Toro 30809 Groundsmaster 3500-G Operator's Manual

FormNo.3396-206RevA

Groundsmaster

®

3500-GRotary

Mower

ModelNo.30809—SerialNo.315000001andUp

Registeratwww.T oro.com.
OriginalInstructions(EN)

*3396-206*A

WARNING

CALIFORNIA

Proposition65Warning

Thisproductcontainsachemicalorchemicals

knowntotheStateofCaliforniatocausecancer,

birthdefects,orreproductiveharm.

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

Figure1

Important:Thisengineisnotequippedwithaspark

arrestermufer.ItisaviolationofCaliforniaPublic
ResourceCodeSection4442touseoroperatetheengine
onanyforest-covered,brush-covered,orgrass-covered
land.Otherstatesorfederalareasmayhavesimilarlaws.

Introduction

Thismachineisaride-on,rotary-bladelawnmowerintended
tobeusedbyprofessional,hiredoperatorsincommercial
applications.Itisprimarilydesignedforcuttinggrasson
well-maintainedlawnsinparks,golfcourses,sportselds,
andoncommercialgrounds.Itisnotdesignedforcutting
brush,mowinggrassandothergrowthalongsidehighways,
orforagriculturaluses.

Readthisinformationcarefullytolearnhowtooperateand
maintainyourproductproperlyandtoavoidinjuryand
productdamage.Youareresponsibleforoperatingthe
productproperlyandsafely.

YoumaycontactTorodirectlyatwww .Toro.comforproduct
andaccessoryinformation,helpndingadealer,ortoregister
yourproduct.

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

Thismanualidentiespotentialhazardsandhassafety
messagesidentiedbythesafetyalertsymbol(Figure2),
whichsignalsahazardthatmaycauseseriousinjuryordeath
ifyoudonotfollowtherecommendedprecautions.

Figure2

1.Safetyalertsymbol

Thismanualuses2wordstohighlightinformation.
Importantcallsattentiontospecialmechanicalinformation
andNoteemphasizesgeneralinformationworthyofspecial
attention.

Wheneveryouneedservice,genuineT oroparts,oradditional
information,contactanAuthorizedServiceDealerorToro
CustomerServiceandhavethemodelandserialnumbersof
yourproductready.Figure1identiesthelocationofthe
modelandserialnumbersontheproduct.Writethenumbers
inthespaceprovided.

©2015—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420

Contactusatwww.Toro.com.

2

PrintedintheUSA

AllRightsReserved

Contents

Safety...........................................................................4

SafeOperatingPractices...........................................4

SoundPowerLevel..................................................6

SoundPressureLevel...............................................6

VibrationLevel......................................................6

SafetyandInstructionalDecals.................................7

Setup...........................................................................11

