Form No. 3452-348 Rev A Rework Kit F60 Flail Mower Model No. 134-7623 Installation Instructions Installation Loose Parts Use the chart below to verify that all parts have been shipped. Procedure 1 2 3 4 5 6 7 8 9 © 2022—The Toro® Company 8111 Lyndale Avenue South Bloomington, MN 55420 Description Use Qty. No parts required – Prepare the machine. No parts required – Remove the gearbox, belt, pulleys, and PTO guard. Toro spray paint 1 Weld the flail mower.
Procedure Description Qty. Use 10 Sensor bracket Carriage bolt (3/8 x 1-1/4 inches) Flange nut (3/8 inch) 1 2 2 Replace the sensor bracket. 11 No parts required – Install the flail mower to the traction unit. Flap mount Carriage bolt (M8 x 25) Flange nut (M8) PTO guard-bracket assembly Screw (3/8 x 3/4 inch) Carriage bolt (5/16 x 3/4 inch) Flange nut (5/16 inch) 1 6 6 1 2 5 5 14 15 16 17 18 No parts required – Adjust the sensor bracket.
2. 2 Disassemble the PTO guard assembly as shown in Figure 2. Retain the circled parts shown in Figure 1 and Figure 2. Removing the Gearbox, Belt, Pulleys, and PTO Guard No Parts Required Removing the PTO Guard 1. Remove the PTO guard assembly from the gearbox (Figure 1). g385166 Figure 2 1. Flange nut (5/16 inch) 5. Bolt (3/8 inch) 2. PTO guard bracket 6. Carriage bolt (5/16 inch) 3. Nut (3/8 inch) 7. Rubber bumper 4. Gearbox bracket 8. Rubber guard g385446 Figure 1 1. Washer (3/8 inch) 3.
g319558 Figure 3 1. Belt-cover bolts (retained) 2. Remove the belt and pulleys as shown in Figure 4. Retain the circled parts shown in Figure 4. g385167 Figure 4 1. Pulley 8. Flange nut (M10) 2. Bushing (includes 2 grub screws) 9. Nut (M20) 3. Bushing (includes 2 grub screws) 10. Idler pulley 4. Key 11. Tensioning spacer 5. Washer (M10) 12. Large washer 6. Bolt (M10 x 30) 13. Bolt (M20 x 110) 7.
Removing the Gearbox Disassemble and remove the gearbox as shown in Figure 5 Retain the circled parts shown in Figure 5. g385385 Figure 5 1. Gearbox 11. Rubber bushing 2. Bolt (M12 X 60) 12. Spacer 3. Washer (M12) 13. Hex-flange nut (7/16 inch) 4. Back plate 14. Flange nut (M12) 5. Thick spacer 15. Flange nut (M12) 6. Thin spacer 16. Hex-head bolt (3/8 x 3/4 inch) 7. Washer (3/8 inch) 17. Thick spacer 8. Hex-head bolt (3/8 x 7/8 inch) 18. Mounting plate 9.
3 Welding the Flail Mower Parts needed for this procedure: 1 Toro spray paint Procedure Figure 6 indicates the continuous weld areas that must be added to the flail mower. 1. Remove any paint from the indicated weld areas to ensure a continuous weld. 2. Weld the areas shown in Figure 6. Important: Ensure that the welds are continuous without gaps or skips. Do not weld between the lift-arm plates (Figure 6). 3. Remove any weld splatter and ensure that all surfaces are clean. 4.
g384445 Figure 7 2. Line 1. 10 mm (3/8 inch) 2. Align a lift-arm bracket to the marked line and the lower edge of the frame (Figure 8).
g384446 Figure 8 1. Lift-arm bracket 3. Drill hole (10 mm) 2. Line 3. Mark the bracket holes on the frame (Figure 8). 4. Repeat the previous steps for each side of the lift-arm plates (Figure 7). 5. Drill 8 holes (10 mm) into the marks on the lift-arm plates (Figure 8). 6. Use 8 bolts (M10 x 35), 8 flange nuts (M10), 2 carriage bolts (3/8 inch x 4 inches), 2 spacers, and 2 flange nuts (3/8 inch) to secure the lift-arm brackets to the frame (Figure 9).
g384856 Figure 9 1. Carriage bolt (3/8 x 4 inches) 4. Flange nut (M10) 2. Spacer 5. Bolt (M10 x 35) 3.
5 Installing the Debris Skirt to the Flail Mower Parts needed for this procedure: 1 Debris skirt 1 Skirt mount bracket 1 Long rubber securing bracket 10 Clinch nut (M8) 10 Hex-head bolt (M8 x 30) 10 Spring washer 10 Flat washer 9 Carriage bolt (M8 X 25) 9 Flange nut (M8) Adding Bracket-Alignment Lines to the Frame Using a non-permanent marker, mark the following lines onto the frame: • 21 mm (13/16 inch) from the flail side plate • 80 mm (3-1/8 inches) up from the lower outer edge of the
g385183 Figure 10 1. 21 mm (13/16 inch) 3. 41 mm (1-5/8 inches) 2. 80 mm (3-1/8 inches) Drilling Holes and Installing Clinch Nuts to the Frame 1. With an assistant, align the edges of the skirt mount bracket with the marked lines and mark the holes for the 2 outside mount-bracket holes. 2. Drill holes (11 mm) in the 2 marked outer holes. 3. Install 2 clinch nuts into the drilled outer holes. 4. Install the skirt mount bracket to the clinch nuts. 5.
g385184 Figure 11 1. Clinch nut 6. Carriage bolt (M8 X 25) 2. Flat washer 7. Flange nut (M8) 3. Spring washer 8. Long rubber securing bracket 4. Hex-head bolt (M8 x 30) 9. Debris skirt 5. Skirt mount bracket Securing the Skirt Mount Bracket to the Frame Use 10 flat washers, 10 spring washers, and 10 hex-head bolts (M8 x 30) to secure the skirt mount bracket to the clinch nuts on the frame.
