FORM NO. 3323-241 Z – Master 48” Recycler for OUT FRONT Z –TRACTION UNIT Model No. 78477– 995001 & Up Operator’s Manual IMPORTANT: Read this manual carefully. It contains information about your safety and the safety of others. Also become familiar with the controls and their proper use before you operate the product.
Introduction We want you to be completely satisfied with your new product, so feel free to contact your local Authorized Service Dealer for help with service, genuine replacement parts, or other information you may require. Whenever you contact your Authorized Service Dealer or the factory, always know the model and serial numbers of your product. These numbers will help the Service Dealer or Service Representative provide exact information about your specific product.
Contents Safety and Instruction Decals . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loose Parts . . . . . . . . . . . . . . . . . . . . . . . . . Install Castor Wheels . . . . . . . . . . . . . . . . . Installing Mower . . . . . . . . . . . . . . . . . . . . Removing the Mower . . . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating the Power Take Off (PTO) . . . . Adjusting Height-of-Cut . . . . .
Safety Safety and Instruction Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost.
Installation Loose Parts Note: Use the chart below to identify parts used for assembly. DESCRIPTION QTY.
Installation Install Castor Wheels Installing Mower IMPORTANT: Make sure your castor wheels are installed correctly as shown in figure 1. 1. Position carrier frame in front of traction unit and place push arms into clevises (Fig. 2). 1. Place spacer and (2) thrust washers on shaft and slide the castor wheel into the mounting tube (Fig. 1). 2. Retain push arms with pivot pin assemblies, aligned with flat against frame, and secure with hairpin cotters (Fig. 2). 2.
Installation 3. Lift carrier frame into vertical position, refer to: Tilting the Mower. 4. Place a block, approximately 4 inches high, under the carrier frame. This will raise the frame vertically. 5. Secure spring end plate assembly to carrier frame with 3/8” x 7/8” (23 mm) shoulder bolt and 3/8” locknut (Fig. 3). 3 2 1 m-3209 3 Figure 4 1. Spring Assembly 2. Shoulder Bolt 3/8” x 7/8” (22 mm) 1 2 7. Position mower in front of traction unit. 8.
Installation 10. Remove wood block. Release the latch levers and push carrier frame down. Latch pins should lock. 11. Select hole in mower hanger bracket corresponding to the height-of-cut desired. Lift on side and front to align holes and insert clevis pin (Fig. 6). Removing the Mower 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key. 2.
Installation 6. Remove 3/8” x 7/8” (23 mm) shoulder bolts and 3/8” locknuts securing spring end plate assemblies to carrier frame (Fig. 8). 10. Remove 5/16–18 x 7/8” (11 mm) shoulder bolt and 5/16” flange nut holding PTO cover down (Fig. 10). 3 3 1 2 2 1 M-4535 Figure 10 m-3209 1. PTO cover 2. Shoulder bolt 5/16–18 x 7/8” (11 mm) Figure 8 1. Spring Assembly 2. Shoulder Bolt 3/8” x 7/8” (22 mm) 3. Locknut 3/8” Note: 7. Remove the block under the carrier frame. 8. Unfold carrier frame. 9.
Installation Note: Remove drive shaft from gearbox shaft if you do not hook up a deck immediately or when putting on optional attachments. 13. Remove (2) 3/8”–16 x 1-5/8” (41.5 mm) bolts and 3/8”–16 locknuts from universal joint and slide the driveshaft off gearbox shaft (Fig. 12). Note: Save all hardware for use when installing mower. 4 3 2 5 m-3198 1 Figure 12 1. PTO Driveshaft 2. Universal Joint 3. Gearbox shaft 8 4. Bolt 3/8”–16 x 1-5/8” (41.5 MM) 5.
Operation Operating the Power Take Off (PTO) 4. To engage lift cover and move the PTO switch to the “ON” position (Fig. 14). Note: The power take off (PTO) switch engages and disengages power to the electric clutch. It is best to engage mower over hard surface or area that has been mowed. Disengaging the PTO Engaging the PTO 1. 1. With engine running, release pressure on the traction control levers and place in neutral (Fig. 13). Closing the cover moves the PTO switch to the “OFF”position (Fig. 14).
Operation Adjusting Height-of-Cut Adjusting Rollers The height-of-cut is adjusted from 1” to 4-1/2” (25 to 115 mm) in 1/2” (13 mm) increments by relocating four clevis pins in different hole locations. The rollers are preset for heights-of-cut above 2” (51 mm) If the height-of-cut is set to the 1” or 1–1/2” (25 or 39 mm) the rollers must be adjusted to the upper hole location. 1. 2. 3. To adjust, remove hairpin cotter and clevis pin from mower hanger bracket (Fig. 15).
Operation Tilting the Mower 4. Standing in front of the mower, lift up and push rearward on front to raise mower (Fig. 18). The mower can be tilted up for ease of service or to shorten unit length for transport and storage. 5. Raise mower until it contacts stops and latch pins snap into locked position. To Raise Mower 1. Lift or push down on side of carrier frame to release weight on latch pin. 2. Pull out on latch pin to release and rotate into notch to hold in the open position (Fig. 17).
Maintenance Service Interval Chart Service Operation Each Use 8 Hours Cutting Blades – check X Push arm bushings – grease X Castor Wheels – grease Storage Service Notes X Initial Gear box – check X X Chipped Surfaces – paint For ease of maintenance and service the mower can be tilted up, refer to: Tilting the Mower, in the Operation section for instructions. Cutting Blades To ensure a superior quality of cut, keep the blades sharp.
Maintenance Inspecting the Blades Checking for Bent Blades 1. Inspect the cutting edges (Fig 19). If the edges are not sharp or have nicks, remove and sharpen the blades. Refer to Sharpening the Blades on page 15. 1. Rotate the blades until the ends face forward and backward (Fig. 20). Measure from a level surface to the cutting edge of the blades (Fig. 21). Note this dimension. 2. Inspect the blades, especially the curved area (Fig. 19).
Maintenance Front 1 1 POTENTIAL HAZARD • A blade that is bent or damaged could break apart and pieces could be thrown at bystanders or at you as you use the mower. WHAT CAN HAPPEN • Pieces of blade that may be thrown could seriously injure or kill you or bystanders. HOW TO AVOID THE HAZARD • Always replace bent or damaged blade with a new blade. • Never file or create sharp notches in the edges or surfaces of blade. 1 m–3372 Figure 22 1. Cutting edge 1.
Maintenance Sharpening the Blades 1. Use a file to sharpen the cutting edge at both ends of the blade (Fig. 24). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges. 1 Correcting Cutting Unit Mismatch If one cutter blade cuts lower than the other, correct as follows: 1. Stop the engine, remove the key and disconnect the spark plug wire(s) from the spark plug(s). 2.
Maintenance Setting the Front-to-Rear Pitch Setting the Side-to-Side Leveling 1. Check the tire pressure on both deck and traction unit. 1. Check the tire pressure on both deck and traction unit. 2. Position one blade front-to-rear (Fig. 26). Measure at “C” and “D” locations (Fig. 26) from a level surface to the cutting edge of the blade tips (Fig. 27). 2. Position the blades side-to-side (Fig.28 ). Measure at “A” and “B” locations (Fig.
Maintenance Greasing and Lubrication Gearbox Fluid The cutting unit must be lubricated regularly. Refer to the Service Interval Chart on page 12. Grease with No. 2 general purpose lithium base or molybdenum base grease. Change fluid: 1. Stop the engine, remove the key and disconnect the spark plug wire(s) from the spark plug(s). 2. Grease the fittings on push arms (Fig. 30). • After initial 100 operating hours. Note: Fluid will not have to be changed again after initial 100 hour fluid change.
Maintenance 3. Raise deck to upright position. Checking Gearbox Fluid 4. With deck raised, remove plug on the bottom side of the gearbox. Let fluid fully drain into a pan. (Fig. 33). The gearbox fluid must be checked after every 100 operating hours. Check all three gearboxes. 5. Reinstall the bottom plug into the gearbox (Fig. 33). 6. Remove the top plug to fill gearbox (Fig. 33). 7. Fill gearbox with 5–1/2 (129.6 ml) ounces of automatic transmission fluid (Dexronr III). 8.
Maintenance Replacing the Castor Wheel Fork Bushings 4. Insert a pin punch into the mounting tube and carefully drive out the bushings (Fig. 35). Clean the inside of the mounting tube. The castor wheel forks are mounted in bushings pressed into the top and bottom of the carrier frame mounting tubes. To check the bushings, move the castor forks back and forth and side-to-side. If a castor fork is loose, the bushings are worn and must be replaced. 5. Grease the inside and outside of the new bushings.
Maintenance Servicing the Castor Wheels and Bearings The castor wheels rotate on a roller bearing supported by a spanner bushing. If the bearing is kept well lubricated, wear will be minimal. Failure to keep the bearing well lubricated will cause rapid wear. A wobbly castor wheel usually indicates a worn bearing. 1. Remove the locknut and wheel bolt holding the castor wheel to the castor fork (Fig. 36). 2.
Maintenance Replacing Push Arm Bushings The push arms have pressed in bushings on the end mounted to the traction unit. To check the bushings, move the push arms side-to-side and examine for wear. If a push arm is loose, the bushings are worn and must be replaced. 1. Remove the mower: refer to Removing the Mower in the Installation section. 2. Inspect the pivot pin assembly for wear and replace if necessary. 3. Remove the retaining ring and flat washer securing the push arm to the mower (Fig. 37). 4.
Maintenance Storage 1. Clean any dirt and chaff from the top of the mower. 2. Scrape any heavy buildup of grass and dirt from the underside of the mower, then wash the mower with a garden hose. 3. Check the condition of the blades. Refer to Cutting Blades on page 12. 4. Check and tighten all bolts, nuts and screws. Repair or replace any damaged or defective parts. 5. Paint all scratched or bare metal surfaces. Paint is available from your Authorized Service Dealer. 6.
Troubleshooting PROBLEM Abnormal vibration. Uneven cutting g height. g Blades do not rotate. POSSIBLE CAUSES CORRECTIVE ACTION 1. Cutting blade(s) is/are bent or unbalanced. 1. Install new cutting blade(s). 2. Blade mounting bolt is loose. 2. Tighten blade mounting bolt. 3. Drive shaft bolts are loose. 3. Tighten drive shaft bolts. 4. Loose gearbox assembly. 4. Tighten the appropriate hardware. 5. Worn gearbox bearings. 5. Replace bearings. 6. Gearbox gears are damaged. 6.