1Activating,Charging,andConnectingthe

Battery..............................................................12

2CheckingtheAngleIndicator.................................13

3AdjustingtheLiftArms........................................13

4AdjustingtheCarrierFrame..................................14

5AdjustingtheHeightofCut...................................15

6CheckingtheMachinebeforeOperation..................16

7AdjustingtheOptionalRollerScraper

........................................................................16

8InstallingtheOptionalMulchingBafe

........................................................................16

ProductOverview.........................................................17

Controls...............................................................17

Specications........................................................19

Attachments/Accessories........................................19

Operation....................................................................19

ThinkSafetyFirst...................................................19

CheckingtheEngine-OilLevel.................................19

FillingtheFuelTank...............................................20

CheckingtheCoolingSystem...................................22

CheckingtheHydraulicSystem................................22

CheckingtheTirePressure......................................23

RearWheelBallast..................................................23

StartingandStoppingtheEngine..............................24

CheckingtheInterlockSystem.................................24

TowingtheTractionUnit.........................................24

StandardControlModule(SCM)..............................25

ChoosingAccessories.............................................27

SelectingaBlade.....................................................27

OperatingTips......................................................28

Maintenance.................................................................30

RecommendedMaintenanceSchedule(s)......................30

DailyMaintenanceChecklist....................................31

ServiceIntervalChart.............................................32

PremaintenanceProcedures........................................32

RemovingtheHood...............................................32

UsingtheCutting-UnitServiceLatch........................33

Lubrication...............................................................33

GreasingtheBearingsAndBushings.........................33

EngineMaintenance..................................................36

ServicingtheAirCleaner.........................................36

ChangingtheEngineOilandFilter...........................37

ReplacingtheSparkPlugs........................................37

FuelSystemMaintenance...........................................38

ReplacingtheFuel-PumpFilter................................38

ServicingtheFuelTank...........................................39

InspectingtheFuelLinesandConnections.................39

ElectricalSystemMaintenance....................................39

CaringfortheBattery..............................................39

Fuses....................................................................40

DriveSystemMaintenance.........................................40

TorquingtheWheelNuts........................................40

AdjustingtheTractionDriveforNeutral....................40

CoolingSystemMaintenance......................................41

CleaningtheEngineCoolingSystem.........................41

BrakeMaintenance....................................................42

AdjustingtheParkingBrake.....................................42

BeltMaintenance......................................................42

ServicingtheEngineBelts.......................................42

HydraulicSystemMaintenance....................................43

ChangingtheHydraulicFilter...................................43

ChangingtheHydraulicFluid...................................44

CheckingtheHydraulicLinesandHoses....................44

MaintainingtheCuttingUnit.......................................45

SeparatingtheCuttingUnitfromtheTraction

Unit..................................................................45

MountingtheCuttingUnitstotheTraction

Unit..................................................................45

ServicingtheBladePlane.........................................45

ServicingtheCutterBlade.......................................46

ServicingtheFrontRoller........................................47

Storage........................................................................49

StoringtheBattery..................................................49

PreparationforSeasonalStorage..............................49

3

Safety

ThismachinemeetsorexceedsANSIB71.4-2012
specicationswhenequippedwithrequiredweightas
listedinRearBallastsection.

Improperuseormaintenancebytheoperatoror
ownercanresultininjury.Toreducethepotential
forinjury,complywiththesesafetyinstructionsand
alwayspayattentiontothesafetyalertsymbol,which
meansCaution,Warning,orDanger—personalsafety
instruction.Failuretocomplywiththeinstructionmay
resultinpersonalinjuryordeath.

SafeOperatingPractices

ThefollowinginstructionsareadaptedfromANSIstandard
B71.4-2012.

Training

•ReadtheOperator'sManualandothertrainingmaterial.

Iftheoperator(s)ormechanic(s)cannotreadEnglishitis
theowner'sresponsibilitytoexplainthismaterialtothem.

•Becomefamiliarwiththesafeoperationoftheequipment,

operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.The

ownerisresponsiblefortrainingtheusers.

•Neverletchildrenoruntrainedpeopleoperateorservice

theequipment.Localregulationsmayrestricttheageof
theoperator.

•Theowner/usercanpreventandisresponsiblefor

accidentsorinjuriesoccurringtopeopleordamageto
property.

Preparation

•Evaluatetheterraintodeterminewhataccessoriesand

attachmentsareneededtoproperlyandsafelyperform
thejob.Onlyuseaccessoriesandattachmentsapproved
bythemanufacturer.

•Inspecttheareawheretheequipmentistobeusedand

removeallobjectssuchasrocks,toysandwirewhichcan
bethrownbythemachine.

•Checkthatoperator'spresencecontrols,safetyswitches

andshieldsareattachedandfunctioningproperly.Donot
operateunlesstheyarefunctioningproperly.

Operation

•Thisproductiscapableofamputatinghandsandfeet,and

throwingobjects.Alwaysfollowallsafetyinstructionsto
avoidseriousinjuryordeath.

•Useofthisproductforpurposesotherthanitsintended

usecouldprovedangeroustotheuserandbystanders.

•Donotoperatetheengineinaconnedspacewhere

dangerouscarbonmonoxideandotherexhaustgasses
cancollect.

•Onlyoperateingoodlight,keepingawayfromholesand

hiddenhazards.

•Besurealldrivesareinneutralandparkingbrakeis

engagedbeforestartingengine.Onlystartenginefrom
theoperator'sposition.

•Alwayswearsubstantial,slip-resistantfootwear,long

trousers,hardhat,safetyglasses,andhearingprotection
whilemowing.Longhair,looseclothing,orjewelrymay
gettangledinmovingparts.Donotoperatethemachine
whenbarefootorwearingopensandals.

