Hayter Mowers Condor Hydrostatic Drive 510D Users Manual

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Part%No.%111*5824%Rev%A

CONDOR

HYDROSTATIC DRIVE

POWER%UNIT%Model%No:%510D%*%Serial%No.%from%312030001

ATTACHMENTS%*%Serial%No.%from%312030001:

Verge%Attachment%3%Blades%*%Code%214D

Verge%Attachment%5%Blades%*%Code%243D

Rotary%Attachment%30”%*%Code%212D

Operator’s Manual

Original Instructions (EN)

Date: 20.02.2012

ATTENTION

THIS SYMBOL MEANS

BE ALERT!

YOUR SAFETY IS INVOLVED

READ THIS MANUAL BEFORE USING THE CONDOR HYDROSTATIC

DRIVE MOWER.

IT IS ESSENTIAL THAT OPERATORS STUDY IT FOR THEIR OWN

SAFETY.

ALL OPERATORS SHOULD SEEK AND OBTAIN PROFESSIONAL AND

PRACTICAL INSTRUCTIONS ON THE SAFE USE OF THE MOWER.

THESE SERVICES ARE AVAILABLE THROUGH HAYTER APPROVED

COMMERCIAL DEALERS.

1.5 1.5

CONTENTS

CONTENTS Page No.

Safety Precautions 1.7 - 1.12

Training 1.7

Preparation 1.7 - 1.8

Operation 1.8 - 1.9

Maintenance and Storage 1.10

Decals 1.11 - 1.12

EC Conformity Information 1.13 - 1.14

Noise / Vibration Levels 1.13

EC Declaration of Conformity 1.14

Introduction 1.15

Specifications 1.16 - 1.18

Engine 1.16

Transmission System 1.16

Cutterhead Drive System 1.16

Power Unit 1.17

Operator Controls 1.17

Weight and Dimensions 1.17

Recommended Lubricants And Hydraulic Fluids 1.18

Verge Attachments 1.18

Rotary Attachments 1.18

Assembling The Mower 1.19 - 1.21

Assembling and Removing the Cutterhead Attachments - Introduction 1.19

Assembling the Cutterhead to the Power Unit 1.20 - 1.21

Operating The Mower 1.22 - 1.28

Safety Notice 1.22

Operator Presence Controls 1.22

Identification of Controls 1.23

Braking System 1.23

Throttle Control 1.23

Travel 1.23 - 1.24

Transmission Bypass Valve Control 1.24

Ignition Switch 1.25

Cutterhead Drive Operation 1.25

Starting the Engine 1.25 - 1.26

Stopping the Engine 1.26

General Operating Hints 1.27

Adjusting Height of Cutter 1.27 - 1.28

Handlebar Height Adjustment 1.28

1.6 1.6

CONTENTS

CONTENTS Page No.

MAINTENANCE 1.29 - 1.43

Maintenance 1.29

Engine 1.30

Running in period - at First 50 Hours of Use 1.30 - 1.31

Daily and before use 1.31 - 1.33

Every 50 hours 1.34

Every 200 hours 1.35 - 1.37

Rotary Attachment 1.41 - 1.42

Cutterblades 1.42

Preparing the Mower for Storage 1.43

GRASS CUTTING FAULTS - Both Types of Attachments 1.44

TROUBLE SHOOTING 1.45 - 1.46

ELECTRICAL CIRCUIT DIAGRAM 1.47

WARRANTY 1.48

NOTES 1.49 - 1.50

CUSTOMER INFORMATION 1.51

1.7 1.7

This manual should be regarded as part of the machine, as it gives essential

information regarding machine safety, operation, maintenance and specifications.

READ THIS MANUAL BEFORE USING THE CONDOR MOWER, IT IS

ESSENTIAL THAT OPERATORS STUDY IT FOR THEIR OWN SAFETY.

THE FOLLOWING PRECAUTIONS MUST BE TAKEN TO HELP PREVENT

ACCIDENTS. A CAREFUL OPERATOR WHO USES COMMON SENSE IS THE

SAFEST OPERATOR.

SAFETY PRECAUTIONS

Training

Read the instructions carefully. Be familiar with the controls and the proper use of the equipment. Learn how

to stop the mower quickly in an emergency.

Never allow children or people unfamiliar with these instructions to use the mower. Local regulations may

restrict the age of the operator.

