FORM NO. 3321-443 Z – Master 48” Recycler for OUT FRONT Z –TRACTION UNIT Model No. 78477– 891696 & 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 . . . . . . . . . . . . . . . . . . . . . . . . . Remove Carrier Frame . . . . . . . . . . . . . . . . Install Castor Wheels . . . . . . . . . . . . . . . . . Installing Push Arms . . . . . . . . . . . . . . . . . Installing Lift Springs . . . . . . . . . . . . . . . . Installing Mower . . . . . . . . . . . . . . . . . . . . Removing the Mower . . . . . . . .
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. USE Castor Wheel 2 Thrust Washer 8 Spacer 2 Retaining Ring 2 Push Arms 2 Flat Washer 1-1/2” O.D. (38 mm) 2 Retaining Ring 2 Spring Assembly 2 Shoulder Bolt 3/8”–16 x 7/8” (22 mm) 2 Locknut 3/8”–16 2 Shoulder Bolt 3/8”–16 x 7/8” (22 mm) 2 Locknut 3/8”–16 2 Bolt 3/8”–16 x 1-5/8” (41.
Installation Remove Carrier Frame Install Castor Wheels 1. 1. Place spacer and (2) thrust washers on shaft and slide the castor wheel into the mounting tube (Fig. 2). 2. Place (2) thrust washers on top of the fork and secure with retaining ring (Fig. 2). Remove hairpin cotters and clevis pins from mower hanger brackets and remove mower from carrier frame (Fig. 1). Note: 2 3 1 3. Grease the fitting on the carrier frame mounting tube using No.
Installation Installing Push Arms Installing Mower 1. Place push arm onto carrier frame pin as shown (Fig. 3). 1. Position carrier frame in front of traction unit and place push arms into clevises (Fig. 5). 2. Secure with 1-1/2” (38 mm) flat washer and retaining ring (Fig. 3). 2. Retain push arms with pivot pin assemblies, aligned with flat against frame, and secure with hairpin cotters (Fig. 5). 1 Note: 2 Pivot pin assemblies and hairpin cotters are part of traction unit.
Installation 3. 4. Lift carrier frame into vertical position, refer to: Tilting the Mower. 5. Roll mower in front of traction unit. 6. Rotate PTO drive shaft so holes in universal joint align with hole in gearbox shaft and slide together (Fig. 7). 7. Drive roll pin through hole in universal joint to secure PTO drive shaft to gearbox shaft (Fig. 7). Secure spring end plate assembly to carrier frame with 3/8” x 7/8” (23 mm) shoulder bolt and 3/8” locknut (Fig. 6).
Installation 8. Release the latch levers 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. Secure clevis pin with hairpin cotter (Fig. 8). Note: All four clevis pins should be in the same hole location for a level cut. Removing the Mower 1. Remove 5/16–18 x 7/8” (11 mm) shoulder bolt and 5/16” flange nut holding PTO cover down (Fig.
Installation 3. Tilt mower into raised position, refer to: Tilting the Mower. 7. Raise the carrier frame and roll the mower away from traction unit. 4. Remove 3/8” x 7/8” (23 mm) shoulder bolt and 3/8” locknut securing spring end plate assembly to carrier frame (Fig. 11). 8. Lower carrier frame and remove hairpin cotters and pivot pin assemblies securing push arms to traction unit clevises (Fig. 13). 3 Note: 2 Save all hardware for use when installing mower.
Installation 9. 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. 14). Note: Save all hardware for use when installing mower. 4 3 2 5 m-3198 1 Figure 14 1. PTO Driveshaft 2. Universal Joint 3. Gearbox shaft 4. Bolt 3/8”–16 x 1-5/8” (41.5 MM) 5.
Operation Operating the Power Take Off (PTO) 3. To engage lift cover and move the PTO switch to the “ON” position (Fig. 16). Disengaging the PTO The power take off (PTO) switch engages and disengages power to the electric clutch. 1. Closing the cover moves the PTO switch to the “OFF”position (Fig. 16). Engaging the PTO 2 1. Release pressure on the traction control levers and place in neutral (Fig. 15). 2. Release the parking brake (Fig. 15). 1 1 2 m-2721 Figure 16 1.
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. 17).
Operation Tilting the Mower 4. The mower can be tilted up for ease of service or to shorten unit length for transport and storage. Standing in front of the mower, lift up and push rearward on front to raise mower (Fig. 20). Raise mower until it contacts stops and latch pins snap into locked position. To Raise Mower 1. Set the parking brake and check that PTO cover is down against footrest (Fig. 15). 2. Remove 5/16–18 x 7/8” (11 mm) shoulder bolt and 5/16” flange nut holding PTO cover down (Fig. 21).
Maintenance Service Interval Chart Service Operation Each Use 8 Hours Cutting Blades – check X Push arm bushings – grease X 25 Storage Hours Service X Castor Wheels – grease X Gear box – check X Mower Housing – clean 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 22). If the edges are not sharp or have nicks, remove and sharpen the blades. Refer to Sharpening the Blades on page 16. 1. Rotate the blades until the ends face forward and backward (Fig. 23). Measure from a level surface to the cutting edge of the blades (Fig. 24). Note this dimension. 2. Inspect the blades, especially the curved area (Fig. 22).
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 1 • 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 Figure 25 1. Cutting edge 1. edges or surfaces of blade.
Maintenance Sharpening the Blades 1. Use a file to sharpen the cutting edge at both ends of the blade (Fig. 27). 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. 1. Check the tire pressure. 2. Position the blades front-to-rear (Fig. 29). Measure at “C” and “D” locations (Fig. 29) from a level surface to the cutting edge of the blades (Fig. 30). 2. Position the blades side-to-side (Fig.31 ). Measure at “A” and “B” locations (Fig. 31) from a level surface to the cutting edge of blades (Fig.32). 3.
Maintenance Greasing and Lubrication The cutting unit must be lubricated regularly. Refer to the Service Interval Chart on page 13. Grease with No. 2 general purpose lithium base or molybdenum base grease. 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. 33). 4. Remove plug on the side of the gearbox and check the level of lubrication in the gearbox. If level is low, add SAE EP-80\90 wt.
Maintenance Replacing the Castor Wheel Fork Bushings 4. Insert a pin punch into the mounting tube and carefully drive out the bushings (Fig. 37). 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. 38). 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. 39). 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 13. 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 height. 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.