•Slowdownanduseextracareonhillsides.Besureto

travelsidetosideonhillsides.Turfconditionscanaffect
themachine'sstability.Usecautionwhileoperatingnear
drop-offs.

•Slowdownandusecautionwhenmakingturnsandwhen

changingdirectionsonslopes.

•Neverraisedeckwiththebladesrunning.

•NeveroperatewiththePTOshield,orotherguardsnot

securelyinplace.Besureallinterlocksareattached,
adjustedproperly ,andfunctioningproperly.

•Neveroperatewiththedischargedeectorraised,

removedoraltered,unlessusingagrasscatcher.

•Donotchangetheenginegovernorsettingoroverspeed

theengine.

•Beforeleavingtheoperator'spositionforanyreason

includingemptyingthecatchersoruncloggingthechute,
stoponlevelground,disengagedrives,engageparking
brake(ifprovided),shutoffengineandremovethekey
fromtheignition.

•Stopequipmentandinspectbladesafterstrikingobjects

orifanabnormalvibrationoccurs.Makenecessary
repairsbeforeresumingoperations.

•Lookbehindanddownbeforebackinguptobesureof

aclearpath.

•Keeppetsandbystandersaway .

•Slowdownandusecautionwhenmakingturnsand

crossingroadsandsidewalks.Stopbladesifnotmowing.

•Beawareofthemowerdischargedirectionanddonot

pointitatanyone.

•Donotoperatethemowerundertheinuenceofalcohol

ordrugs.

•Usecarewhenloadingorunloadingthemachineinto

orfromatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs,trees,

orotherobjectsthatmayobscurevision.

•Lightningcancausesevereinjuryordeath.Iflightning

isseenorthunderisheardinthearea,donotoperate
themachine;seekshelter.

•Knowhowtostopthemachineandenginequickly.

•Keephands,feet,andclothingawayfrommovingparts

andthecuttingunit.

4

•Checkthesafetyinterlockswitchesdailyforproper

operation.Ifaswitchshouldfail,replacetheswitch
beforeoperatingthemachine.

•Whenstartingtheengine,engagetheparkingbrake,put

thetractionpedalinneutral,anddisengagetheblade
drive.Aftertheenginestarts,releasetheparkingbrake
andkeepyourfootoffofthetractionpedal.Themachine
mustnotmove.Ifmovementisevident,refertothe
Maintenancesectionofthismanualtoadjustthetraction
drive.

•Useextremecautionwhenoperatingclosetosandtraps,

ditches,creeks,steephillsides,orotherhazards.

•Reducespeedwhenmakingsharpturns.

•Donotturnonhills.

•Donotoperateonasidehillthatistoosteep.Arollover

mayoccurbeforelosingtraction.

•Theslopeangleatwhichthemachinewilltipisdependent

onmanyfactors.Amongthesearemowingconditions
suchaswetorundulatingterrain,speed(especiallyin
turns),positionofthecutting-units(withtheSidewinder),
tirepressure,andoperatorexperience.Atsidehillangles
of20degreesorless,theriskofarolloverislow .As
theslopeangleincreasestoarecommendedmaximum
limitof25degrees,theriskofarolloverincreasestoa
moderatelevel.Donotexceeda25degreesidehill

slopeanglebecausetheriskofarolloverandserious
injuryordeathisveryhigh.

•Forsteeringcontrol,lowerthecutting-unitswhengoing

downslopes.

•Avoidsuddenstopsandstarts.

•Usethereversepedalforbraking.

•Watchfortrafcwhennearorcrossingroads.Always

yieldtheright-of-way.

•Raisethecutting-unitswhendrivingfromoneworkarea

toanother.

•Donottouchtheengine,mufer,exhaustpipe,or

hydraulictankwhiletheengineisrunningorsoonafterit
hasstopped.Theseareascouldbehotenoughtocause
burns.

•Thismachineisnotdesignedorequippedforon-roaduse

andisaslow-movingvehicle.Ifyoumustcrossortravel
onapublicroad,youshouldbeawareofandcomplywith
localregulations,suchasrequiredlights,slowmoving
vehiclesigns,andreectors.

RolloverProtectionSystem(ROPS)­UseandMaintenance

•TheROPSisanintegralandeffectivesafetydevice.