Never mow while people, especially children, or pets are nearby.

Keep in mind that the operator or user is responsible for accidents or hazards occurring to other people or

their property.

All drivers should seek and obtain professional and practical instruction. Such instruction should

emphasise:

The need for care and concentration when working with this machine.

Preparation

Check that the machine complies with all applicable regulations, including those in force when used on the

public highway.

While mowing, always wear substantial footwear and long trousers. Do not operate the equipment when

barefoot or wearing open sandals. Eye protection should be worn.

Thoroughly inspect the area where the equipment is to be used and remove all objects which can be thrown

by the machine.

Replace faulty silencers.

Always ensure that the mower is in a safe operating condition. Frequently check all nuts, bolts and screws for

tightness. Use only genuine Hayter replacement parts.

Damaged cutterblades or loose fixing bolts are major hazards. Before use, always visually inspect the cutting

mechanism to ensure that there are in good condition. Damaged cutterblades must be replaced immediately

with genuine Hayter replacement parts. Unbalanced cutterblades may cause serious damage to your machine.

Refer to MAINTENANCE.

On attachment with twin cutterheads, take care as rotating one cutterblade will cause the other to rotate.

1.8 1.8

Preparation Continued

WARNING: Petrol is highly flammable.

- Store fuel in containers specifically designed for this purpose.

- Refuel outdoors only and do not smoke while refuelling.

- Add fuel before starting the engine. Never remove the cap from the fuel tank or add petrol whilst the

engine is running or when the engine is hot. Allow the engine to cool for at least two minutes before

refuelling.

- Do not attempt to start the engine if petrol is spilled or a smell of petrol is present. Move the mower

away from the area of spillage and avoid creating any source of ignition until petrol vapors have

dissipated.

- Always use fresh fuel. Stale fuel can block the carburettor and cause leakage.

- Replace fuel tank and oil tank caps securely.

Operation

Do not operate the engine in a confined space where dangerous carbon monoxide fumes can collect.

Mow only in daylight or in good artificial light.

Avoid using the mower on wet grass, where feasible.

Walk, never run.

Do not use on slopes of more than 20 degrees.

Always be sure of your footing on slopes and stay alert for humps, hollows and other hidden hazards.

Ground conditions may affect the ability of the operator to maintain safe footing. Particular conditions may

not permit safe operation on the slope limit stated.

Mow across the face of the slopes, never up and down.

Exercise extreme caution when changing direction on slopes.

Do not mow excessively steep slopes.

Use extreme caution when reversing or pulling the mower towards you.

Disengage the cutterhead drive if the mower has to be tilted for transportation when crossing surfaces other

than grass and when transporting the mower to and from the area to be mowed.

Never operate the mower unless the guards are securely in position and in good condition and all safety

devices are in place.

Do not change the engine governor settings or overspeed the engine. Operating an engine at excessive speed

may increase the hazard of personal injury.

Disengage the cutterhead and ground drive clutches before starting the engine.

SAFETY PRECAUTIONS

1.9 1.9

Operation Continued

Start the engine carefully, with feet well away from the cutting devices.

Do not tilt the mower when starting the engine.

Do not put hands or feet near or under rotating parts. Keep clear of discharge openings at all times.

Stop the engine, turn the ignition control to the ‘off’ position, set the parking brake and disconnect the spark

plug lead:

- Before clearing blockages or unclogging the discharge chute.

- Before cleaning/checking or working the mower.

- After striking a foreign object. Inspect the mower for damage and ensure necessary repairs are

made before re-starting.

- If the mower starts to vibrate abnormally (check immediately).

Stop the engine, turn the ignition control to the ‘off’ position, set the parking brake:

- Whenever you leave the mower.

- Before refuelling.

- Before making a height of cut adjustment.

Reduce throttle control setting during engine shutdown.

Turn off the fuel tap at the conclusion of mowing.

WARNING: The cutting devices can continue to rotate after the engine is switched off.

SAFETY PRECAUTIONS

1.10 1.10

SAFETY PRECAUTIONS

Maintenance and Storage

Keep all nuts, bolts, and screws tight to be sure the equipment is in safe working condition.

Allow the engine to cool before storing in any enclosure.

To reduce the risk of fire, keep the engine, silencer, fuel tank and battery compartment free of grass, leaves or

excessive grease.

Replace worn or damaged parts for safety.

Ensure that all safety decals are properly secured and in good condition.

If the fuel tank has to be drained, this should be done outdoors.

Be careful during adjustment of the machine to prevent entrapment of the fingers between moving blades and

fixed parts of the machine. On twin bladed cutterheads, take care as rotating one bottom plate will cause the

other to rotate.

Health & Safety

The Condor Mower has been designed and constructed so that, in so far as is reasonably practical,

they meet the safety requirements of the Machinery Directive 2006/42/EC, they will not endanger the

safety and health of those working with them. This is, however, subject to the machine being properly

used and maintained according to the conditions stated in this manual and elsewhere, which have been

found necessary as a result of the research and testing.

1.11 1.11

SAFETY PRECAUTIONS

Decals

Decal - Control Panel

Part No: 510226 (2)

Location: Control Panel

A) Ground travel control: controls forward & reverse transmission speed

B) Bypass valve important: prevent damage - do not operate the bypass valve lever whilst the engine is

running as this will cause a rapid temperature rise in the bypass valve.

C) Hydrostatic unit bypass valve control - grip lever to close the bypass valve, grip lever to open bypass valve

release.

D) Engine stop/run switch

E) Stop engine and remove spark plug lead before performing maintenance or repair work.

F) Parking break - grip a latch lever to engage the parking brake. Unlatch and release lever to disengage the

parking brake.

G) Engine speed control - push the lever forward to increase engine speed, pull the lever back to reduce engine

speed

H) Engage cutterhead drive

I) Disengage cutterhead drive

J) WARNING: CAUTION - risk of danger/safety alert

K) Carefully read the operators manual before using the machine

L) Do not open or remove safety shields while the engine is running

M) Danger of being hit by thrown objects. Keep bystanders at a safe distance

A B C D E

H

F G

IJ K L M

12

1.12 1.12

SAFETY PRECAUTIONS

Decals continued

Decal - Cutting height adjustment

Part No: 320006 (3)

Location: R.H side of deck (212D)

Both sides of unit (214D, 243D)

Decal - Cylinder cut adjustment

Part No: 214053 (0)

Location: Top front of verge unit, both sides

Decal - Severing of hand of fingers

Part No: 40-13-010 (1)

Location: Both sides of the deck (212D)

R.H side of deck (214D)

R.H side of deck (243D)

Decal - Cutterhead timing

Part No: 111-3904 (A)

Location: Between gearboxes on the rotary attachment

1.13 1.13

EC CONFORMITY INFORMATION

Noise Levels

Operator Daily Personal Noise Exposure:

HAYTER LIMITED have no control over site

conditions, duration of use, state of maintenance or

adjustment of the mower. All of these factors will affect

the operator’s daily personal noise exposure level - LEP,d

Under typical working conditions operators could be

exposed to a daily personal noise exposure level in

excess of 80 dB (A) LEP,d

Sound pressure level:

The sound pressure level at the operator’s position is

87.5 dB (A) measured in accordance with European

Standard EN836.

Sound power level:

The guaranteed sound power level is 100 dB (A)

measured in accordance with EC Directive 2000/14/EC.

If hearing protection is required, ear protectors with good

attenuation in the 63 - 8000 Hz frequency range should

be used.

Employers of personnel using this machine should refer

to the 2003/10/EC Directive for minimum health and

safety requirements regarding exposure and risks to

physical agents (noise).

Vibration Levels

Operator Daily Personal Vibration Exposure:

HAYTER LIMITED have no control over site condi-

tions, duration of use, state of maintenance or adjustment

of the mower. All of these factors will affect the opera-

tor’s daily personal vibration exposure level.

Under certain working conditions the operator may be

exposed to vibration levels above those stated.

EC Declaration of Conformity

WARNING: Under no circumstances can attachments

other than those covered by the EC Declaration of

Conformity or other attachments that may be introduced

by Hayter Limited in the future, having a similar EC

Declaration of Conformity, be supplied for or fitted to

the Code 510D Condor Hydrostatic Drive Power Unit.

Unauthorised use of other equipment will invalidate the

EC Declaration of Conformity and may cause the mower

to be unsafe. The fitting of genuine ‘Hayter’ attachments

which fall outside the definition of ‘Machinery’ is per-

mitted and is the only exception to this rule.

100

dB

Code Serial No:

510D

310000001

CONDOR - HYDRO

POWER UNIT

kg: 135 RPM:2900 kW:

SPELLBROOK, BISHOP'S STORTFORD,

HERTS. CM23 4BU. ENGLAND.

