Toro Groundsmaster 200 User manual

FormNo.3430-135RevA
62inSideDischargeMower
Groundsmaster®200,1000,3320and3280-D
SeriesTractionUnit
ModelNo.30551—SerialNo.400000000andUp
Registeratwww.Toro.com.
OriginalInstructions(EN)*3430-135*A

ThisproductcomplieswithallrelevantEuropean
directives.Fordetails,pleaseseetheDeclarationof
Incorporation(DOI)atthebackofthispublication.
WARNING
CALIFORNIA
Proposition65Warning
Useofthisproductmaycauseexposure
tochemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orotherreproductiveharm.
Introduction
Thisrotary-bladelawncuttingdeckismounted
toaride-onmachineandisintendedtobeused
byprofessional,hiredoperatorsincommercial
applications.Itisprimarilydesignedforcuttinggrass
onwell-maintainedlawnsinparks,sportselds,
andoncommercialgrounds.Usingthisproductfor
purposesotherthanitsintendedusecouldprove
dangeroustoyouandbystanders.
Readthisinformationcarefullytolearnhowtooperate
andmaintainyourproductproperlyandtoavoid
injuryandproductdamage.Youareresponsiblefor
operatingtheproductproperlyandsafely.
Visitwww.Toro.comforproductsafetyandoperation
trainingmaterials,accessoryinformation,helpnding
adealer,ortoregisteryourproduct.
Wheneveryouneedservice,genuineT oroparts,or
additionalinformation,contactanAuthorizedService
DealerorT oroCustomerServiceandhavethemodel
andserialnumbersofyourproductready.Figure1
identiesthelocationofthemodelandserialnumbers
ontheproduct.Writethenumbersinthespace
provided.
Important:Withyourmobiledevice,youcan
scantheQRcodeontheserialnumberdecal(if
equipped)toaccesswarranty,parts,andother
productinformation.
g243406
Figure1
1.Serialnumberlocation
ModelNo.
SerialNo.
Thismanualidentiespotentialhazardsandhas
safetymessagesidentiedbythesafety-alertsymbol
(Figure2),whichsignalsahazardthatmaycause
seriousinjuryordeathifyoudonotfollowthe
recommendedprecautions.
g000502
Figure2
1.Safety-alertsymbol
Thismanualuses2wordstohighlightinformation.
Importantcallsattentiontospecialmechanical
informationandNoteemphasizesgeneralinformation
worthyofspecialattention.
©2019—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN554202
Contactusatwww.Toro.com.
PrintedintheUSA
AllRightsReserved

Contents
Safety.......................................................................4
GeneralSafety...................................................4
CuttingUnitSafety..............................................4
SafetyandInstructionalDecals..........................5
Setup........................................................................8
1InstallingtheCastorWheelAssemblies............8
2InstallingtheLiftArms......................................9
3ConnectingtheLiftArmstotheCutting
Unit...............................................................10
4ConnectingthePTOShaftandGuardto
theCuttingUnitGearbox................................11
5InstallingtheRearWeight...............................11
6GreasingtheMachine.....................................11
ProductOverview...................................................12
Specications..................................................12
Attachments/Accessories.................................12
Operation................................................................12
AdjustingtheHeightofCut...............................12
AdjustingtheRollersandGageWheel..............14
.........................................................................14
AdjustingtheWeightTransfer...........................14
UsingtheGrassDeector.................................15
OperatingTips.................................................15
Maintenance...........................................................17
RecommendedMaintenanceSchedule(s)...........17
DailyMaintenanceChecklist.............................17
Lubrication........................................................18
CheckingtheLubricantintheGearbox..............18
SeparatingtheCuttingUnitfromtheTraction
Unit...............................................................19
ServicingtheBushingsintheCastor
Arms.............................................................19
ServicingtheCastorWheelsand
Bearings........................................................20
ServicingtheCuttingBlades.............................20
CheckingandCorrectingMismatchof
Blades...........................................................22
AdjustingtheIdlerPulley..................................23
ReplacingtheDriveBelt...................................23
ReplacingtheGrassDeector..........................24
CleaningUndertheCuttingUnit........................24
Storage...................................................................25
Troubleshooting......................................................26
3

Safety
Thismachinehasbeendesignedinaccordancewith
ANSIB71.4-2017andENISO5395.
GeneralSafety
Thisproductiscapableofamputatinghandsand
feetandofthrowingobjects.Alwaysfollowallsafety
instructionstoavoidseriouspersonalinjury.
•Readandunderstandthecontentsofthis
Operator’sManualbeforestartingtheengine.
•Useyourfullattentionwhileoperatingthe
machine.Donotengageinanyactivitythat
causesdistractions;otherwise,injuryorproperty
damagemayoccur.
•Donotoperatethemachinewithoutallguards
andothersafetyprotectivedevicesinplaceand
functioningproperlyonthemachine.
•Keepyourhandsandfeetawayfromrotating
parts.Keepclearofthedischargeopening.
•Keepbystandersandchildrenoutoftheoperating
area.Neverallowchildrentooperatethemachine.
•Shutofftheengine,removethekey(ifequipped),
andwaitforallmovementtostopbeforeyouleave
theoperator’sposition,Allowthemachinetocool
beforeadjusting,servicing,cleaning,orstoringit.
Improperlyusingormaintainingthismachinecan
resultininjury.Toreducethepotentialforinjury,
complywiththesesafetyinstructionsandalways
payattentiontothesafety-alertsymbol,which
meansCaution,Warning,orDanger—personalsafety
instruction.Failuretocomplywiththeseinstructions
mayresultinpersonalinjuryordeath.
CuttingUnitSafety
•Thecuttingunitisonlyapartofacomplete
machinewheninstalledonatractionunit.Read
thetractionunitOperator’sManualcarefully
forcompleteinstructionsonthesafeuseofthe
machine.
•Stopthemachine,removethekey,andwaitfor
allmovingpartstostopbeforeinspectingthe
attachmentafterstrikinganobjectorifthereis
anabnormalvibrationinthemachine.Makeall
necessaryrepairsbeforeresumingoperation.
•Keepallpartsingoodworkingconditionandall
hardwaretightened.Replaceallwornordamaged
decals.
•Useonlyaccessories,attachments,and
replacementpartsapprovedbyToro.
4

SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyarea
ofpotentialdanger.Replaceanydecalthatisdamagedormissing.
decal92-3035
92-3035
1.Heightofcut
decal93-6697
93-6697
1.ReadtheOperator's
Manual.
2.Checktheoilevery50
hours.AddSAE80w-90
(APIGL-5)oilifneeded.
decal93-7818
93-7818
1.Warning—readtheOperator'sManualforinstructionson
torquingthebladebolt/nutto115-149N-m(85-110ft-lb).
decal99-5172
99–5172
decal105-9553
105-9553
1.Warning—readtheOperator'sManual.
2.Tippinghazard—lowerthecuttingunitwhendrivingdown
slopes;for2-wheeldriveunits,adda25kg(55lb)rear
weighttoGM228Dunitsanda48kg(105lb)rearweightto
GM225units;for4-wheeldriveunits,donotaddweight.
decal107-2908
107-2908
1.Thrownobjecthazard—keepbystandersaway.
2.Thrownobjecthazard—lowerthedeectorbeforeusing
themachine.
3.Cutting/dismembermenthazardofhandorfoot,mower
blade—stayawayfrommovingparts.
5

decal107-2915
107-2915
1.Entanglementhazard,shaft—keepbystandersaway.
decal107-2916
107-2916
1.Removethekeyandreadthe
Operator'sManualbeforeperforming
maintenance.
2.Thrownobjecthazard—donotoperate
themowerwiththedeectorupor
removed;lowerthedeectorbefore
usingthemachine;keepbystanders
away.
3.Cutting/dismembermenthazardof
handorfoot,mowerblade—stayaway
frommovingparts.
decal117-4979
117–4979
1.Entanglementhazard,belt—stayawayfrommovingparts,
keepallguardsandshieldsinplace.
6

decal120-6604
120-6604
1.Thrownobjecthazard—keepbystandersawayfromthe
machine.
2.Cutting/dismembermenthazardofhand,mower
blade—stayawayfrommovingparts,keepallguardsand
shieldsinplace.
3.Cutting/dismembermenthazardoffoot,mowerblade—stay
awayfrommovingparts,keepallguardsandshieldsin
place.
decal133-8061
133-8061
7

Setup
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
Frontcastorwheelassembly2
1Rearcastorwheelassembly2Installthecastorwheelassemblies.
Rightliftarm1
Leftliftarm1
Pivotpin2
2Cotterpin(5/32x1-3/4inches)2
Installtheliftarms.
3Nopartsrequired–Connecttheliftarmstothecuttingunit.
4Nopartsrequired–ConnectthePTOshaftandguardtothe
cuttingunitgearbox.
5Nopartsrequired–Installtherearweight.
6Nopartsrequired–Greasethemachine.
MediaandAdditionalParts
DescriptionQty.Use
Operator'sManual1Reviewthematerialandsaveinanappropriateplace
PartsCatalog1Usetoreferencepartnumbers
WARNING
Ifyouleavethekeyintheignitionswitch,
someonecouldaccidentallystarttheengine
andseriouslyinjureyouorotherbystanders.
Removethekeyfromtheignitionswitch
beforeyoudoanymaintenance.
DANGER
IftheengineisstartedandthePTOshaftis
allowedtorotate,seriousinjurycouldresult.
DonotstarttheengineandengagethePTO
leverwhenthePTOshaftisnotconnectedto
thegearboxonthecuttingunit.
Note:Determinetheleftandrightsidesofthe
machinefromthenormaloperatingposition.
Note:Wheninstallingthe62-inchdeckontoa
Groundsmaster200Seriestractionunit,youmust
installtheWeightTransferKit,ToroPartNo.70-8100.
1
InstallingtheCastorWheel
Assemblies
Partsneededforthisprocedure:
2Frontcastorwheelassembly
2Rearcastorwheelassembly
Procedure
Note:Thethrustwashers,spacers,andtensioning
capshavebeeninstalledonthecastorwheelspindles
forshipping.
1.Removethetensioningcapsfromthespindle
shaftsandslideoffthespacersandthrust
washers(Figure3andFigure4).
8

g010826
Figure3
FrontCastorWheelAssembly
1.Tensioningcap3.Spacers
2.Thrustwashers4.Frontcastorspindle
g010827
Figure4
RearCastorWheelAssembly
1.Tensioningcap3.Spacers
2.Thrustwashers4.Rearcastorspindle
2.Slidethespacersontothecastorspindletoget
thedesiredheightofcut;refertothechartin
AdjustingtheHeightofCut(page12).
3.Slideathrustwasherontothespindle,pushthe
roundcastorspindlethroughthefrontcastor
arm,andthehexcastorspindlethroughtherear
castorarm.
4.Installanotherthrustwasherandtheremaining
spacersontothespindleandinstallthe
tensioningcaptosecuretheassembly.
Important:Thethrustwashers,notthe
spacers,mustcontactthetopandbottom
ofthecastorarm.
5.Ensurethatall4castorwheelsaresetatthe
sameheightofcutandrollthecuttingunitoff
thepallet.
2
InstallingtheLiftArms
Partsneededforthisprocedure:
1Rightliftarm
1Leftliftarm
2Pivotpin
2Cotterpin(5/32x1-3/4inches)
Procedure
1.Ononesideofthetractionunit,loosen(donot
remove)thewheelnutsthatsecurethewheel
andtireassemblytothefrontwheelstuds.
2.Jackupthemachineuntilthefrontwheelisoff
theoor.Usejackstandstopreventitfrom
accidentallyfalling.
3.Removethewheelnutsandslidethewheeland
tireassemblyoffthestuds.
4.Mountaliftarm(withtheballjointendpositioned
outward)tothepivotbracketwithapivotpinand
acotterpin(5/32x1-3/4inches)(Figure5).
9