•DonotremovetheROPS.

•Becertainthattheseatbeltcanbereleasedquicklyin

theeventofanemergency.

•Checkcarefullyforoverheadclearances(i.e.branches,

doorways,electricalwires)beforedrivingunderany
objectsanddonotcontactthem.

•AnyalterationstoaROPSmustbeapprovedbythe

manufacturer.

•KeeptheROPSinsafeoperatingcondition.Thoroughly

inspectfordamageperiodicallyandalwayskeepall
mountingfastenerstight.

•ReplaceadamagedROPS.Donotrepairorrevise.

SafeHandlingofFuels

•Toavoidpersonalinjuryorpropertydamage,use

extremecareinhandlinggasoline.Gasolineisextremely
ammableandthevaporsareexplosive.

•Extinguishallcigarettes,cigars,pipes,andothersources

ofignition.

•Useonlyanapprovedfuelcontainer.

•Neverremovefuelcaporaddfuelwiththeengine

running.

•Allowenginetocoolbeforerefueling.

•Neverrefuelthemachineindoors.

•Neverstorethemachineorfuelcontainerwherethereis

anopename,spark,orpilotlightsuchasonawater
heateroronotherappliances.

•Neverllcontainersinsideavehicleoronatruckor

trailerbedwithaplasticliner.Alwaysplacecontainerson
thegroundawayfromyourvehiclebeforelling.

•Removeequipmentfromthetruckortrailerandrefuelit

ontheground.Ifthisisnotpossible,thenrefuelsuch
equipmentwithaportablecontainer,ratherthanfroma
fueldispensernozzle.

•Keepthenozzleincontactwiththerimofthefueltank

orcontaineropeningatalltimesuntilfuelingiscomplete.
Donotuseanozzlelock-opendevice.

•Fillthefueltankuntillevelis6to13mm(1/4to1/2

inch)belowthebottomofthellerneck.Donotoverll.

•Iffuelisspilledonclothing,changeclothingimmediately.

•Neveroverllfueltank.Replacefuelcapandtighten

securely.

MaintenanceandStorage

•Disengagedrives,setparkingbrake,stopengineand

removekeyordisconnectsparkplugwire.W aitforall
movementtostopbeforeadjusting,cleaning,orrepairing.

•Cleangrassanddebrisfromcuttingunit,drives,mufers,

andenginetohelppreventres.Cleanupoilorfuel
spillage.

•Letenginecoolbeforestoringanddonotstorenear

ame.

•Shutofffuelwhilestoringortransporting.Donotstore

fuelnearamesordrainindoors.

•Parkmachineonlevelground.Setparkingbrake.

•Neverallowuntrainedpersonneltoservicemachine.

•Usejackstandstosupportcomponentswhenrequired.

5

•Carefullyreleasepressurefromcomponentswithstored

energy.

•Usefullwidthrampsforloadingmachineintotraileror

truck.

•Disconnectthebatteryorremovesparkplugwirebefore

makinganyrepairs.Disconnectthenegativeterminalrst
andthepositivelast.Reconnectthepositiverstand
negativelast.

•Usecarewhencheckingblades.Wraptheblade(s)or

weargloves,andusecautionwhenservicingthem.Only
replaceblades.Neverstraightenorweldthem.

•Keephandsandfeetawayfrommovingparts.Ifpossible,

donotmakeadjustmentswiththeenginerunning.

•Keepallpartsingoodworkingconditionandallhardware

tightened.Replacewornordamageddecals.

•Keepyourbodyandhandsawayfrompin-holeleaksor

nozzlesthatejecthydraulicuidunderhighpressure.
Ifuidisinjectedintotheskin,itmustbesurgically
removedwithinafewhours,byadoctorfamiliarwiththis
formofinjuryorgangrenemayresult.

•Hydraulicuidescapingunderpressurecanhave

sufcientforcetopenetratetheskinandcauseserious
injury.Usepaperorcardboard,notyourhands,tosearch
forleaks.

•Beforedisconnectingorperforminganyworkon

thehydraulicsystem,allpressureinthesystemmust
berelievedbystoppingtheengineandloweringthe
cutting-unitstotheground.

•Makesurethatallhydraulic-lineconnectorsaretightand

allhydraulichosesandlinesareingoodconditionbefore
applyingpressuretothesystem.

