Form No. 18235SL Rev C Groundsmaster® 1200 Pull-Behind Rotary Mower © 2021—The Toro® Company 8111 Lyndale Avenue South Bloomington, MN 55420 Original Instructions (EN) Contact us at www.Toro.com.
Revision History Revision Date A 11/2018 Initial issue. B 07/2020 Updated Cutting Unit chapter and added Foldout Drawings. C 06/2021 Updated Chassis chapter.
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Notes: Notes: Page 4 Groundsmaster® 1200 Pull-Behind Rotary Mower 18235SL Rev C
Preface The purpose of this publication is to provide the service technician with the information for troubleshooting, testing, and repair of the major systems and components on the Groundsmaster 1200 Pull-Behind Rotary Mower (Model No. 31905). Refer to the Operator’s Manual for installation, operation, maintenance, and adjustment instructions. Keep a copy of the Operator’s Manual and Parts Catalog for your machine and its accessories with this Service Manual for reference.
g241343 Figure 1 Groundsmaster 1200 Pull-Behind Rotary Mower Preface Page 6 Groundsmaster® 1200 Pull-Behind Rotary Mower 18235SL Rev C
Service Procedure Icons The following icons appear throughout this Service Manual to bring attention to specific important details of a service procedure. Critical Process This icon is used to highlight: • installing safety equipment (shields, guards, seat belts, brakes and R.O.P.S. components) that may have been removed. • dimensions or settings that must be maintained for proper machine operation. • a specific fastener tightening sequence. • component orientation that may not be obvious.
Table of Contents Preface ................................................................................................................ 5 Chapter 1: Safety ............................................................................................ 1–1 Safety Instructions ....................................................................................... 1–2 Safety and Instructional Decals ....................................................................
Chapter 1 Safety Table of Contents Safety Instructions ................................................................................................................................ 1–2 Before Operating the Machine ........................................................................................................... 1–2 While Operating the Machine ............................................................................................................. 1–3 Maintenance and Service.................
Safety Instructions The Groundsmaster 1200 Pull-Behind Rotary Mower machine is tested and certified by Toro for compliance with existing safety standards and specifications. Hazard control and accident prevention are partially dependent upon the design and configuration of the machine. They are also dependent upon awareness, concern and proper training of the personnel involved in the operation, transport, maintenance and storage of the machine.
While Operating the Machine • Operate the machine cutting units only in well-lit areas. • Watch for holes or other hidden hazards. • Do not drive close to sand traps, ditches, creeks, or other hazards. • Reduce speed when making sharp turns. Avoid sudden stops and starts. • Before backing up, look to the rear to ensure no one is behind the machine. • Watch out for traffic when near or crossing roads. Always yield the right-of-way.
Maintenance and Service The maintenance procedures and recommended service intervals for the Groundsmaster 1200 Pull-Behind Rotary Mower is covered in the Groundsmaster 1200 Operator’s Manual. Refer to this publication when performing the regular equipment maintenance. Several maintenance procedures have break-in intervals identified in the operators manual.
Safety and Instructional Decals Numerous safety and instruction decals are affixed to the Groundsmaster 1200 Pull-Behind Rotary Mower. If any decal becomes illegible or damaged, install a new decal. Decal part numbers are listed in the Groundsmaster 1200 Parts Catalog. Order replacement decals from Authorized Toro Distributor.
Safety: Safety and Instructional Decals Page 1–6 Groundsmaster® 1200 Pull-Behind Rotary Mower 18235SL Rev C
Chapter 2 Specifications and Maintenance Table of Contents Specifications ....................................................................................................................................... 2–2 Overall Dimensions............................................................................................................................ 2–2 Chassis ..............................................................................................................................................
Specifications Overall Dimensions g241347 Figure 2 Groundsmaster 1200 Pull-Behind Rotary Mower Cutting Units Lowered (Mow Position) Specifications and Maintenance: Specifications Page 2–2 Groundsmaster® 1200 Pull-Behind Rotary Mower 18235SL Rev C
Overall Dimensions (continued) g265562 Figure 3 Groundsmaster 1200 Pull-Behind Rotary Mower Cutting Units Raised (Transport Position) Groundsmaster® 1200 Pull-Behind Rotary Mower 18235SL Rev C Page 2–3 Specifications and Maintenance: Specifications
Chassis Item Description Tire size 20 x 10 - 10, 6 ply, Tubeless Tire pressure 206.8 kPa (30 psi) Wheel lug nut torque 75 to 101 N∙m (55 to 75 ft-lb) Torsion axle bolt 37 to 45 N∙m (27 to 33 ft-lb) Cutting Units Mounting Cutting units are supported by lift arms, controlled with hydraulic lift cylinders Construction Cutting unit decks are welded steel, reinforced with channels and plates Height−of−cut range 13 to 102 mm (0.
Torque Specifications The recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in this manual. These torque specifications for the installation and tightening of the fasteners will apply to all the fasteners which do not have a specific requirement identified in this manual.
Identifying the Fastener g206088 Figure 5 Inch Series Bolts and Screws 1. Grade 1 2. Grade 5 3. Grade 8 g206089 Figure 6 Metric Bolts and Screws 1. Class 8.8 2. Class 10.9 Fasteners with a Locking Feature IMPORTANT If a fastener with a locking feature or previously applied thread locking compound is reused, clean the fastener threads and apply new thread locker to the fastener during installation. Locking features are designed to create friction and prevent a fastener from loosening.