g010783
Figure5
1.Pivotpin3.Liftarmpivotbracket
2.Liftarm4.Brakereturnspring
5.Mounttherearoftheliftarmtotheliftcylinder
withapivotpinand2cotterpins(suppliedwith
thetractionunit).
6.Hookthebrakereturnspringintotheholeinthe
liftarm(Figure5).
7.Repeatthisprocedurefortheoppositesideof
themachine.
3
ConnectingtheLiftArmsto
theCuttingUnit
NoPartsRequired
Procedure
1.Movethecuttingunitintopositioninfrontofthe
tractionunit.
2.Measurethedistancefromtheendofeachlift
armtothecenteroftheballjoint(greasetting).
Thedistanceshouldbe57mm(2-1/4inches)
(Figure6).
Note:Ifthedistanceisnot57mm(2-1/4
inches),loosenthejamnutthatsecurestheball
jointtotheliftarmandrotatetheballjointinor
outuntilyouattainthedistance.Donottighten
thejamnutsatthistime.
g010784
Figure6
1.Liftarm3.Jamnut
2.Balljoint4.57mm(2–1/4inch)
3.MovetheliftlevertotheFLOATposition.Push
theliftarmsdownuntiltheholesintheballjoint
mountslineupwiththeholesinthecastorarms.
Note:FortheGroundsmaster3280–Dand
3320,theenginemustberunningtolowerthe
liftarms.
4.Securetheballjointmountstoeachcastorarm
with2capscrews(7/16x3inches)andange
nuts(7/16inches)(Figure7).
g010785
Figure7
1.Castorarm4.Capscrew(7/16x3
inches)
2.Balljointmount5.Flangenut(7/16inches)
3.Balljoint
Note:Theballjointmountshouldbeabovethe
castorarmwhenyouassembleit.
5.Tightenthelargejamnutthatsecurestheball
jointtotheliftarm(Figure7).
10

Note:Whentighteningthejamnut,holdtheball
jointstraighttopermitproperoscillationduring
raisingandloweringofthecuttingunit.
4
ConnectingthePTOShaft
andGuardtotheCutting
UnitGearbox
NoPartsRequired
Procedure
1.Removethe2capscrewsandlockwashersthat
securethePTOguardmountingbracketstothe
gearbox(Figure8).
g010546
Figure8
1.PTOguard2.Gearbox
Note:Retainthefastenersforfutureinstallation.
2.SlidethePTOshaftguardontothePTOshaft,
positioningtheguardasshowninFigure8.
3.SlidethemalePTOshaftintothefemalePTO
shaft.
Note:Alignthemountingholesinthegearcase
inputshaftwiththeholesinthePTOshaftand
slidethemtogether.
4.Securethemwitharollpin.
5.Tightenthecapscrewsandnuts.
6.AttachthePTOshaftguardtothegearboxwith
the2capscrewsandlockwasherspreviously
removed.
5
InstallingtheRearWeight
NoPartsRequired
Procedure
Two-WheelDriveGroundsmaster1000and200
SeriestractionunitscomplywithENISO5395and
ANSIB71.4-2017whenequippedwithrearweight.
RefertothechartinthetractionunitOperator’s
Manualtodeterminethecombinationsofweight
required.Orderthepartsfromyourlocalauthorized
Torodistributor.
Four-WheelDriveGroundsmaster200Seriestraction
unitsdonotneedadditionalrearweighttocomplywith
ENISO5395andANSIB71.4-2017.
Two-WheelDriveGroundsmaster3280-Dand
Groundsmaster3320tractionunitswithserial
numbers250000101through259999999complywith
ENISO5395andANSIB71.4-2017whenequipped
withtherearweightkit,PartNo.24-5780.
Two-WheelDriveGroundsmaster3280-Dand
Groundsmaster3320tractionunitswithserial
numbers260000101andupdonotneedadditional
rearweighttocomplywithENISO5395andANSI
B71.4-2017.
Four-WheelDriveGroundsmaster3280-Dtraction
unitsdonotneedadditionalrearweighttocomplywith
ENISO5395andANSIB71.4-2017.
6
GreasingtheMachine
NoPartsRequired
Procedure
Beforeoperatingthemachine,greaseittoensure
properlubricatingcharacteristics;refertoLubrication
(page18).Failuretoproperlygreasethemachinewill
resultinprematurefailureofcriticalparts.
11

ProductOverview
Specications
Note:Specicationsanddesignaresubjectto
changewithoutnotice.
Width
ofCut
1.56m(61-5/8inches)
Height
ofCut
Adjustablefrom25to102mm(1to4inches)in13
mm(1/2inch)increments
Blade
Tip
Speed
15,480ft/minute@3250enginerpm
Cutting
Blades
3heat-treatedsteelblades,each4.8mm(3/16inch)
thickand55cm(24-3/4inches)long
Castor
Wheels
203mm(8inch)diametergreaseablerollerbearings
(inatedto241-345kPa[35-50psi])
Drive
System
PTOdrivengearboxtransmitspowerthrougha"AA"
sectionbelttoallbladespindles.
Net
Weight
244kg(539lb)
Attachments/Accessories
AselectionofT oroapprovedattachmentsand
accessoriesisavailableforusewiththemachine
toenhanceandexpanditscapabilities.Contact
yourAuthorizedServiceDealerorauthorizedToro
distributororgotowww.T oro.comforalistofall
approvedattachmentsandaccessories.
Toensureoptimumperformanceandcontinuedsafety
certicationofthemachine,useonlygenuineT oro
replacementpartsandaccessories.Replacement
partsandaccessoriesmadebyothermanufacturers
couldbedangerous,andsuchusecouldvoidthe
productwarranty.
Operation
Note:Determinetheleftandrightsidesofthe
machinefromthenormaloperatingposition.
AdjustingtheHeightofCut
Theheightofcutisadjustablefrom25to102mm
(1to4inches)in13mm(1/2inch)increments,by
addingorremovinganequalnumberofspacerson
thefrontandrearcastorforks.Theheight-of-cutchart
belowgivesthecombinationsofspacerstousefor
allheight-of-cutsettings.
SpacersBelowCastorArm Height-of-Cut
SettingFrontRear
25mm(1inch)00
38mm(1-1/2
inches)
11
51mm(2inches)22
64mm(2-1/2
inches)
33
76mm(3inches)44
89mm(3-1/2
inches)
55
102mm(4inches)66
1.Starttheengineandraisethecuttingunitsothat
theheightofcutcanbechanged.
2.Stoptheengineafterraisingthecuttingunit.
AdjustingtheFrontCastorWheels
1.Removethetensioningcapfromthespindle
shaftandslidethespindleoutofthefrontcastor
arm(Figure9).
12

g010786
Figure9
1.Frontcastorwheel3.Spacers
2.Tensioningcap4.Thrustwashers
2.Removethewasherfromthespindleshaft.
3.Slidethespacersontothespindleshafttoget
thedesiredheightofcut,thenslidethewasher
ontotheshaft.
4.Pushthecastorspindlethroughthefrontcastor
arm.
5.Installtheotherthrustwasherandremaining
spacersontothespindle.
6.Installthetensioningcaptosecuretheassembly.
AdjustingtheRearCastorWheels
1.Removethetensioningcapsecuringthegage
wheeltothecuttingunitbrackets(Figure10).
g010787
Figure10
1.Rearcastorwheel3.Spacers
2.Tensioningcap4.Thrustwashers
2.Removeoradd”C”shapedspacersatthe
narrowportionofthespindleshaft,belowthe
castorarm,togetthedesiredheightofcut.
Note:Ensurethatthethrustwashers,notthe
spacers,contactthetopandbottomofthe
castorarm.
3.Installthetensioningcaptosecuretheassembly.
Note:Ensurethatall4castorwheelsaresetat
thesameheightofcut.
13

AdjustingtheRollersand
GageWheel
Note:Ifyouwanttousethecuttingunitinthe25mm
(1inch)or38mm(1-1/2inches)height-of-cutsetting,
positionthecuttingunitrollersinthetopbracketholes.
AdjustingtheFrontRoller
1.Removethecapscrewandnutsecuringthe
rollershafttothecuttingunitbracket(Figure11).
g010788
Figure11
1.Externalroller2.Rollershaft
2.Slidetheshaftoutofthelowerbracketholes,
aligntherollerwiththetopholes,andinstallthe
shaft.
3.Securetherollershafttothecuttingunitbracket
withthecapscrewandnut.
AdjustingtheFrontGageWheel
1.Removethecapscrewandnutsecuringthe
gagewheeltothecuttingunitbrackets(Figure
12).
g010789
Figure12
1.Gagewheel
2.Aligntherollerandspacerwiththetopholesin
thebracketsandsecurethemwiththecapscrew
andnut.
AdjustingtheRear(Internal)
Rollers
1.Removethecotterpinssecuringtherollershafts
tothebracketsontheundersideofthedeck
(Figure13).
g010790
Figure13
1.Internalrollers
2.Slidetheshaftsoutofthelowerbracketholes,
aligntherollerswiththetopholes,andinstall
theshafts.
3.Installthecotterpinstosecuretheassemblies.
AdjustingtheWeight
Transfer
OnGroundsmaster3280-Dand3320modelsonly,
refertothetractionunitOperator'sManualforthe
proceduretoadjustthecounterbalancepressurefor
bestperformance.
14