•Iftheenginemustberunningtoperformamaintenance

adjustment,keephands,feet,clothing,andanypartsof
thebodyawayfromthecutting-units,attachments,and
anymovingparts.Keepeveryoneaway.

•Donotoverspeedtheenginebychanginggovernor

settings.Toensuresafetyandaccuracy,havean
AuthorizedToroDistributorcheckthemaximumengine
speedwithatachometer.

•Tiethemachinedownsecurelyusingstraps,chains,cable,

orropes.Bothfrontandrearstrapsshouldbedirected
downandoutwardfromthemachine.

SoundPowerLevel

Thisunithasaguaranteedsoundpowerlevelof106dBA,
whichincludesanUncertaintyValue(K)of1dBA.

Soundpowerlevelwasdeterminedaccordingtothe
proceduresoutlinedinISO11094.

SoundPressureLevel

Thisunithasasoundpressurelevelattheoperator’searof93
dBA,whichincludesanUncertaintyValue(K)of1dBA.

Soundpressurelevelwasdeterminedaccordingtothe
proceduresoutlinedinEN836.

VibrationLevel

Hand-Arm

Measuredvibrationlevelforrighthand=0.5m/s

Measuredvibrationlevelforlefthand=0.7m/s

UncertaintyValue(K)=0.5m/s

Measuredvaluesweredeterminedaccordingtotheprocedures
outlinedinEN836.

WholeBody

Measuredvibrationlevel=0.44m/s

UncertaintyValue(K)=0.5m/s

Measuredvaluesweredeterminedaccordingtotheprocedures
outlinedinEN836.

2

2

2

2

2

•Theenginemustbeshutoffbeforecheckingtheoilor

addingoiltothecrankcase.

•Ifmajorrepairsareeverneededorifassistanceisdesired,

contactanAuthorizedToroDistributor.

•Toensureoptimumperformanceandcontinuedsafety

certicationofthemachine,useonlygenuineToro
replacementpartsandaccessories.Replacementparts
andaccessoriesmadebyothermanufacturerscouldbe
dangerous,andsuchusecouldvoidtheproductwarranty.

Hauling

•Usecarewhenloadingorunloadingthemachineintoa

trailerortruck.

6

SafetyandInstructionalDecals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaofpotential
danger.Replaceanydecalthatisdamagedorlost.

94-3353

1.Crushinghazardofhand—keepyourhandsasafedistance
away.

106-6755

100-4837

93-7276

1.Explosionhazard—weareyeprotection.

2.Causticliquid/chemicalburnhazard—toperformrstaid,
ushwithwater.

3.Firehazard—nore,openames,orsmoking.

4.Poisonhazard—keepchildrenasafedistancefromthe
battery.

1.Enginecoolantunder
pressure.

2.Explosionhazard—read
theOperator'sManual.

3.Warning—donottouchthe
hotsurface.

4.Warning—readthe

Operator'sManual.

104-0484

93-7818

1.Warning—readtheOperator'sManualforinstructionson
torquingthebladebolt/nutto85-110ft-lb(115-149N-m).

93-6681

1.Cutting/dismemberment—hazard,fan-stayawayfrom
movingparts.

106-6754

1.Warning—donottouchthehotsurface.

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

7

BatterySymbols

99-3444

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

99-3444

1.Transportspeed—fast

2.Mowingspeed—slow

distancefromthebattery.

explosivegasescan
causeblindnessandother
injuries

blindnessorsevereburns.

withwaterandgetmedical
helpfast.

discard.

117-4764

1.Thrownobjecthazard—keepbystandersasafedistance
fromthemachine.

2.Cuttinghazardofhand,mowerblade—stayawayfrom
movingparts,keepallguardsandshieldsinplace.

3.Cuttinghazardoffoot,mowerblade—stayawayfrom
movingparts,keepallguardsandshieldsinplace.

107–1971

1.Inputs5.Inseat

2.Notactive

3.High-temperature
shutdown

4.High-temperaturewarning8.Neutral

6.PowerTake-off(PTO)10.PowerTake-off(PTO)

7.ParkingbrakeOff11.Start

106-9290

9.Outputs13.Start

14.Power

12.EnergizetoRun(ETR)

8

121–3531

1.EngagePTO6.Moveleft11.ReadtheOperator’sManualfor

2.DisengagePTO

3.Lowercuttingunit8.Engine—stop

4.Moveright9.Engine—run

5.Raisecuttingunit10.Engine—start

7.Lock12.Fast

informationonstoppingtheengine—

1)Disengagethereel;2)Movethekey
totheenginestopposition;3)Remove
thekeyfromtheignition;4)Engage
theparkingbrake.

13.Slow

1.Heightofcut

104-1086

9

1.ReadtheOperator’sManualforinformationonmaintenance.

121–3533

10

Setup

LooseParts

Usethechartbelowtoverifythatallpartshavebeenshipped.

ProcedureDescription

1

2
3
4
5
6
7
8

MediaandAdditionalParts

Description

Qty.

Nopartsrequired

Nopartsrequired

Nopartsrequired

Nopartsrequired

Nopartsrequired

Nopartsrequired

Nopartsrequired

Nopartsrequired

Qty.

–

–

–

–

–

–

–

–

Activate,charge,andconnectthe
battery.

Checktheangleindicator.

Adjusttheliftarms.

Adjustthecarrierframe.

Adjusttheheightofcut.

Checktheuidlevels.

Adjusttheoptionalrollerscraper.

Installtheoptionalmulchingbafe.

Use

Use

Ignitionkeys2

Operator'sManual
EngineOperator'sManual

PartsCatalog

Operatorvideo

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

1
1

1Usetolookupandorderparts.

1

Starttheengine.

Readbeforeoperatingthemachine.

Viewbeforeoperatingthemachine.

11

3.Removethellercapsfromthebatteryandslowlyll
eachcelluntilelectrolyteisjustabovetheplates.

1

Activating,Charging,and ConnectingtheBattery

NoPartsRequired

Procedure

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandleadcompounds,

chemicalsknowntotheStateofCalifornia

tocausecancerandreproductiveharm.

W ash hands after handling .

Note:Ifthebatteryisnotlledwithelectrolyteoractivated,
bulkelectrolytewith1.260specicgravitymustbepurchased
fromalocalbatterysupplyoutletandaddedtothebattery.

DANGER

Batteryelectrolytecontainssulfuricacidwhichisa
deadlypoisonandcausessevereburns.

•Donotdrinkelectrolyteandavoidcontactwith
skin,eyes,orclothing.Wearsafetyglassesto
shieldyoureyesandrubberglovestoprotect
yourhands.

•Fillthebatterywherecleanwaterisalways
availableforushingtheskin.

1.Openthehood.

2.Removethebatterycover(Figure3).

4.Installthellercapsandconnecta3to4ampbattery
chargertothebatteryposts.Chargethebatteryata
rateof3to4amperesfor4to8hours.

WARNING

Chargingthebatteryproducesgassesthatcan
explode.

•Keepsparksandamesawayfrombattery.

•Neversmokenearthebattery.

5.Whenthebatteryischarged,disconnectthecharger
fromtheelectricaloutletandbatteryposts.

6.Removethellercaps.Slowlyaddelectrolytetoeach
celluntilthelevelisuptothellring.Installtheller
caps.

Important:Donotoverllthebattery.Electrolyte
willoverowontootherpartsofthemachineand
severecorrosionanddeteriorationwillresult.

7.Installthepositivecable(red)tothepositive(+)
terminalandthenegativecable(black)tothenegative
(–)terminalofthebatteryandsecurethemwithbolts
andnuts(Figure4).Makesurethatthepositive(+)
terminalisallofthewayontothepostandthecable
ispositionedsnugtothebattery.Thecablemustnot
contactthebatterycover.

WARNING

Incorrectbatterycableroutingcoulddamage
thetractionunitandcablescausingsparks.
Sparkscancausethebatterygassesto
explode,resultinginpersonalinjury.

•Alwaysdisconnectthenegative(black)
batterycablebeforedisconnectingthe
positive(red)cable.

•Alwaysconnectthepositive(red)battery
cablebeforeconnectingthenegative
(black)cable.

1.Batterycover

Figure3

12

Figure4

1.Positive(+)batterycable2.Negative(–)batterycable

Figure5

1.Angleindicator

Important:Ifthebatteryiseverremoved,make
surethatthebatteryclampboltsareinstalledwith
theboltheadspositionedonthebottomsideand
thenutsonthetopside.Iftheclampboltsare
reversed,theymayinterferewiththehydraulic
tubeswhenshiftingthecutting-units.

8.CoatbothbatteryconnectionswithGrafo112X(skin
over)grease,T oroPartNo.505-47,petroleumjelly ,or
lightgreasetopreventcorrosion.

9.Slidetherubberbootoverthepositiveterminalto
preventapossibleshortfromoccurring.

10.Installthebatterycover.

2

CheckingtheAngleIndicator

NoPartsRequired

Procedure

3.Iftheinclinometerdoesnotreadzerodegrees,move
themachinetoalocationwhereazerodegreereading
isobtained.Theangleindicator,mountedonthe
machine,shouldnowreadzerodegreesaswell.

4.Iftheangleindicatordoesnotreadzerodegrees,loosen
the2screwsandnutssecuringtheangleindicatorto
themountingbracket,adjusttheindicatortoobtaina
zerodegreereading,andtightenthebolts.

3

AdjustingtheLiftArms

NoPartsRequired

Procedure

1.Starttheengine,raisethecutting-units,andcheckto
ensurethattheclearancebetweeneachliftarmandthe
oor-platebracketis5to8mm(0.18to0.32inch)as
showninFigure6.

DANGER

Donotoperatethemachineonsidehillssteeper
than25ºtoreduceriskofinjuryordeathdueto
rollover.

1.Parkthemachineonaat,levelsurface.

2.Verifythatthemachineislevelbyplacingahandheld
inclinometer(suppliedwiththemachine)ontheframe
crossrail,bythefueltank(Figure5).Theinclinometer
shouldreadzerodegreeswhenviewedfromthe
operator’sposition.

Figure6

cutting-unitsremovedforclarity

1.Liftarm3.Clearance

2.Floor-platebracket

13

Iftheclearanceisnotinthisrange,adjustitasfollows:

A.Backoffthestopbolts(Figure7).

Figure7

1.Stopbolt3.Clearance

2.Liftarm

B.Backoffthejamnutonthecylinder(Figure8).

Figure9

1.Wearbar2.Bumperstrap

Iftheclearanceisnotinthisrange,adjusttherear
cylinderasfollows:

Note:Iftherearliftarmclunksduringtransport,
clearancecanbereduced.

A.Lowerthecutting-unitsandbackoffthejamnut

onthecylinder(Figure10).

Figure8

1.Frontcylinder2.Jamnut

C.Removethepinfromtherodendandrotatethe

clevis.

D.Installthepinandchecktheclearance.Repeat

theprocedureifrequired.

E.Tightentheclevis-jamnut.

2.Checktomakesurethattheclearancebetweeneachlift
armandstopboltis0.13to1.02mm(0.005to0.040
inch)asshowninFigure7.Iftheclearanceisnotin
thisrange,adjustthestopboltstoattainclearance.

3.Starttheengine,raisethecuttingunits,andcheckto
makesurethattheclearancebetweenthewearstrap
onthetopoftherearcuttingunitwearbarandthe
bumperstrapis0.51to2.54mm(0.02to0.10inch)as
showninFigure9.

Figure10

1.Rearcylinder2.Adjustingnut

B.Graspthecylinderrodclosetothenutwitha

pliersandrag,androtatetherod.

C.Raisethecutting-unitsandchecktheclearance.

Repeattheprocedureifrequired.

D.Tightentheclevis-jamnut.

Important:Lackofclearanceatthefrontstopsorrear
wearbarcoulddamagetheliftarms.

4

AdjustingtheCarrierFrame

NoPartsRequired

AdjustingtheFrontCuttingUnit

Thefrontandrearcuttingunitsrequiredifferentmounting
positions.Thefrontcuttingunithas2mountingpositions
dependingonwhatheightofcutanddegreeofrotationyou
desire.

14

1.Foraheightofcutinthe2to7.6cm(3/4to3inch)
range,mountthefrontcarrierframesinthelower,
frontmountingholes(Figure11).

samebenchsetting.Itmaybenecessarytohavethe
rotary-cuttingunitbenchset6mm(1/4inch)abovethat
ofareel-cuttingunitinthesamearea.

