FORM NO. 3319-441 RN Z — Master 48” Recycle for OUT FRONT Z -TRACTION UNIT Model No. 78477— 890001 & 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 (o 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 Page Safety and Instruction Decals . . Maintenance i3 Installation e Service Interval Chart 13 Cutting Blades e 13 Correcting Cutting Unit Mismatch . 16 Setting the 16 Setting the Side-to-Side Leveling 17 Installing Lift Springs . Creasing and Lubrication ..o 18 Installing Mower Replacing the Castor Whee! Fork Bushings 19 Removing the Mower Servicing the Castor Wheels and Bearings 20 Operation Replacing Push Arm Bushings 21 Operating the Power Take O (PTO) 10 Siesta 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. ON RIGHT SIDE ON EACH CORNER (Part No. 88—1304) (Part No. 43--B8480) KEEP HANDS and FEET AWAY NEXT TO CENTER ON LEFT SIDE OF CARRIER FRAME GEARBOX — (Part No. 68-8340) (Part No. 96-0518) WU HEIGHT OF CUT ADJUSTMENT TURN ENGINE OFF. POSITION ALL PINS IN SAME @ 4” .31’2” HEIGHT OF CUT HOLES.
Installation Loose Parts Note: Use the chart below to identify parts used for assembly. DESCRIPTION o 3 USE Castor Wheel Thrust Washer Spacer Retaining Ring Install castor wheels to carrier frame Push Arms Flat Washer 0.D.
Installation Remove Carrier Frame 1. Remove hairpin cotters and clevis pins from mower hanger brackets and remove mower from carrier frame (Fig. 1). 13531 1. Mower Hanger Bracket 3. Hairpin Cotter 2. Clevis Pin Install Castor Wheels 1. 1. Place spacer and (2) thrust:washers on shaft and sited the castor wheel into the mounting tube (Fig. 2). Place (2) thrust washers on top of the fork and secure with retaining ring (Fig. 2).
installing Push Arms 1. Place push arm onto carrier frame pin as shown (Fig, 3). 2, Secure with (38 mm) flat washer and retaining ring (Fig. 3). Figure 3 1. Pin 3. Flat washer 2. Pu sham (38 mm) 4. Retaining dng Installing Lift Springs 1. Secure spring end plate assembly to traction unit with 3/8” x 7/8” (23 mm) shoulder bolt and 3/8” lockout (Fig. 4). 3208 1. Spring Assembly 2. Shoulder Bolt ¥8° x 7/8" (22 mm) 3. Lockout 38" Installation Installing Mower 1.
Installation 3. Lift tarrier frame into vertical position, refer to: 5. Roll mower in front of traction unit. Tilting the Mower. L. 6. Rotate PTO drive shaft so holes in universal 4, Secure spring end plate assembly to carrier Joint align with hole in gearbox shaft and slide frame with 3/87 x 7/8" (23 mm) shoulder bolt together (Fig. 7). and 3/8” lockout (Fig. 6). / 7. Drive roll pin through hole in universal joint to secure PTO drive shaft to gearbox shaft (Fig. 7).
8. Release the latch Severs and push carrier frame down. Latch pins should lock. 9. Select hole in mower hanger bracket corresponding to the height-of-cut desired. Lift on side and front handles to align holes and insert clevis pin (Fig. 8). 10. Sc cure clevis pin with hairpin cotter (Fig. 8). Note: Al four clevis pins should be in the same hole location for a Revel cut. [went TURN ENGINE OFF, o9 POSITION ALL FINS Iy Sue CUT HOLES, wane 4" Figure 8 1. Mows Hanger Bracket 3. Hairpin Cotter 2.
Installation 2. Tilt mower into raised position, refer to: Tilting the Mower. 3. Remove 3/8” x 7/8” (23 mm) shoulder bolt and 3/8" lockout securing spring end plate assembly to carrier frame (Fig. 10). Figure 10 1. Spring Assembly 3. Lockout 3/8° 2. Shoulder Alt 318" x 7/8" (22 ram) 4. Carefully lower mower from vertical position aching front lift handles, refer to: Tilting the Mower. 5. Remove hairpin cotters and clevis pins from mower hanger brackets and remove mower from carrier frame (Fig. 11).
Installation 8. Remove (2) x (41.5 mm) bolts and lockouts from universal joint and slide the driveshaft off gearbox shaft (Fig. 13). Note: Save all hardware for use when installing mower. meats Figure 13 1. PTO Driveshaft 4. Bolt X 2. Universal Joint {415 MM 3. Gearbox shaft 8.
Operation Operand the Power Take Off 3. To engage lift cover and move the PTO switch to the “ON” position (Fig. 15} (PTO) The power take off (PTO) switch engages and Disengaging the PTO disengages power to the electric clutch. 1. Closing the cover moves the PTO switch to the “OFF " position (Fig. 13). Engaging the PTO 2 1. Release pressure on the traction control levers and place in neutral (Fig. 14). 2. Release the parking brake (Fig. 14). g7t Figure 18 1. PTO-Of 2. PTO-On 3180 Figure 14 1.
Adjusting Height-of-Cut The bright-of-cut is adjusted from 17 to {25 to 115 mm) in 1/2” (13 mm) increments by relocating four clevis pins in different hole locations. 1. To adjust, remove hairpin cotter and clevis pin from mower hanger bracket (Fig. 16). 2, Select hole in mower hanger bracket corresponding to the height-of-cut desired. Lift on side and front handles to align holes and insert clevis pin (Fig, 16}, 3. Secure clevis pin with hairpin cotter (Fig. 16).
Q Operation Tilting the Mower 3 The mower can be tilted up for ease of service or to shorten unit length for transport and storage, To Raise Mower 1. Set the parking brake and check that PTO cover is down against footrest (Fig. 14} 2. Liston side of mower to release weight on latch pin and pull out on latch pin to release (Fig. 18). Lower rear of mower onto roller. Repeat on the other side. 1. 1. m-saga 2 Figure 18 1. Parking brake 3. l Latch pin 2. PTO cover 4.
Maintenance Service Interval Chart Each 8 25 |Storage Service Operation Use | Hours | Hours | Service Notes Cutting Blades — check X X Push arm bushings — grease X Castor Wheels — grease X Gear box — check X Mower Housing — clean X X Chipped Surfaces — paint X For ease of maintenance and service the mower can be tilted up, refer to: Tilting the Mower, in the Operation section for instructions.
Maintenance Inspecting the Blades Checking for Bent Blades 1. Inspect the cutting edges (Fig 20). If the edges 1. Rotate the blades until the ends face forward and are not sharp or have nicks, remove and sharpen backward (Fig. 21). Measure from a level the blades. Refer to Sharpening the Blades on surface to the cutting edge of the blades page 16. {Fig. 22). Note this dimension. 2. Inspect the blades, especially the curved area 2. Rotate the opposite ends of the blades forward. (Fig. 20).
Maintenance IR TR 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 1. * Always replace bent or damaged blade with . a new blade, * Never file or create sharp notches in the edges or surfaces of blade.
Maintenance Sharpening the Blades L 16 Use a file to sharpen the cutting edge at both ends of the blade (Fig. 25). Maintain the original angle. The blade retains its balance if the muse amount of material is removed from both cutting edges. /1 Figure 25 1. Sharpen at original angle 1854 Check the balance of the blade by putting it on a blade balance {Fig. 26). If the blade stays in a horizontal position, the blade is balanced and can be used.
Setting the Front-to-Rear Pitch Maintenance Setting the Side-to-Side Leveling 1. Check the tire pressure. 1. Check the tire pressure. 2. Position the blades front-to-rear (Fig. 27). 2. Position the blades side-to-side {Fig.29 ). Measure at “C” and “D” locations (Fig. 27) from Measure at “A” and “B” locations (Fig. 29} from a level surface to the cutting edge of the blades a level surface to the cutting edge of blades {Fig. 28). (Fig.30). 3. The mower should be (3-16 mm)} 3.
Maintenance 4. To change the side-to-side leveling, remove the retaining ring and move the thrust washers on one castor wheel fork only. Move the thrust washers from the top of the carrier frame mounting tube to the bottom o raise the corresponding side of the mower. Move the thrust washers from the bottom of the mounting tube to the top to lower the corresponding side of the mower. (Fig. 34). 5.
1. Remove plug on the side of the gearbox and check the level of lubrication in the gearbox. If level is low, add SAE EP-80R90 wt. gear oil until level is up to side plug in gearbox. (Fig. 33). Repeat for remaining gearboxes. Figure 33 Gearbox 2. Side plug Maintenance Replacing the Castor Wheel Fork Bushings 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.
Maintenance Insert a pin punch into the mounting tube and carefully drive out the bushings (Fig. 35). Clean the inside of the mounting tube: Grease the inside and outside of the new bushings. Use a hammer and flat plate to carefully drive the bushings into the mounting tube (Fig. 35). Inspect the castor wheel fork for wear and replace if necessary (Fig. 34), Slide the castor wheel fork through the bushings in the mounting tube.
0N To assemble, place one (1) bushing into the wheel hub. Grease the roller bearing and spanner bushing and slide them into the wheel hub. Place the second bushing into the wheel hub (Fig. 36). Install the castor wheel into the castor fork and secure with the wheel bolt and lockout. Tighten the lockout until the spanner bushing bottoms against the inside of the castor forks (Fig. 36). Grease the fitting on the castor wheel. m-4288 Figure 36 Lockout 5. Spanner Bushing West Bolt 6. Holler Bearing Washer 7.
Maintenance 5 1 22 Insert a pin punch into the push arm and carefully drive out the bushings (Fig. 38). Clean the inside of the push arm. Use a hammer and flat plate to carefully drive new bushings into the end of push arm (Fig. 38). Place push arm onto carrier frame pin and secure with {38 mm) flat washer and retaining ring (Fig 37). Grease the fitting on the push arm using No. 2 general purpose lithium base or molybdenum base grease. Figure 38 2. Bushing Push arm Storage 1.
Troubleshooting PROBLEM POSSIBLE CAUSES CORRECTIVE ACTION Abnormal vibration, 1. Cutting blade(s) is/are bettor | 1. Install new cutting blade(s). unbalanced. Blade mounting bolt is loose. | 2. Tighten blade mounting bolt. Drive shaft bolts are loose. Tighten:drive shalt bolts. Loose gearbox assembly. Tighten:the appropriate hardware, 5. Worn gearbox bearings. 5. Replace bearings. 6. Gearbox gears are damaged. | 6. Replace gears. 7. Blade spindle bent. 7. Replace spindle. 8. Universal joint worn. 8.