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size # 6 - 32 UNC # 6 - 40 UNF # 8 - 32 UNC # 8 - 36 UNF # 10 - 24 UNC # 10 - 32 UNF Grade 1, 5 and 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, and Studs with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in-lb in-lb N∙cm 10 ± 2 13 ± 2 147 ± 23 13 ± 2 25 ± 5 282 ± 56 18 ± 2 30 ± 5 339 ± 56 SAE Grade 5 Bolts, Screws, and Studs with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) SAE Grade
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) Thread Size Class 8.8 Bolts, Screws, and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws, and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.8 57 ± 6 in-lb 644 ± 68 N∙cm 78 ± 8 in-lb 881 ± 90 N∙cm M6 X 1.0 96 ± 10 in-lb 1085 ± 113 N∙cm 133 ± 14 in-lb 1503 ± 158 N∙cm M8 X 1.25 19 ± 2 ft-lb 26 ± 3 N∙m 28 ± 3 ft-lb 38 ± 4 N∙m M10 X 1.
Other Torque Specifications (continued) Wheel Bolts and Lug Nuts Thread Size Recommended Torque* 7/16 - 20 UNF Grade 5 65 ± 10 ft-lb 88 ± 14 N∙m 1/2 - 20 UNF Grade 5 80 ± 10 ft-lb 108 ± 14 N∙m M12 X 1.25 Class 8.8 80 ± 10 ft-lb 108 ± 14 N∙m M12 X 1.5 Class 8.8 80 ± 10 ft-lb 108 ± 14 N∙m *For steel wheels and non-lubricated fasteners Thread Cutting Screws (Zinc Plated Steel) Thread Size Threads per Inch Baseline Torque** Type A Type B No. 6 18 20 20 ± 5 in-lb No.
Shop Supplies The procedures found in this Service Manual may recommend the use of commonly used shop supplies (lubricants, sealants and adhesives). A symbol denoting the use of a shop supply may appear in figures that support a procedure. Always refer to the written procedure for specific information regarding the type and the application of a shop supply. IMPORTANT Always follow manufacturers instructions when using or storing shop supplies.
GASKET COMPOUND Used to create a seal between mating parts. Gasket compounds may be used with or without the presence of a pre-formed gasket. Gasket compounds may be solvent or silicone based, and cure when exposed to air or designed to cure in an air-less environment (anaerobic). Most gasket compounds are designed to be applied to clean surfaces free of oil, chemical residue and previously used gaskets or gasket compounds.
Special Tools You can order these special tools from your Toro Distributor. Some tools may also be available from a local tool supplier. Hydraulic O-Ring Kit Toro Part No. 117-2727 This kit includes O-rings in a variety of sizes for the face seal and port seal hydraulic connections. To help prevent a hydraulic leak, replace the O-rings when you open the hydraulic connection.
Troubleshooting There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf conditions. Conditions such as the excessive thatch, sponginess, or attempting to cut off too much grass height may not always be overcome by adjusting the cutting unit or machine. It is important to remember that the lower the height-of-cut setting, the more critical these factors are.
GEARS – The Systematic Approach to Defining, Diagnosing and Solving Problems Gather Information • Information reported by the customer. • Information observed by you. • Establish the what, where, and when of the issue. Evaluate Potential Causes • Consider possible causes of the problem to develop a hypothesis. • Narrow down the focus of the problem. Assess Performance • Ensure you have all the necessary tools for testing. • Test all potential causes of the failure.
Chapter 3 Chassis Table of Contents General Information .............................................................................................................................. 3–2 Service and Repairs ............................................................................................................................. 3–3 Wheels ............................................................................................................................................... 3–3 Wheel Bearings.....
General Information The operators manuals provides information regarding the operation, general maintenance, and maintenance intervals for your Groundsmaster 1200 Pull-Behind Rotary Mower. Refer to the operators manual for additional information when servicing the machine.
Service and Repairs Wheels g241364 Figure 7 1. Wheel and tire assembly 3. Wheel hub assembly 2. Wheel lug nut (5 each per wheel) 4. Torsion axle Removing the Wheel 1. Park the machine on a level surface, lower the cutting units and disengage the PTO. Remove the main drive shaft and disconnect the machine from the tow vehicle. Secure the machine with tow bar jack (refer to the Groundsmaster 1200 Operator’s Manual for further instructions on the proper way to use the tow bar jack). 2.
Removing the Wheel (continued) IMPORTANT Before lifting the machine with a jack, review and follow the Jacking Instructions from the Groundsmaster 1200 Operator’s Manual. 5. Jack the machine up until the wheel is off the ground. Support the machine with appropriate jack stands. 6. Remove the 5 wheel-lug nuts (2) and remove the wheel. Installing the Wheel 1. Install the wheel (1) to the wheel hub assembly (3). 2. Install the 5 lug nuts until they are snug. 3. Lower the machine to the ground.
Wheel Bearings g241363 Figure 8 1. Torsion axle 5. Wheel hub 2. Oil seal 6. Spindle washer 3. Bearing cone (2 each per axle) 7. Slotted nut 4. Bearing cup (2 each per axle) 8. Dust cap 9. 10. Drive studs (5 each per hub) Cotter pin Disassembling the Wheel Bearings Note: Refer to Figure 8 during this procedure. 1. Park the machine on a level surface, lower the cutting units and disengage the PTO. Remove the main drive shaft and disconnect the machine from the tow vehicle.
Disassembling the Wheel Bearings (continued) 6. Straighten and remove the cotter pin (10) from the torsion axle. 7. Remove the slotted nut (7) and spindle washer (6) that secure the wheel hub (5) to the torsion axle (1). 8. Slide and remove the wheel hub (5) from the torsion axle (1). 9. Disassemble the wheel hub (5) as follows: Note: Ensure that you do not damage the hub bore. A. Pull the oil seal (2) out of the wheel hub. Discard the used oil seal. B.