Torque the bolts to 45 N∙m (33 ft-lb). 6 Installing the Gearbox to the Back Plate Installing the Gearbox 1. Apply medium-strength thread-locking compound to the 4 hex-head bolts (3/8 x 7/8 inch). 2. Loosely assemble the previously removed 2 bolts (M12 x 60) and M12 washers into the back plate (Figure 12). 3. Use 4 hex-head bolts (3/8 x 7/8 inch) and the previously removed washers to loosely secure the back plate to the gearbox (Figure 12).
Installing the Gearbox to the Flail Mower Refer to Figure 13 for this procedure. 1. Insert the new rubber bushings and the existing metal spacers into the 3 positions on the end of the gearbox. 2. Lower the gearbox into the frame partially inserting the gearbox output shaft through the frame. 3. Ensure that all the spacers are installed in the correct positions and insert the M12 bolts, washers, spacers, and nuts. Leave these fasteners loose. g385397 Figure 13 1. Thick spacer 8.
B. Torque the bolts (M12 X 60) shown in Figure 12 to 100 N∙m (74 ft-lb). C. Torque the hex-head bolts (M12 x 60) shown in Figure 13 to 100 N∙m (74 ft-lb). D. Torque the hex-head bolts (3/8 x 7/8 inch) shown in Figure 12 to 45 N∙m (33 ft-lb). 7 Installing the Belts and Pulleys Parts needed for this procedure: 2 Pulley 1 Idler pulley 1 Thin nut (M20) 1 Belt 2 Spacer Installing the Pulleys Refer to Figure 14 for this procedure. g385448 Figure 14 1. Pulley 5. Washer (M10) 9.
3. Loosely fit the grub screws to the pulleys. Lightly tighten the grub screws so the pulleys can still be moved on the shaft. 4. Use a straight-edge tool to align the pulleys. Ensure that the pulleys are secured past the chamfered edge on the flail-rotor and gearbox shafts. 5. Install a new spacer to the existing bolt (M20 x 110), install the new idler pulley, and the new outside spacer. 6. Ensure that all tension is removed from the tensioning spacer.
9 10 Using the Guard Bracket to Install the Debris Guard Replacing the Sensor Bracket Parts needed for this procedure: Parts needed for this procedure: 1 Guard bracket 1 Sensor bracket 5 Rivet 2 Carriage bolt (3/8 x 1-1/4 inches) 2 Flange nut (3/8 inch) Procedure Procedure Use 5 rivets and the new guard bracket to secure the debris guard to the front axle (Figure 16). 1. Remove the existing sensor bracket from the traction-unit right lift arm. g384845 Figure 17 1.
11 Installing the Flail to the Traction Unit No Parts Required Procedure Install the flail mower to the traction unit; refer to the flail mower Operator’s Manual. 12 Installing the Debris Skirt to the Traction Unit Parts needed for this procedure: 1 Flap mount 6 Carriage bolt (M8 x 25) 6 Flange nut (M8) Procedure Use 6 carriage bolts (M8 x 25), 6 flange nuts (M8), and the flap mount to secure the debris skirt to the axle bracket.
13 Installing the PTO Guard Parts needed for this procedure: 1 PTO guard-bracket assembly 2 Screw (3/8 x 3/4 inch) 5 Carriage bolt (5/16 x 3/4 inch) 5 Flange nut (5/16 inch) Procedure 1. g385446 Use 5 carriage bolts (5/16 x 3/4 inch) and 5 flange nuts (5/16 inch) to secure the new PTO guard bracket to the rubber guard (Figure 19). Figure 20 1. Washer (3/8 inch) 3. PTO guard assembly 2.
properly grease the machine will result in premature failure of critical parts. If the clearance is incorrect, perform the following steps to adjust the sensor bracket: 1. Loosen the locknuts that secure the switch to the switch bracket and adjust it so that the correct clearance exists between the sensor and the sensor plate. 2. Tighten the sensor locknuts from 19 to 21 N·m (14 to 16 ft-lb).
Engaging the LOW RPM PTO ENGAGE Mode Note: LOW RPM PTO ENGAGE mode automatically reduces the engine speed when the PTO is engaged, then automatically raises the engine speed to full speed. For Traction Unit Models 31902 and 31903 Important: Using LOW RPM PTO ENGAGE mode Use the traction-unit display screen to engage LOW RPM PTO ENGAGE mode; refer to your traction unit Operator's Manual. with the flail helps prevent premature driveline wear.
g383974 Figure 22 Several traction-unit parts removed for clarity. 1. Rubber pads 3. Spacers 2. Existing screws (1/4 inch) 4.
Notes:
