27-inch 8 or 11-Blade or 32-inch 8-Blade EdgeSeries™ DPA Cutting Unit

This product is capable of amputating hands and feet. Always follow all safety instructions to avoid serious personal injury.

• Read and understand the contents of this Operator’s Manual before starting the machine.

• Use your full attention while operating the machine. Do not engage in any activity that causes distractions; otherwise, injury or property damage may occur.

• Do not put your hands or feet near moving components of the machine.

• Do not operate the machine without all guards and other safety protective devices in place and functioning properly on the machine.

• Keep clear of any discharge opening.

• Keep bystanders and children out of the operating area. Never allow children to operate the machine.

• Before you leave the operator’s position, do the following:

  • Park the machine on a level surface.

  • Lower the cutting unit(s).

  • Disengage the drives.

  • Engage the parking brake (if equipped).

  • Shut off the engine and remove the key.

  • Wait for all movement to stop.

Improperly using or maintaining this machine 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 these instructions may result in personal injury or death.

• The cutting unit is only a complete machine when installed on a traction unit. Read the traction unit Operator’s Manual carefully for complete instructions on the safe use of the machine.

• Stop the machine, remove the key (if equipped), and wait for all movement to stop before inspecting the attachment after striking an object or if there is an abnormal vibration in the machine. Make all necessary repairs before resuming operation.

• Keep all parts in good working condition and all hardware tightened. Replace all worn or damaged decals.

• Use only accessories, attachments, and replacement parts approved by Toro.

A worn or damaged blade can break, and a piece of the blade could be thrown toward you or bystanders, resulting in serious personal injury or death.

• Inspect the blade periodically for wear or damage.

• Use care when checking the blades. Wrap the blades or wear gloves, and use caution when servicing the blades. Only replace or sharpen the blades; never straighten or weld them.

• On multi-bladed machines, take care as rotating 1 blade can cause other blades to rotate.

Parts needed for this procedure:

Install the grease fitting on the reel-motor side of the cutting unit. Refer to Figure 3 to determine the position of the reel motors based on the position of the cutting unit on the machine.

Figure 3

1. Cutting unit 1
2. Cutting unit 2
3. Cutting unit 3
4. Weight
5. Reel motor

1. Remove and discard the setscrew on the reel-motor side plate (Figure 4).

   

   Figure 4

   1. Hex bolt (2)
   2. Setscrew
   3. Grease fitting
   4. Grease vent

2. Install the straight grease fitting (Figure 4).

   Note: The grease fitting is for lubricating reel motor splines.

1. Adjust the bedknife to the reel.

2. Adjust the rear roller for your height-of-cut requirements.

3. Set the height of cut.

4. Adjust the rear shield if necessary.

Refer to for complete instructions for performing these adjustments.

Parts needed for this procedure:

Important: Before installing the reel motors, obtain and install the counter weights or other accessories on the opposite side of the cutting units from the reel motors as described in the instructions provided with the weights or accessories.

1. Install the cutting units onto the traction unit; refer to the traction unit Operator’s Manuals for instructions.

2. If there are no cap screws on the reel-motor side plate, install them (Figure 4).

3. Install the O-ring on the reel motor (Figure 5).

   

   Figure 5

   1. O-ring

4. Install the reel motor and secure it with the cap screws.

5. Grease the side plate until excess grease comes out of the grease vent (Figure 4).

Adjust the shop roller positions before operating the cutting units for the first time; refer to Adjusting the Shop Roller Assemblies (Model 03192 Only).

A selection of Toro approved attachments and accessories is available for use with the machine to enhance and expand its capabilities. Contact your Authorized Service Dealer or authorized Toro distributor or go to www.Toro.com for a list of all approved attachments and accessories.

To ensure optimum performance and continued safety certification of the machine, use only genuine Toro replacement parts and accessories. Replacement parts and accessories made by other manufacturers could be dangerous, and such use could void the product warranty.

Note: Use Height-of-Cut Chart (Models 03189, 03190, and 03191) to determine the number of rear spacers needed for the desired aggressiveness-of-cut setting; refer to Height-of-Cut Chart(Models 03189, 03190, and 03191 Only).

1. Loosen the locknuts securing the height-of-cut brackets to the cutting-unit side plates (Figure 14).

   

   Figure 14

   1. Adjusting bolt
   2. Locknut
   3. Height-of-cut bracket

2. Loosen the nut on the gauge bar (Figure 15) and set the adjusting bolt to the desired height of cut.

   Note: The distance between the bottom of the bolt head and the face of the bar is the height of cut.

   

   Figure 15

   1. Gauge bar
   2. Height-adjusting screw
   3. Nut

3. Hook the bolt head on the cutting edge of the bedknife and rest the rear end of the bar on the rear roller (Figure 16).

4. Rotate the adjusting bolt until the front roller contacts the gauge bar (Figure 16). Adjust both ends of roller until the entire roller is parallel to the bedknife.

   

   Figure 16

   Important: When set properly, the rear and front rollers will contact the gauge bar and the bolt will be snug against the bedknife. This ensures that the height-of-cut is identical at both ends of the bedknife.

5. Tighten the nuts to secure adjustment.

   Note: Do not overtighten the nuts. Tighten them just enough to remove any play from the washer.

Before you lower the cutting units to the shop floor or remove them from the traction unit, lower the shop roller assemblies to protect the reel and bedknife blades from hard surface contact.

Before operating the cutting units, install them to the machine, raise the cutting units, and raise the shop roller assemblies to prevent them from touching the grass and interfering with operation.

1. Remove the cotter pin from the clevis pin that secures the shop roller bracket to the side plate.

2. Position the shop roller assembly as needed:

   • Lower the shop roller brackets before the cutting unit is lowered to the shop floor or removed from the traction unit (Figure 17).

     

     Figure 17

     1. Clevis pin (always installed in the top square hole in the side plate)
     2. Side plate
     3. Shop roller assembly (in lowered/shop position)

   • Raise the shop roller brackets after the cutting unit is raised to the operating position (Figure 18).

     

     Figure 18

     1. Clevis pin (always installed in the top square hole in the side plate)
     2. Side plate
     3. Shop roller assembly (in raised/operating position)

     Note: Ensure that the clevis pin is always installed in the top square hole in the side plate.

3. Secure the shop roller bracket to the clevis pin with the cotter pin.

4. Repeat this procedure on the opposite end of the cutting unit, and for all other cutting units as needed.

On Model 03192, adjust the height of cut (HOC) by adding or removing the adjustment (slotted) rear spacers below the side plate pad on the cutting unit.

Note: Spacers installed above the side plate pad do not affect HOC.

The adjustment (slotted) rear spacers are stored above the side plate pad; to increase HOC, move them below the side plate pad.

There are 2 types of slotted rear spacers used for adjusting HOC on Model 03192 cutting units:

• 1/4 inch (6.4 mm) slotted rear spacers, up to 3 on each side.

• 0.075 inch (1.9 mm) thin slotted rear spacers, up to 2 on each side.

Additionally there are 5 fixed rear spacers (1/4 inch, 6.4 mm) always located below the side plate pad.

Important: Do not remove or adjust the 5 lower rear spacers; this cutting unit is designed to operate at a HOC between 1.25 to 2.00 inches (32 to 51 mm) and removing the lower fixed spacers causes the HOC to leave that range.

Figure 19

1. Thin (0.075 inch) adjustment spacers
2. 1/4 inch adjustment spacers
3. Side plate pad
4. Lower fixed spacers (do not adjust)

To adjust the aggressiveness of cut on Model 03192 cutting units, proceed as follows:

• Install the cutting unit onto the traction unit as described in the traction unit Operator's Manual.

• Loosen, but do not remove, the locknuts at the front of the fixed plates and remove the carriage bolts, spacers, and locknuts from the rear of the fixed plates and adjust their position.

  Note: To achieve a less aggressive cut, mount the cutting unit links in the number 1 position or mount the links to the number 3 position for a more aggressive cut (Figure 20).