Assembling the Wheel Bearings (continued) 5. Rotate the wheel hub and tighten the slotted nut (7) to a final torque of 1.7 to 2.3 N·m (15 to 20 in-lb). After you torque the nut, ensure that the wheel hub (5) does not wobble as it turns. 6. Tighten the nut until the next-possible cotter pin hole in the nut is aligned. Install the cotter pin (10) to secure the slotted nut. 7. Install the dust cap (8). 8. Install the wheel; refer to Installing the Wheel (page 3–4). 9.
Torsion Axle Assembly g241362 Figure 9 1. Flange head bolt (6 each) 4. Nut (4 each) 2. Rubber flap 5. Nut (6 each) 3. Flange head bolt (4 each) 6. Torsion axle 7. Flap bracket Replacement torsion axle assemblies are supplied with new wheel hub assemblies already installed. Removing the Torsion Axle Assembly Note: Refer to Figure 9 during this procedure. 1. Park the machine on a level surface, lower the cutting units and disengage the PTO.
Removing the Torsion Axle Assembly (continued) 5. If necessary, remove the wheel bearings; refer to Disassembling the Wheel Bearings (page 3–5). 6. Remove the 6 nuts (5) and bolts (1) that secures the torsion axle (6) and flap bracket (7) to the frame assembly. 7. Remove the torsion axle (6) and flap bracket (7) from the frame assembly. 8. If necessary, remove the 4 nuts (4) and bolts (3) that secures the rubber flap (2) to the flap bracket (7). Remove the rubber flap from the flap bracket. 9.
Hitch Assembly g264027 Figure 10 1. Bolt (2 each) 6. Hose guide (2 each) 11. Flange bushing 2. Flat washer (2 each) 7. Hitch assembly 12. Clevis assembly 3. Nut (4 each) 8. Hitch pin assembly 13. Flat washer (2 each) Hair pin 14. Bolt (2 each) Nut (2 each) 15. Tow bar jack 4. Frame assembly 5. Nut (2 each) 9. 10. Disassembling the Hitch Assembly Note: Refer to Figure 10 during this procedure. 1.
Disassembling the Hitch Assembly (continued) D. Remove the clevis assembly (12) from the hitch assembly (7). 5. If necessary, remove the 2 nuts (3) that secures the hose guide (6) to the frame assembly (4). Remove the hose guides from the frame assembly. Assembling the Hitch Assembly 1. If removed, install the hose guides (6) to the frame assembly (4) and secure with the 2 nuts (3). 2. Assemble the hitch assembly (7) as follows: A.
Side Cutting Unit Lift Arm Assembly g241354 Figure 11 Right side lift arm assembly (shown) 1. Impact arm assembly 6. Washer (2 each) 11. Bolt 2. Lift cylinder 7. Pin 12. Latch wing pin assembly 3. Lift arm (RH shown) 8. Lift arm pin assembly 13. Bolt 4. Grease fitting (2 each) 9. Bolt 14. Frame assembly 5. Snap ring (2 each) 10. Lift cylinder pin assembly Removing the Side Cutting Unit Lift Arm Assembly Note: Refer to Figure 11 during this procedure. 1.
Removing the Side Cutting Unit Lift Arm Assembly (continued) g264331 Figure 12 1. Flange bushing (2 each) 3. Straight bushing (2 each) 2. Lift arm assembly 4. Grease fitting 7. If necessary, remove the grease fitting (item 4 in Figure 12), flange bushings (1) and straight bushings (3) from the lift arm assembly (2). 8. Thoroughly clean the lift arm assembly bores (2). Installing the Side Cutting Unit Lift Arm Assembly 1.
Lift Arm Joint Yoke (side cutting units only) g241365 Figure 13 Left Side Cutting Unit (shown) 1. Cotter pin 7. Base mount (2 each) 13. Bolt plate (2 each) 2. Slotted hex nut 8. Shim (2 each) 14. Deck mount assembly 3. Hardened washer 9. Spacer - 4.2 mm (0.165 in) 15. Cutting unit 4. Thrust washer - 3.2 mm (0.125 in) 10. (2 each) Joint yoke 16. Lift arm 5. Impact arm 11. Bolt (8 each) 17. Thrust washer - 0.8 mm (0.032 in) 6. Grease fitting 12.
Removing the Lift Arm Joint Yoke (continued) 3. Remove the cotter pin (1), slotted hex nut (2), hardened washer (3) and thrust washers (4 and 17) from joint yoke shaft. 4. Remove the 8 bolts (11), hardened washers (12) and 2 bolt plates (13) that secure the base mounts to the deck mount assembly (14). 5. Raise the lift arm assembly (16) enough to free the joint yoke (10) and base mounts (7) from the lift arm assembly and deck mount assembly (14). 6.
Disassembling the Joint Yoke (continued) D. Repeat process for remaining bearing. E. Thoroughly clean and inspect all components. Assembling the Joint Yoke 1. Apply a coating of grease to the bearing bores of the yoke and base mounts. Also, apply grease to the bearings and seals of the cross assembly. 2. Press one bearing partially into the yoke. IMPORTANT Take care when installing the cross into the bearing to avoid damaging the bearing seal. 3. Carefully insert the cross into the bearing and yoke. 4.
Installing the Lift Arm Joint Yoke (continued) 3. Install the shims (8) between the cutting unit connection and base mounts and secure the base mounts with 8 cap screws (11), hardened washers (12) and 2 bolt plates (13). Tighten the bolts (11) from 53 to 64 N·m (39 to 47 ft−lb). 4. Grease the joint yoke and lift arm bushing after installation. 5.
Rear Cutting Unit Lift Arm Assembly g241358 Figure 15 1. Lock nut 8. Retaining ring (2 each) 15. Washer head bolt 2. Hub support assembly 9. Thrust washer (2 each) 16. Lift arm pin assembly 3. Tapered stud 10. Lift arm LH assembly 17. Hex nut 4. Grease fitting 11. Cylinder pin 18. Bolt 5. Spherical bearing 12. Grease fitting 19. Lift arm RH assembly 6. Retaining ring 13. Roller 20. Flat washer 7. Flange nut 14.
Removing the Rear Cutting Unit Lift Arm Assembly (continued) 6. Remove the nuts, bolts and washers that secures the hub support assembly to the cutting unit assembly. 7. Remove the cutting unit lift arm assembly from the machine. 8. As required, disassemble the lift arm assembly: A. Remove the flange nut (7) and carefully drive the tapered shaft and hub support from the lift arm. B. Remove the retaining ring and spherical bearing from the lift arm. C. Press the flange bushing from the lift arm.
Installing the Rear Cutting Unit Lift Arm Assembly (continued) D. Thoroughly clean the tapered surfaces of the stud (3) and mounting boss of hub support. Secure the hub support to tapered stud with a flat washer and lock nut. Tighten the lock nut (1) from 184 to 223 N·m (135 to 165 ft-lb). 2. Position the slotted hole of the hub supports toward the rear of the machine and install the cutting unit lift arm assembly (10) to the cutting unit and secure with 4 nuts, bolts and washers. 3.
Impact Arm Assembly g241352 Figure 17 1. Rod end 9. Jam nut (2 each) 17. Spacer tube 2. Jam nut 10. Pipe plug 18. Pivot hub 3. Spring shaft 11. Bolt 19. Flange bushing (2 each) 4. Housing 12. Flat washer (2 each) 20. Grease fitting 5. Washer (3 each) 13. Lock nut 21. Lift arm pin assembly 6. Spring 14. Flange nut (4 each) 22. Bolt 7. Plastic bearing 15. Impact arm housing 23. Bolt (4 each) 8. Flat washer 16. Flange bushing (2 each) 24.
Removing the Impact Arm Assembly (continued) g254260 Figure 18 1. Impact arm assembly 6. 2. Bolt 7. Thrust washer 12. Nut (4 each) 3. Spindle spacer (2 each) 8. Nut (2 each) 13. Carriage bolt (4 each) 4. Lock nut Bolt (2 each) 14. Cutting unit 5. Nut 9. 10. Hardened washer 11. Deck mount assembly Lift arm assembly 2. Remove the nut (item 4 in Figure 18), spacers (3) and the bolt (2) that secures the impact arm assembly (1) to cutting unit assembly (14). 3.
Disassembling the Impact Arm Assembly 1. Disassemble the impact arm assembly (15) and pivot hub (18) as required. 2. Thoroughly clean the impact arm components and inspect for worn parts. Replace components as needed. Assembling the Impact Arm Assembly 1. Slide the washer (5), compression spring (6), second washer (5), plastic bearing (7), third washer (5), flat washer (8) and one jam nut (9) onto the spring shaft (3). Tighten jam nut so that spring length is 30.4 cm (12 inch). 2.
Assembling the Impact Arm Assembly (continued) g241353 Figure 19 10. Thread rod end (1) with jam nut (2) into end of the spring shaft so that distance from center of the impact housing mounting hole is from 73.4 to 73.7 cm (28.91 to 29.03 in); refer to Figure 19. Do not tighten the jam nut until the impact arm is installed to cutting unit. Installing the Impact Arm Assembly 1. Install the new pivot hub bushings (16 and 19). 2. Install the grease fitting (20) onto the pivot hub (18).
Latch Linkage Assembly g243402 Figure 20 Side Cutting Unit Assembly (shown) 1. Latch spacer 6. Hex nut (left or right-hand thread) (2 each) 11. Wing latch pin assembly 2. Wing latch 7. Quadrant linkage rod 12. Washer head bolt 3. Latch spacer 8. Flat head nut 13. Yoke linkage 4. Rod end (left-hand thread) 9. Lock washer (2 each) 14. Clevis spring pin 5. Bolt 10. Latch shaft assembly The entire latch linkage assembly must be secure and move freely.
Latch Linkage Assembly (continued) g243403 Figure 21 Rear Cutting Unit Assembly (shown) 1. 2. Rear latch Washer head bolt 7. 8. Flat washer Linkage brake yoke 13. 14. Bolt Rod end (left or right-hand thread) 3. Latch pin assembly 9. Hex nut (left or right-hand thread) (2 each) 15. Lock washer 4. Thrust washer 10. Latch shaft assembly 16. Flat head nut 5. Retaining ring 11. Bolt (2 each) 17. Quadrant linkage rod 6. Clevis spring pin 12.
Chapter 4 Hydraulic System Table of Contents General Information .............................................................................................................................. 4–2 Hydraulic Hoses................................................................................................................................. 4–2 Installing Hydraulic Hoses and Tubes (O-Ring Face Seal) .................................................................
General Information The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your Groundsmaster 1200 Pull-Behind Rotary Mower. Refer to the Operator’s Manual for additional information when servicing the Groundsmaster 1200 Pull-Behind Rotary Mower.
Installing Hydraulic Hoses and Tubes (O-Ring Face Seal) g212099 Figure 22 1. Tube or hose 2. Swivel nut 3. 4. O-ring Fitting body 1. Ensure that all the threads, the sealing surfaces of the hose/tube, and the fitting are free of burrs, nicks, scratches, or unwanted material. 2. To help prevent a hydraulic leak, replace the face seal O-ring when you open the connection. Ensure that the O-ring is installed and correctly seated in the groove of the fitting.
Installing Hydraulic Hoses and Tubes (O-Ring Face Seal) (continued) Hose/Tube Installation Torque Table Fitting Dash Size Hose/Tube Side Thread Size (inch(es)—threads per inch) Installation Torque 4 9/16—18 25 to 29 N∙m (18 to 22 ft-lb) 6 11/16—16 37 to 44 N∙m (27 to 33 ft-lb) 8 13/16—16 51 to 63 N∙m (37 to 47 ft-lb) 10 1—14 82 to 100 N∙m (60 to 74 ft-lb) 12 1–3/16—12 116 to 142 N∙m (85 to 105 ft-lb) 16 1–7/16—12 150 to 184 N∙m (110 to 136 ft-lb) 20 1–11/16—12 190 to 233 N∙m (140 to 1
Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) Installing a Non-Adjustable Fitting g212226 Figure 24 1. Fitting 2. O-ring 1. Ensure that all the threads, the sealing surfaces of fitting, and the component port are free of burrs, nicks, scratches, or unwanted material. 2. To help prevent a hydraulic leak, replace the O-ring when you open the connection. 3. Lightly lubricate the O-ring with clean hydraulic fluid.
Installing an Adjustable Fitting g212224 Figure 25 1. Locknut 2. Back-up washer 3. O-ring g212225 Figure 26 1. Step 1: clearance the lock nut 3. Step 3: align the fitting 2. Step 2: seat the back-up washer 4. Step 4: tighten the lock nut 1. Ensure that all the threads, the sealing surfaces of fitting, and the component port are free of burrs, nicks, scratches, or unwanted material. 2. To help prevent a hydraulic leak, replace the O-ring when you open the connection. 3.
Installing an Adjustable Fitting (continued) 7. Tighten the fitting lock nut (Step 4 in Figure 26): A. Hold the fitting in the correct alignment with a wrench and use a torque wrench and tighten the lock nut to the recommended torque value within the specified range of torque values; refer to the Fitting Installation Torque Table (page 4–7). This tightening procedure requires a drive-adapter wrench (e.g., crowfoot wrench); refer to Calculating the Torque Values When Using a Drive-Adapter Wrench (page 2–5).
Hydraulic Schematic g267285 Figure 27 Hydraulic System: Hydraulic Schematic Page 4–8 Groundsmaster® 1200 Pull-Behind Rotary Mower 18235SL Rev C
Service and Repairs Cutting Unit Lift Cylinder g241355 Figure 28 1. Impact arm assembly 5. Snap ring (2 each) 2. Lift cylinder 6. Washer (2 each) 10. Lift cylinder pin assembly 11. Bolt 3. Lift arm (RH shown) 7. Pin 4. Grease fitting (2 each) 8. Lift arm pin assembly 9. Bolt Removing the Cutting Unit Lift Cylinder Note: Refer to Figure 28 during this procedure. 1. Park the machine on a level surface, lower the cutting units and disengage the PTO.
Removing the Cutting Unit Lift Cylinder (continued) WARNING Ensure that the cutting units are fully lowered before loosening any of the machine hydraulic lines. If cutting units are not fully lowered as the hydraulic lines are loosened, the cutting unit may drop unexpectedly. Note: To ease assembly, label all hydraulic hoses prior to disassembly to identify their correct position on the lift cylinder (item 2 in Figure 28). 3. Disconnect the hydraulic hoses from the lift cylinder fittings.
Servicing the Cutting Unit Lift Cylinder g241356 Figure 29 Side Cutting Unit Cylinder (shown) 1. Lock nut 6. Barrel assembly 11. External collar 2. Piston 7. Shaft assembly 12. BT seal 3. O-ring 8. Head 13. Dust seal 4. Piston seal 9. O-ring 14. Square O-ring 5. O-ring Back−up ring 15. Set screw (2 each) 10. Disassembly of the Cutting Unit Lift Cylinder Note: Refer to Figure 29 during this procedure. 1.
Disassembly of the Cutting Unit Lift Cylinder (continued) IMPORTANT Prevent damage when clamping the cylinder’s barrel into a vise; clamp on the barrel clevis only. Do not close vise on barrel. 2. Mount the lift cylinder in vise equipped with the soft jaws by clamping in the barrel clevis. 3. Remove the 2 set screws from the collar and remove the collar from the cylinder barrel. 4. Extract shaft assembly (7) with head (8) and piston (2) by carefully twisting and pulling the shaft.
Assembly of the Cutting Unit Lift Cylinder (continued) C. Secure the piston (2) to the shaft with the lock nut (1). Tighten lock nut: • Side cutting unit cylinder 5/8 in. lock nut to 102 Nm (75 ft-lb). • Rear cutting unit cylinder 1/2 in. lock nut to 54 Nm (40 ft-lb). 4. Lubricate head and piston with clean hydraulic oil. Slide the shaft assembly carefully into the cylinder barrel. IMPORTANT Prevent damage when clamping the cylinder’s barrel into a vise; clamp on the barrel clevis only.
Hydraulic Hoses g251725 Figure 30 1. Cylinder assembly (2 each) 7. Hose assembly (2 each) 13. Tube assembly 2. Straight fitting 8. Flat head nut 14. Tube clamp 3. Orifice straight fitting 9. 4. Hydraulic hose (2 each) 5. 6. Tube assembly 15. Flat head screw 10. Flat head screw (2 each) 16. Hydraulic hose (2 each) Tee fitting (2 each) 11. Manifold 17. Hydraulic hose (2 each) Cylinder assembly (2 each) 12. Elbow fitting 18.
Chapter 5 Cutting Unit Drive Table of Contents General Information .............................................................................................................................. 5–2 Service and Repairs ............................................................................................................................. 5–3 Main Drive Shaft ................................................................................................................................
General Information The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your Groundsmaster 1200 Pull-Behind Rotary Mower. Refer to the Operator’s Manual for additional information when servicing the Groundsmaster 1200 Pull-Behind Rotary Mower.
Service and Repairs Main Drive Shaft g241357 Figure 31 1. Main drive shaft 3. Quick release pin 2. Center gear box shaft 4. Clamp Removing the Main Drive Shaft 1. Park the machine on a level surface, lower the cutting units and disengage the PTO. Remove the main drive shaft and disconnect the machine from the tow vehicle. Secure the machine with tow bar jack; refer to the Groundsmaster 1200 Operator’s Manual.
Installing the Main Drive shaft g263851 Figure 32 1. Yoke 5. Outer shield tube 9. Inner tube yoke 2. 3. Shield cone Central body 6. 7. Outer cardan tube Inner shield tube 10. 11. Shield cone Yoke 4. Outer tube yoke 8. Inner cardan tube 12. Shield chain IMPORTANT If the drive shaft tube and shaft were separated, ensure that the slip shaft yoke and slip tube yoke are aligned when the tube and shaft are assembled.
Cutting Unit Drive Shafts g241350 Figure 33 1. Cutting unit gear box 3. Cutting unit drive shaft 2. Quick release pin 4. Center gear box Removing the Cutting Unit Drive Shafts 1. Park the machine on a level surface, lower the cutting units and disengage the PTO. Remove the main drive shaft and disconnect the machine from the tow vehicle. Secure the machine with tow bar jack; refer to the Groundsmaster 1200 Operator’s Manual.
Removing the Cutting Unit Drive Shafts (continued) g263855 Figure 34 1. Cutting unit gear box 3. Cutting unit drive shaft 2. Clamp (2 each) 4. Main gear box 2. Disconnect the cutting unit drive shaft (3) from the centre gear box shaft (4) as follows: A. Loosen the clamp (2) and slide the shield cone (10) on the cutting unit drive shaft (3). B. Press and hold the quick release pin and (2) on the end yoke (11) of the cutting unit drive shaft (3). C.
Installing the Cutting Unit Drive Shafts g263852 Figure 35 1. Yoke 5. Slip tube 2. 3. Shield cone Slip tube yoke 6. 7. Inner shield tube Slip shaft 4. Outer shield tube 8. Slip shaft yoke 9. Shield cone 10. 11. Yoke Shield chain IMPORTANT If the cutting unit drive shaft tube and shaft were separated, ensure that the slip shaft yoke and slip tube yoke are aligned when the tube and shaft are assembled.
Installing the Cutting Unit Drive Shafts (continued) A. Align the splines on the cutting unit gear shaft (1) to the cutting unit drive shaft and press the quick release pin (2) and slide the cutting unit drive shaft onto the cutting unit gear shaft. B. Release the quick release pin (2) and check the locking of drive shaft (3) by slightly pulling backward. 4. Repeat steps 2 and 3 for the left hand drive shaft. 5. Repeat steps 2 and 3 for the rear drive shaft. 6.
Servicing the Drive Shaft g241349 Figure 36 Cutting Unit Drive Shaft (shown) 1. End yoke 3. Grease fitting 5. Slip tube yoke 2. Universal joint kit (cross and bearings) (2 each) 4. Slip shaft yoke 6. End yoke Disassembling the Drive Shaft 1. Remove the cutting unit drive shaft from the machine; refer to Removing the Cutting Unit Drive Shafts (page 5–5). 2. Remove the snap rings (3) that secure the bearings in the yokes.
Assembling the Drive Shaft g241348 Figure 37 Cutting Unit Drive Shaft (shown) 1. End yoke 3. Retaining ring 2. Cross and bearing kit 4. Shaft yoke 5. Grease fitting 1. Install new cross and bearings as follows: A. Apply a thick layer of grease to the bearing bores in the end yoke and shaft yoke. B. Press 1 bearing partially into the yoke. C. Insert the cross into the yoke and bearing. D. Hold the cross in alignment and press the bearing in until it hits the yoke. E.
Cutting Unit Gear Box g255202 Figure 38 1. Gear box 4. Bolt (4 each) 7. Drive pulley 2. Key 5. Set screw (2 each) 8. Cutting unit 3. Deck mount assembly 6. Taper lock bushing Removing the Cutting Unit Gear Box Note: Refer toFigure 38 during this procedure. 1. Park the machine on a level surface, lower the cutting units and disengage the PTO. Remove the main drive shaft and disconnect the machine from the tow vehicle.
Removing the Cutting Unit Gear Box (continued) 5. Remove the drive pulley (7) from the gear box shaft (1) as follows: A. Remove the 2 set screws (5) that secure the taper lock bushing (6) to the drive pulley (7) on the cutting unit gear box shaft. g266928 Figure 39 1. Set screw installation position 4. Taper lock bushing 2. Set screw removal position 5. Key 3. Drive pulley B. Install 1 of the removed set screws into the threaded hole of the bushing; refer to Figure 39.
Installing the Cutting Unit Gear Box g263967 Figure 40 1. Right cutting unit gear box 2. Center cutting unit gear box 3. Left cutting unit gear box 1. If removed, fill the cutting unit gear box (1) with 1.06 L (1.13 qt) of Toro premium tractor fluid or Mobil 424. 2. If oil seals were removed from the cutting unit gear box, install new seals to the cutting unit gear box (1). 3. Clean the bolts (4) and apply blue loctite (Toro part number 114-5069) to the threads of the bolts (4). 4.