UsingtheGrassDeector
DANGER
Withoutagrassdeector,dischargecover,or
completegrasscatcherassemblymountedin
place,youandothersareexposedtoblade
contactandthrowndebris.Contactwith
rotatingmowerblade(s)andthrowndebris
willcauseinjuryordeath.
•Neverremovethegrassdeectorfrom
themowerbecausethegrassdeector
routesmaterialdowntowardtheturf.Ifthe
grassdeectoriseverdamaged,replaceit
immediately.
•Neverputyourhandsorfeetunderthe
mower.
•Nevertrytoclearthedischargeareaor
mowerbladesunlessyoumovethepower
takeoff(bladecontrolswitch(PTO)tothe
OFFposition,rotatetheignitionkeytothe
OFFpositionandremovethekey.
•Makesurethatthegrassdeectorisinthe
downposition.
Note:Thedeectorisspringloadedintoitsdownward
normaloperatingposition(Figure14),butyoucan
temporarilyswingitoutofthewaywhennecessary.
g010791
Figure14
1.Grassdeector2.Springhinges
OperatingTips
FastThrottleSetting/Ground
Speed
Tomaintainenoughpowerforthemachineanddeck
whilemowing,operatetheengineatthefastthrottle
positionandadjustyourgroundspeedforconditions.
Decreasethegroundspeedastheloadonthecutting
bladesincreases.Increasethegroundspeedasthe
loadonthebladesdecreases.
MowingDirection
Alternatemowingdirectiontoavoidmakingrutsin
theturfovertime.Thisalsohelpsdisperseclippings
whichenhancesdecompositionandfertilization.
CuttingSpeed
Toimprovecutquality,useaslowergroundspeed.
AvoidCuttingTooLow
Ifthecuttingwidthofthecuttingunitiswiderthanthe
moweryoupreviouslyused,raisethecuttingheightto
ensurethatuneventurfisnotcuttooshort.
SelecttheProperHeight-of-Cut
SettingtoSuitConditions
Removeapproximately25mm(1inch)orno
morethan1/3ofthegrassbladewhencutting.In
exceptionallylushanddensegrass,youmayneedto
slowdowntheforwardspeedand/orraisetheheight
ofcuttothenexthighersetting.
Important:Ifcuttingmorethan1/3ofthe
grassbladeoff,orinsparselonggrassor
dryconditions,theuseofatsailbladesis
recommendedtoreduceair-bornechaff,debris,
anddeckdrivecomponentstrain.
LongGrass
Ifthegrassiseverallowedtogrowslightlylongerthan
normal,orifitcontainsahighdegreeofmoisture,
raisethecuttingheighthigherthanusualandcutthe
grassatthissetting.Thencutthegrassagainusing
thelower,normalsetting.
KeeptheCuttingUnitClean
Cleanclippingsanddirtfromtheundersideofthe
cuttingunitaftereachuse.Ifgrassanddirtbuild
upinsidethecuttingunit,thecuttingqualitywill
eventuallybecomeunsatisfactory.
Toreducetheriskofrehazard,keeptheengine,
mufer,batterycompartment,parkingbrake,cutting
units,andfuelstoragecompartmentfreeofgrass,
leaves,orexcessivegrease.Cleanupanyspilledoil
orfuel.
15

BladeMaintenance
Maintainasharpbladethroughoutthecuttingseason
becauseasharpbladecutscleanlywithouttearingor
shreddingthegrassblades.T earingandshredding
turnsgrassbrownattheedges,whichslowsgrowth
andincreasesthechanceofdisease.Checkthe
bladesdailyforsharpness,andforanywearor
damage.Sharpenthebladesasnecessary.Ifablade
isdamagedorworn,replaceitimmediatelywitha
genuineTororeplacementblade.RefertoRemoving
andInstallingtheCutting-UnitBlade(s)(page21).
16

Maintenance
RecommendedMaintenanceSchedule(s)
MaintenanceService
IntervalMaintenanceProcedure
Aftertherst2hours•Tightenthecastorwheelnuts.
Aftertherst10hours•Tightenthecastorwheelnuts.
Beforeeachuseordaily•Lubricatethecastorarmbushings.
•Lubricatethecastorwheelbearings.
Aftereachuse•Cleanthecuttingunit.
Every50hours
•Lubricatethegreasettings.
•Checkthegearboxlubricant.
•Tightenthecastorwheelnuts.
Every400hours•Changethegearboxlubricant.
DailyMaintenanceChecklist
Duplicatethispageforroutineuse.
Fortheweekof: MaintenanceCheckItem
Mon.Tues.Wed.Thurs.Fri.Sat.Sun.
Checkthegrassdeector
inthedownposition(if
applicable).
Checkthetirepressure.
Checktheconditionofthe
blades.
Lubricateallthegrease
ttings.1
Touch-updamagedpaint.
1.Immediatelyaftereverywashing,regardlessoftheintervallisted.
NotationforAreasofConcern
Inspectionperformedby:
ItemDateInformation
CAUTION
Ifyouleavethekeyintheignitionswitch,someonecouldaccidentlystarttheengineand
seriouslyinjureyouorotherbystanders.
Removethekeyfromtheignitionbeforeyoudoanymaintenance.
17

Important:Thefastenersonthecoversofthismachinearedesignedtoremainonthecoverafter
removal.Loosenallthefastenersoneachcoverafewturnssothatthecoverisloosebutstillattached,
thengobackandloosenthemuntilthecovercomesfree.Thispreventsyoufromaccidentallystripping
theboltsfreeoftheretainers.
Lubrication
ServiceInterval:Every50hours
Themachinehasgreasettingsthatyoumust
lubricateregularlywithNo.2lithiumgrease.Lubricate
allbearingsandbushingsimmediatelyafterevery
washing.
Lubricatethefollowingareas:
•Frontcastorspindlebushings(Figure15)
•Frontandrearcastorwheelbearings(Figure15)
g004772
Figure15
•Rightandleftliftarmpivotpins(Figure16)
g010550
Figure16
•Bladespindlebearings(Figure17)
g010792
Figure17
•Rightandleftpusharmballjoints(Figure17)
CheckingtheLubricantin
theGearbox
ServiceInterval:Every50hours
Thegearboxisdesignedtooperateoneither
petroleumorsyntheticSAE80W–90gearlube.
Althoughthegearboxisshippedwithlubricantfrom
thefactory,checkthelevelbeforeoperatingthe
cuttingunit.Thegearboxcapacityis283ml(12oz).
1.Positionthemachineandcuttingunitonalevel
surface.
2.Removethedipstick/llplugfromthetopofthe
gearbox(Figure18)andmakesurethatthe
lubricantisbetweenthemarksonthedipstick.If
thelubricantlevelislow,addenoughlubricant
untilthelevelisbetweenthemarks.
g010548
Figure18
1.Dipstick/llplug
18

SeparatingtheCuttingUnit
fromtheTractionUnit
1.Positionthemachineonalevelsurface.
2.Lowerthecuttingunittotheoor,movethelift
levertotheFLOATposition,engagetheparking
brake,putthetractionpedalinneutral,setthe
PTOleverintheOFFposition,shuttheengine
off,andremovetheignitionkey.
3.Removethecapscrewsandlocknutssecuring
theballjointmountstothecastorarmsonthe
cuttingunit(Figure19).
g010793
Figure19
1.Castorarm2.Balljointmount
4.Rollthecuttingunitawayfromthetractionunit,
separatingthemaleandfemalesectionsofthe
PTOshaft(Figure20).
DANGER
IftheengineisstartedandthePTOshaft
isallowedtorotate,seriousinjurycould
result.
Donotstarttheengineandengagethe
PTOleverwhenthePTOshaftisnot
connectedtothegearboxonthecutting
unit.
g010552
Figure20
1.PTOshaft
ServicingtheBushingsin
theCastorArms
Thecastorarmshavebushingspressedintothetop
andbottomportionofthetubewhich,aftermany
hoursofoperation,willwear.T ocheckthebushings,
movethecastorforkbackandforthandfromsideto
side.Ifthecastorshaftislooseinsidethebushings,
thebushingsarewornandmustbereplaced.
1.Raisethecuttingunitsothatthewheelsareoff
theoorandblockitsothatitcannotfall.
2.Removethetensioningcap,spacer(s),and
thrustwasherfromthetopofthecastorspindle.
3.Pullthecastorspindleoutofthemountingtube.
Allowthethrustwasherandspacer(s)toremain
onthebottomofthespindle.
4.Insertapinpunchintothetoporbottomofthe
mountingtube,anddrivethebushingoutofthe
tube(Figure21).Also,drivetheotherbushing
outofthetube.
g010828
Figure21
1.Frontcastorarmtube2.Bushings
5.Cleantheinsideofthemountingtubesto
removeanydirt.
6.Applygreasetotheinsideandoutsideofthe
newbushings.
19

7.Useahammerandatplatetodrivethe
bushingsintothemountingtube.
8.Inspectthecastorspindleforwear,andreplace
itifitisdamaged.
9.Pushthecastorshaftthroughthebushingsand
mountingtube.
10.Slidethethrustwasherandspacer(s)ontothe
spindle.
11.Installthetensioningcaponthecastorspindle
toretainallthepartsinplace.
ServicingtheCastor
WheelsandBearings
Thecastorwheelrotatesonahigh-qualityroller
bearingandissupportedbyaspannerbushing.Even
aftermanyhoursofuse,providedthatthebearing
waskeptwelllubricated,bearingwearwillbeminimal.
However,failingtokeepthebearinglubricatedwill
causerapidwear.Awobblycastorwheelusually
indicatesawornbearing.
1.Removethelocknutfromthecapscrewholding
thecastorwheelassemblybetweenthecastor
fork(Figure22).
g010829
Figure22
1.Castorwheel4.Spannerbushing
2.Capscrewandlocknut5.Rollerbearing
3.Bushing(2)6.Washer(2)
2.Graspthecastorwheelandslidethecapscrew
outofthefork.
3.Pullthespannerbushingoutofthewheelhub
(Figure22).
4.Removethebushingfromthewheelhuband
allowthebearingtofallout.
5.Removethebushingfromtheoppositesideof
thewheelhub.
6.Checkthebearing,spanner,andinsideofthe
wheelhubforwear,andreplaceanydamaged
parts.
7.Toassemblethecastorwheel,pushthebushing
intothewheelhub.
8.Slidethebearingintothewheelhub.
9.Pushtheotherbushingintotheopenendofthe
wheelhubtocaptivatethebearinginsidethe
wheelhub(Figure22).
10.Carefullyslidethespannerthroughthebushings
andthewheelhub.
11.Installthecastorwheelassemblybetween
thecastorforkandsecureitinplacewiththe
capscrew,washers,andlocknut.
12.Lubricatethecastorwheelbearingthroughthe
greasettingwithNo.2lithiumgrease.
ServicingtheCutting
Blades
BladeSafety
•Inspectthebladeperiodicallyforwearordamage.
•Usecarewhencheckingtheblades.Wrapthe
bladesorweargloves,andusecautionwhen
servicingtheblades.Onlyreplaceorsharpenthe
blades;neverstraightenorweldthem.
•Onmulti-bladedmachines,takecareasrotatinga
bladecancauseotherbladestorotate.
CheckingforaBentBlade
Afterstrikingaforeignobject,inspectthemachine
fordamageandmakerepairsbeforestartingand
operatingtheequipment.Torqueallthespindle-pulley
nutsto176to203N∙m(130to150ft-lb).
1.Positionthemachineonalevelsurface,raise
thecuttingunit,engagetheparkingbrake,put
thetractionpedalinNEUTRAL,putthePTOlever
intheOFFposition,shutofftheengine,and
removetheignitionkey.
Note:Blockthecuttingunittopreventitfrom
accidentallyfalling.
20