FORM NO. 3319–937 ProLine 60” MOWER for OUT FRONT Z TRACTION UNIT Model No. 78478– 890220 & 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 Grass Deflector . . . . . . . . . . . . . . . . Install Castor Wheels . . . . . . . . . . . . . . . . . Installing Push Arms . . . . . . . . . . . . . . . . . Installing Lift Springs . . . . . . . . . . . . . . . . Reverse Gage Wheels . . . . . . . .
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 Retaining Ring 2 Deflector 1 Bolt 3/8–16 x 3-3/4” (95 mm) 2 Spring 2 Locknut 3/8–16 2 Push Arms 2 Flat Washer 1-1/2” O.D.
Installation Remove Carrier Frame Install Grass Deflector 1. 1. Locate the deflector mounts over the pivot brackets and secure with the (2) 3/8–3-3/4” (95 mm) bolts, (2) springs and (2) 3/8” locknuts. Make sure the straight ends of the springs are positioned between the deflector mounts and the grass deflector (Fig. 2). 2. Tighten the locknuts until they contact the pivot brackets (Fig. 2). Remove hairpin cotters and clevis pins from mower hanger brackets and remove mower from carrier frame (Fig.
Installation Install Castor Wheels Installing Push Arms 1. Place (1) thrust washer on shaft and slide the castor wheel into the mounting tube (Fig. 3). 1. Place push arm onto carrier frame pin as shown (Fig. 4). 2. Place (3) thrust washers on top of shaft and secure with retaining ring (Fig. 3). 2. Secure with 1-1/2” (38 mm) flat washer and retaining ring (Fig. 4). Note: The location of the thrust washers on each fork may need adjustment to maintain a level deck. 3.
Installation Reverse Gage Wheels Installing Mower 1. Remove hairpin cotter and pin to remove gage wheel from on mower mount (Fig. 6). Slide gage wheel out of mount and reverse location. 1. Position carrier frame in front of traction unit and place push arms into clevises (Fig. 7). 2. 2. Select a hole position so the gage wheel is 3/8” (9.5 mm) off the ground for the height-of-cut to be used (Fig. 6).
Installation 5. Roll mower in front of traction unit. 8. Release the latch levers and push carrier frame down. Latch pins should lock. 6. Rotate PTO drive shaft so holes in universal joint align with hole in gearbox shaft and slide together (Fig. 9). 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. 10). 7.
Installation Removing the Mower 1. Drive roll pin through hole in universal joint to remove PTO drive shaft from gearbox shaft (Fig. 9). Note: 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” locknut securing spring end plate assembly to carrier frame (Fig. 12). Roll pin and drive shaft remain with traction unit. 3 2 1 4 1 m-3209 Figure 12 2 1. Spring Assembly 2. Shoulder Bolt 3/8” x 7/8” (22 mm) 3 m-3196 4.
Installation 6. Raise the carrier frame and roll the mower away from traction unit. 7. Lower carrier frame and remove hairpin cotters and pivot pin assemblies securing push arms to traction unit clevises (Fig. 14). Note: 8. 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. 15). Note: Save all hardware for use when installing mower. Save all hardware for use when installing mower.
Operation Operating the Power Take Off (PTO) 3. To engage lift cover and move the PTO switch to the “ON” position (Fig. 17). 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. 17). Engaging the PTO 2 1. Release pressure on the traction control levers and place in neutral (Fig. 16). 2. Release the parking brake (Fig. 16). 1 1 2 m-2721 Figure 17 1.
Operation Adjusting Height-of-Cut Adjusting Gage Wheels The height-of-cut is adjusted from 1” to 5” (25 to 127 mm) in 1/2” (13 mm) increments by relocating four clevis pins in different hole locations. The gage wheels must be adjusted in the proper hole location for each height-of-cut position. 1. To adjust, remove hairpin cotter and clevis pin from mower hanger bracket (Fig. 18). 2. Select hole in mower hanger bracket corresponding to the height-of-cut desired.
Operation Tilting the Mower 3. 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 handles to raise mower (Fig. 22). 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. 16). 2.
Maintenance Service Interval Chart Service Operation Each Use Cutting Blades – check 8 Hours 25 Storage Hours Service X X Belts – check for wear/cracks X Blade Spindle Bearings – grease X Castor Wheels – grease X Gear box – check X Mower Housing – clean Notes 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.
Maintenance Inspecting the Blades Checking for Bent Blades 1. Inspect the cutting edges (Fig 23). 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. 24). Measure from a level surface to the cutting edge of the blades (Fig. 25). Note this dimension. 2. Inspect the blades, especially the curved area (Fig. 23).
Maintenance Sharpening the Blades 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. 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. WHAT CAN HAPPEN • Pieces of blade that may be thrown could seriously injure or kill you or bystanders.
Maintenance Correcting Cutting Unit Mismatch Setting the Front-to-Rear Pitch 1. Check the tire pressure. If one cutter blade cuts lower than the other, correct as follows: 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). 3. The mower should be 1/8”–5/8” (3–16 mm) lower in front “C” than in the rear “D”. 1.
Maintenance Setting the Side-to-Side Leveling 1. Check the tire pressure. 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. The difference between measurements “A” and “B” should be no more than 1/4” (6 mm). 4. To change the side-to-side leveling, remove the retaining ring and move the thrust washers on one castor wheel fork only.
Maintenance Greasing and Lubrication 4. Grease the fittings on the carrier frame mounting tubes and castor wheels (Fig. 35). 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 the three spindle bearings (Fig. 33). 1 2 m-3281 2 Figure 35 1.
Maintenance Replacing the Deck Belt 2 5 Squealing when the belt is rotating, blades slipping when cutting grass, frayed belt edges, burn marks and cracks are signs of a worn deck belt. Replace the deck belt if any of these conditions are evident. 1. Stop the engine, remove the key and disconnect the spark plug wire(s) from the spark plug(s). 2. Remove the belt covers on top of the outer blade spindles (Fig. 38). 3.
Maintenance Replacing Blade Spindle and Bearings 1. 2. Stop the engine, remove the key and disconnect the spark plug wire(s) from the spark plug(s). Remove the deck belt: refer to Replacing the Deck Belt, page 19. 10. Slide pulley onto spindle shaft and secure with locknut (Fig. 39). 11. Torque locknut to 100–120 ft–lb. (135–162 NDm). Rotate shaft to check foe free rotation. 12. Install washer, spindle cup and blade (Fig. 39). Secure with previously removed bolt and washer. 3.
Maintenance Replacing the Castor Wheel Fork Bushings 4. Insert a pin punch into the mounting tube and carefully drive out the bushings (Fig. 41). 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. 42). 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. 43). 4.
Maintenance Replacing the Grass Deflector Storage 1. Remove the locknuts, bolts and springs holding the deflector mounts to the pivot brackets (Fig. 45). 1. Clean any dirt and chaff from the top of the mower. 2. 2. If the pivot brackets need to be replaced, remove the carriage bolts and cone locknuts holding the old brackets to the top of the discharge opening, then install the replacement pivot brackets. Make sure the carriage bolt heads are on the inside of the cutting unit (Fig. 45).
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 pulley, idler pulley, or blade pulley. 4. Tighten the appropriate pulley. 5. Gearbox pulley is damaged. 5. Replace gearbox pulley. 6.