Installing the Cutting Unit Gear Box (continued) 7. Position the key (item 2 in Figure 38), pulley, and then the taper lock bushing (6) to the cutting unit gear box output shaft (1). Slide the taper lock bushing (6) onto the shaft. Align the threaded holes of the pulley with the non-threaded holes of the taper lock bushing (6). 8. Make sure that the bottom of the taper lock bushing (6) is 15.5 mm (0.61 in) from end of the gear box output shaft. 9.
Center Gear Box g241346 Figure 42 1. Bolt (4 each) 3. Center gear box 2. Frame assembly 4. Washer (4 each) Removal of Center Gear Box Note: Refer to Figure 42 during this procedure. 1. Park the machine on a level surface, lower the cutting units and disengage the PTO. Remove the main drive shaft and disconnect the machine from the tow vehicle. Secure the machine with tow bar jack; refer to the Groundsmaster 1200 Operator’s Manual. 2.
Removal of Center Gear Box (continued) 6. If necessary, remove and replace the oil seals in the center gear box. Note: The gear box replacement is necessary as the internal gear box components are not available separately. Installing the Center Gear Box g263989 Figure 43 1. Input shaft 4. Output shaft to right cutting unit 2. Output shaft to left cutting unit 5. Dip stick 3. Output shaft to rear cutting unit (no bolts surface) 1.
Chapter 6 Cutting Units Table of Contents General Information .............................................................................................................................. 6–2 Operator's Manual.............................................................................................................................. 6–2 Adjustments ..........................................................................................................................................
General Information Operator's Manual The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for the cutting unit on your machine. Refer to the Operator’s Manual for additional information when servicing the cutting unit.
Adjustments CAUTION Do not work on the cutting unit or lift arms with the tow vehicle engine running. Always shut off the engine and remove the key from the key switch of the tow vehicle before working on the cutting unit. Refer to the Operator’s Manual for cutting unit adjustment procedures.
Service and Repairs WARNING Do not start the engine and engage the PTO switch when the PTO drive shaft is disconnected from the cutting unit. If you start the engine and the PTO shaft is allowed to rotate, serious personal injury and machine damage could result. CAUTION Do not work on the cutting unit or lift arms with the tow vehicle engine running. Always shut off the engine and remove the key from the key switch of the tow vehicle before working on the cutting unit.
Deck Mount Assembly g254260 Figure 44 1. Impact arm assembly 6. Hardened washer 11. Deck mount assembly 2. Bolt 7. Thrust washer 12. Nut (4 each) 3. Spindle spacer (2 each) 8. Nut (2 each) 13. Carriage bolt (4 each) 4. Lock nut 9. Bolt (2 each) 14. Cutting unit 5. Nut 10. Lift arm assembly Removing the Deck Mount Assembly Note: Refer to Figure 44 during this procedure. 1. Park the machine on a level surface, lower the cutting units and disengage the PTO.
Removing the Deck Mount Assembly (continued) 5. Disconnect the impact arm assembly (1) from cutting unit assembly (14) by removing the nut (3), spacers (3) and bolt (2); refer to Removing the Impact Arm Assembly (page 3–21). 6. Remove the lift arm assembly (10) from the cutting unit assembly (14); refer to Removing the Lift Arm Joint Yoke (page 3–14) and Removing the Rear Cutting Unit Lift Arm Assembly (page 3–18). 7.
Removing the Deck Mount Assembly (continued) 11. If necessary, remove the 2 screws (5 in Figure 45) that secures the bumper pad (4) to the deck stop assembly (3). Remove the bumper pad from the deck stop assembly. Installing the Deck Mount Assembly 1. If removed, install the bumper pad (4) onto the deck stop assembly (3) and secure with the 2 screws (5) and nuts (1). Ensure that the heads of screws are flushed and recessed to 1.5 mm (0.06 in) with the bumper pads (4). 2.
Idler Assemblies g241351 Figure 46 1. Grease fitting 6. Flat washer 11. Button head screw 2. Retaining ring 7. Grease fitting 12. Washer 3. Flange bushing (2 each) 8. Locknut 13. Cutting unit 4. Idler arm 9. Flat washer 14. Idler pivot 5. Torsion spring 10. Idler spacer 15. Lock washer Removing the Idler Assembly Note: Refer to Figure 46 during this procedure. 1. Park the machine on a level surface, lower the cutting units and disengage the PTO.
Removing the Idler Assembly (continued) 4. Remove the retaining ring (2) that secures the idler assembly to the idler pivot (14). CAUTION The torsion spring (5) is under heavy load and can cause personal injury. Be careful when removing the tension from the torsion spring of the idler arm. 5. For additional leverage, slide a nut driver or small piece of pipe onto either end of the idler arm torsion spring (5).
Installing the Idler Assembly 1. Assemble the idler components as shown in Figure 46. 2. If removed, install the flat washer (6) over the idler pivot (14). CAUTION The spring is under heavy load and can cause personal injury. Be careful when applying the tension from the torsion spring of the idler arm. 3. For additional leverage, slide nut driver or small piece of pipe onto either end of the idler arm torsion spring (5).
Blade Spindles g241342 Figure 48 1. Ribbed neck bolt (8 each per spindle) 6. Anti-scalp cup (3 each) 11. Drive pulley 2. Grease nipple 7. Cutting blade (3 each) 12. Drive belt (2 each) 3. Left spindle assembly 8. Right spindle assembly 13. Flange nut (24 each) 4. Cutting unit 9. Idler assembly (2 each) 5. Blade bolt (3 each) 10. Center spindle assembly Removing the Blade Spindle Note: Refer to Figure 48 during this procedure. 1.
Removing the Blade Spindle (continued) CAUTION Contact with a sharp blade can cause serious injury. Wear gloves or wrap sharp edges of the blade with a rag. IMPORTANT The cutting unit blades rotate counterclockwise when viewed from overhead. The blade bolts (5) have left hand threads. 4. Remove the blade bolt (5), anti-scalp cup (6), and cutting blade (7) from the spindle; refer to Figure 48. 5. Remove 8 flange nuts (13) and 8 ribbed neck bolts (1) that secure spindle assembly to the cutting unit. 6.
Disassembling the Blade Spindle g241361 Figure 49 Low Spindle Assembly (shown) 1. Locknut 6. Bearing set 11. Large snap ring 2. Special hardened washer 7. Bearing spacer 12. Spacer ring 3. Pulley 8. Ribbed neck bolt (8 each) 13. Shaft spacer 4. O-ring 9. Spindle housing Spindle shaft 5. Oil seal (2 each) 10. 14. Grease fitting Note: Refer to Figure 49 during this procedure. 1. Remove the locknut (1) from the top of the spindle shaft (14). 2.
Disassembling the Blade Spindle (continued) 6. Discard the spindle shaft O−ring (4). 7. Use an arbor press to remove the 2 bearing sets (6) and bearing spacer (7) from the spindle housing. Note: The large retaining ring can remain inside the spindle housing. Removing the large retaining ring is very difficult. 8. Remove the damaged drive studs (8) and replace as needed. Assembling the Blade Spindle g189007 Figure 50 1. Bearing 4. Inner bearing spacer 2. Spacer ring 5. Outer bearing spacer 3.
Assembling the Blade Spindle (continued) PRESS g266961 Figure 51 1. Bearing cups 4. Arbor press 2. Large snap ring 5. Support 3. Large spacer 6. Arbor press base 3. Use an arbor press to push the bearing cups into the top and bottom of the spindle housing. The top bearing cup must contact the outer spacer that was previously installed, and the bottom bearing cup must contact the snap ring. 4.
Assembling the Blade Spindle (continued) IMPORTANT If you are replacing the bearings, ensure that you use the spacer ring that is included with a new bearing set; refer to Figure 50. 7. Slide the spacer ring and inner bearing spacer into the spindle housing, then install the upper bearing cone and oil seal into the top of the housing. The upper seal must have the lip facing in (down). Also, install upper seal so it is flush to 1.5 mm (0.060 inch) recessed to the housing surface; refer to Figure 52. 8.
Assembling the Blade Spindle (continued) IMPORTANT A pneumatic grease gun can produce high pressure inside the spindle housing that can damage the spindle seals. Thus, do not use a pneumatic grease gun for greasing of the spindle housings. 12. Attach a hand pump grease gun to the grease fitting on the housing and fill the housing cavity with grease until the grease starts to come out of the lower seal. 13. Rotate the spindle shaft to ensure that it turns freely.
Installing the Blade Spindle (continued) 2. Attach the spindle assembly to the cutting unit with the 8 ribbed neck bolts (item 1 in Figure 48) and 8 flange nuts (13). IMPORTANT The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting. IMPORTANT The cutting unit blades rotate counterclockwise when viewed from overhead. The blade bolts (5) have left hand threads. 3.
Rollers g241360 Figure 55 1. Lock nut (8 each) 5. Bolt (8 each) 2. Skid assembly LH 6. Grease fitting (4 each) 3. Bearing shim (4 each) 7. Nut (4 each) 4. Flange bushing (4 each) 8. Carriage bolt (4 each) 9. 10. Roller assembly Cutting unit assembly Removing the Rollers Note: Refer to Figure 55 during this procedure. 1. Park the machine on a level surface, lower the cutting units and disengage the PTO. Remove the main drive shaft and disconnect the machine from the tow vehicle.
Installing the Rollers 1. If removed, install the grease fittings (6) on the flange bushing (4). IMPORTANT Replacement roller bearings include straight grease fittings. Fit 90° grease fittings in bearings prior to installation. Position grease fitting toward the outside of the cutting unit. 2. If removed, install the bearing shim (3), flange bushing (4), bolts (5) and nuts (1) onto the LH skid assembly (2). 3. Slide the roller assembly (9) into the skid assemblies. 4.
Kicker Roller and Balance Weights (Side cutting units only) g264310 Figure 56 Side Cutting Unit (shown) 1. Bolts (2 each) 6. Kicker roller assembly 11. Flange nut (2 each) 2. Roller (2 each) 7. Bolt (4 each) 12. Carriage bolt (4 each) 13. Carriage bolt (2 each) 3. Spacer tube (2 each) 8. Flange nut (4 each) 4. Flange nut (4 each) 9. Weight bracket 5. Nut (2 each) 10. Weights Park the machine on a level surface, lower the cutting units and disengage the PTO.
Cutting Units: Service and Repairs Page 6–22 Groundsmaster® 1200 Pull-Behind Rotary Mower 18235SL Rev C
Appendix A Foldout Drawings Table of Contents Electrical Drawing Designations.........................................................................................................A–2 Wire Harness Drawing - Homologation Kit .........................................................................................
Electrical Drawing Designations Note: A splice used in a wire harness will be identified on the wire harness diagram by SP. The manufacturing number of the splice is also identified on the wire harness diagram (e.g., SP01 is splice number 1). Wire Color The following abbreviations are used for wire harness colors on the electrical schematics and wire harness drawings in this chapter.
Wire Harness Drawing - Homologation Kit CV g330374 Groundsmaster 1200 - Homologation Kit, Drawing 122-1479 Rev B, Sheet 1 18235SL Rev C Page A–3