  

  Figure 20

  Left side shown

  1. Less aggressive
  2. Production/Standard
  3. More aggressive
  4. Just loosen these locknuts before adjusting aggressiveness of cut

Use the following chart to determine which bedknife is best suited for the desired height of cut.

Figure 21

1. Bedknife lip height*

Whenever the cutting unit has to be tipped to expose the bedknife/reel, prop up the rear of the cutting unit with the kickstand (supplied with the traction unit) to make sure that the nuts on the back end of the bedbar adjusting screws are not resting on the work surface (Figure 24).

Figure 24

1. Kickstand

Regularly lubricate the 5 grease fittings of each cutting unit (Figure 25) with No. 2 lithium grease.

There are 2 lubrication points on the front roller, 2 on the rear roller, and 1 at the reel-motor spline.

Note: Model 03192 does not have a front roller; there are only the 2 lubrication points on the rear roller and 1 at the reel-motor spline.

Important: Lubricating the cutting units immediately after washing helps purge water out of the bearings and increases bearing life.

1. Wipe each grease fitting with a clean rag.

2. Apply grease until clean grease comes out of the roller seals and the bearing relief valve.

3. Wipe any excess grease away.

   

   Figure 25

   Grease fittings on the reel-motor side

   1. Relief valve

1. Remove all parts (refer to the Installation Instructions for the HD DPA Kit and to Figure 40).

2. Apply anti-seize compound to the inside of the bushing area on cutting unit center frame (Figure 40).

3. Align the keys on flange bushings to the slots in the frame and install the bushings (Figure 40).

4. Install a wave washer onto the adjuster shaft and slide the adjuster shaft into the flange bushings in the frame of the cutting unit (Figure 40).

5. Secure the adjuster shaft with a flat washer and locknut (Figure 40).

6. Torque the locknut to 20 to 27 N∙m (15 to 20 ft-lb).

   Note: The bedbar adjuster shaft has left-hand threads.

   

   Figure 40

   1. Shaft adjuster
   2. Wave washer
   3. Flange bushing
   4. Apply anti-seize compound here.
   5. Flat washer
   6. Locknut
   7. Apply anti-seize compound here.
   8. Bedbar-adjuster screw
   9. Hardened washer
   10. Compression spring
   11. Spring-tension nut

7. Apply anti-seize compound to the threads of the bedbar-adjuster screw that fit into the adjuster shaft.

8. Thread the bedbar-adjuster screw into the adjuster shaft.

9. Loosely install the hardened washer, spring, and spring tension nut onto the adjuster screw.

10. Install the bedbar, positioning the mounting ears between the washer and the bedbar adjuster.

11. Secure the bedbar to each side plate with the bedbar bolts (nuts on bolts) and 6 washers.

    Note: Position a nylon washer on each side of the side-plate boss.

12. Place a steel washer outside each of the nylon washers (Figure 40).

13. Torque the bedbar bolts to 37 to 45 N∙m (27 to 33 ft-lb).

14. Tighten the locknuts until the outside steel washer stops rotating and end play is removed but do not overtighten or deflect the side plates.

    Note: The washers on the inside may have a gap (Figure 40).

15. Tighten the nut on each bedbar-adjuster assembly until the compression spring is fully compressed, then loosen the nut 1/2 turn (Figure 40).

16. Repeat this procedure on the other end of the cutting unit.

17. Adjust the bedknife to the reel; refer to Adjusting the Bedknife to the Reel.

The Roller Rebuild Kit (Part No. 114-5430) and the Roller Rebuild Tool Kit (Part No. 115-0803) (Figure 41) are available for servicing the roller. The Roller Rebuild Kit includes all the bearings, bearing nuts, inner seals, and outer seals to rebuild a roller. The Roller Rebuild Tool Kit includes all the tools and the installation instructions required to rebuild a roller with the roller rebuild kit. Refer to your parts catalog or contact your authorized Toro distributor for assistance.

Figure 41

1. Roller Rebuild Kit (Part No. 114-5430)
2. Roller Rebuild Tool kit (Part No. 115-0803)
3. Inner seal
4. Bearing
5. Outer seal
6. Bearing nut
7. Inner seal tool
8. Washer
9. Bearing/outer-seal tool