Installthemotorbyrotatingitclockwisesothat
themotorangesclearthecapscrews(

Figure19).
Rotatethemotorcounterclockwiseuntiltheanges
encirclethecapscrewsthentightenthecapscrews

1.Carrierframe

2.Pivotknuckle

3.Liftarmsteeringplate

4.Lynchpin

5.Steeringlockingpin

2.Insertthehorizontalshaftofthepivotknuckleinto
themountingtubeofthecarrierframe(Figure17).

3.Securepivotknuckletocarrierframewithathrust
washer,atwasherandaangeheadcapscrew
(Figure17).

4.Insertathrustwasherontoverticalshaftofpivot
knuckle(

Figure17).

5.Ifremoved,inserttheverticalshaftofthepivot
knuckleintoliftarmpivothub(

Figure17).Guide

Important:Makesurethereelmotorhoses
arenottwisted,kinkedorintheriskofbeing
pinched.

19

Figure20

Figure19

1.Reeldrivemotor

2.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.

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).

1.Tightenlocknutonrearofspringroduntilthegap
(C)betweenrearofspringbracketandfrontof
washeris2in.(51mm)(

Figure20).

20