Note:Thispermitsmoreuptravelofthecuttingunit
relativetothetractionunitwhenapproachingquick
uphillchangesinterrain.Itdoeshoweverlimitthe
clearanceofthechambertothecarrierwhencresting
sharpknolls.

Figure11

1.Upper,frontmountinghole

2.Lower,frontmountinghole

3.Rearmountinghole

Important:Accesstotherear,cuttingunitsisgreatly
improvedbyremovingthecuttingunitfromthetraction
unit.IftheunitisequippedwithaSidewinder®,
sidewindthecuttingunitstotheright,removetherear
cuttingunit,andslideitouttotherightside.

1.Lowerthecuttingunittotheground,stoptheengine,
andremovethekeyfromtheignition.

2.Loosentheboltsecuringeachheightofcutbracketto
theheightofcutplate(frontandeachside)asshown
inFigure12.

3.Beginningwithfrontadjustment,removethebolt.

2.Foraheightofcutinthe6.3to10cm(2-1/2to4inch)
range,mountthefront,carrierframesintheupper,
frontmountingholes(Figure11).

Note:Thisincreasesthechamber-to-carrierclearance
duetothehigherpositionofthecuttingchamber,but
willcausethecuttingunittoreachtheirmaximumup
travelsooner.

AdjustingtheRear,CuttingUnit

Thefrontandrear,cuttingunitsrequiredifferentmounting
positions.Therearcuttingunithasonemountingposition
forproperalignmentwiththesidewinder-underframe.

Forallheightsofcut,mounttherearcuttingunitintherear
mountingholes(Figure11).

5

AdjustingtheHeightofCut

NoPartsRequired

Procedure

Figure12

1.Heightofcutbracket3.Spacer

2.Heightofcutplate

4.Whilesupportingthechamber,removethespacer
(Figure13).

5.Movethechambertothedesiredheightofcutand
installaspacerintothedesignatedheightofcuthole
andslot(Figure13).

Figure13

6.Positionthetappedplateinlinewiththespacer.

7.Hand-tightenthebolts.

8.Repeatsteps4-7foreachsideadjustment.

Important:Thiscuttingunitoftencutsapproximately
6mm(1/4inch)lowerthanareel-cuttingunitwiththe

9.Tightenall3boltsto41N-m(30ft-lb).Alwaystighten
thefrontboltrst.

15

Note:Adjustmentsofmorethan3.8cm(1-1/2inch)

G011346

1

2

3

G011347

1

mayrequiretemporaryassemblytoanintermediate
heighttopreventbinding.

6

2.Slidethescraperupordownuntilagapof0.5to1
mm(0.020to0.040inch)isachievedbetweentherod
andtheroller.

3.Securethegreasettingandscrewto41N-m(30ft-lb)
inanalternatingsequence.

CheckingtheMachinebefore Operation

NoPartsRequired

Procedure

Performthefollowingcheckbeforeoperation:

•CheckingtheEngine-OilLevel(page19)

•CheckingtheCoolingSystem(page22)

•CheckingtheHydraulicSystem(page22)

•CheckingtheTirePressure(page23)

•TorquingtheWheelNuts(page40)

7

AdjustingtheOptionalRoller

8

InstallingtheOptional
MulchingBafe

NoPartsRequired

Procedure

1.Thoroughlycleandebrisfromthemountingholeson
therearandleft,sidewallsofthechamber.

2.Installthemulchingbafeintherearopeningand
secureitwith5ange-headbolts(Figure15).

Scraper

NoPartsRequired

Procedure

Theoptionalrear-rollerscraperisdesignedtoworkbest
whenthereisanevengapof0.5to1mm(0.020–0.040inch)
betweenthescraperandroller.

1.Loosenthegreasettingandthemountingscrew
(Figure14).

Figure14

1.Rollerscraper

2.Mountingscrew

3.Greasetting

Figure15

1.Mulchingbafe

3.Verifythatmulchingbafedoesnotinterferewith
thetipofthebladeanddoesnotprotrudeinsidethe
surfaceoftherear,chamberwall.

WARNING

Donotusethehigh-liftbladewiththe
mulchingbafe.Thebladecouldbreak,
resultinginpersonalinjuryordeath.

16