2010

Wear Hearing

Protection

1.14 1.14

EC CONFORMITY INFORMATION

VIBRATION INFORMATION

Hand / Arm Vibration Level at the Operator Position measured in accordance with European Standard EN 836 & EN 1033:

Measured Vibration Level ahv =

Uncertainty of measurement K =

Whole Body Vibration Level at the Operator Seat measured in accordance with European Standard EN 836:

Measured Vibration Level aw =

Uncertainty of measurement K =

SOUND PRESSURE INFORMATION

Sound Pressure Level at the Operator Position measured in accordance with European Standard EN 836 & EN 11094:

Measured Sound Pressure Level LPA =

Uncertainty of measurement K =

ms-2

dB(A)

ms-2

dB(A)

ms-2

dB(A)

ms-2

dB(A)

ms-2

dB(A)

ms-2

dB(A)

EC DECLARATION OF CONFORMITY

Manufactured by: HAYTER LIMITED,

declare that thelawnmower :

Model name:

Type:

Model No:

Cutting width:

Speed of rotation of the

cutting device:

Complies with the provisions of Directive: 2006/42/EC Essential Health & Safety Requirements relating to the Design &

Construction of Machinery and Safety Components and the regulations transposed into national law.

Also Directive 2000/14/EC Noise emission in the environment by equipment for use outdoors, as amended and the regulations

Also Directive 2004/108/EC Electromagnetic Compatibility and the regulations transposed into national law.

transposed into national law.

Procedure applied for the conformity assessment: ANNEX VI, procedure 1.

Notified Body: Sound Research Laboratories Ltd, Holbrook House, Little Waldingfield, Sudbury, Suffolk. CO10 0TH

ENGLAND

Notified body identification No: 1088

Measured sound power level:

Guaranteed sound power level:

Authorised Signatory:

S.A Maryniak

(Technical Director)

Declaration done and technical documentation kept at:

HAYTER LIMITED

Spellbrook, Bishop’s Stortford,

Herts. CM23 4BU ENGLAND

Date: 12.04.10

Address: Spellbrook, Bishop s Stortford, Herts. CM23 4BU. ENGLAND

Serial No.

Speed of rotation of engine:

Attachment model no:

Cutting device model name:

Cutting width:

2.0

3.0

N/A

N/A

212

86

3

212

212

2.0

3.5

N/A

N/A

214

86

3

214

214

2.0

3.5

N/A

N/A

243

86

3

243

243

2800 rpm

99 dB(A)

100 dB(A)

99 dB(A)

100 dB(A)

99 dB(A)

100 dB(A)

Hydrostatic Power Unit

Pedestrian lawnmower

510

81 cm

2900 rpm

212

30" Rotary Attachment

76 cm

1230 rpm

214

30" Verge Attachment

76 cm

1230 rpm

243

30" Verge Attachment

76 cm

Condor

Hydrostatic Power Unit

Pedestrian lawnmower

510

81 cm

2900 rpm

Condor

Hydrostatic Power Unit

Pedestrian lawnmower

510

81 cm

2900 rpm

Condor

1.15 1.15

INTRODUCTION

Introduction

The Condor Hydrostatic System is a total grass cutting system designed for professional use. A range of optional

attachments are available which can be quickly interchanged.

This machine is designed solely for cutting grass and similar low lying ground vegetation within the limitations

stated in this manual. Use in any other way is considered as contrary to the intended use. Compliance with and

strict adherence to the conditions of operation, service and repair as specified in this Operator’s Manual also con-

stitute essential elements of the intended use.

This machine should be operated, serviced and repaired only by persons who are familiar with its particular char-

acteristics and who are acquainted with the relevant safety procedures.

The safety precautions listed herein together with all other generally recognised regulations on safety and all road

traffic regulations must be observed at all times.

Any arbitrary modifications carried out to this machine may relieve Hayter Limited of liability for any resulting

damage or injury.

The unit is petrol engine powered and has separate clutch controls for engaging the cutterhead and ground drives.

The Condor system is well balanced and incorporates a number of features for effortless safe mowing. The handle-

bar controls are ‘user friendly’ and incorporate an operator presence control system. This system will automati-

cally disengage the cutterhead and ground drive clutches when the operator releases the controls.

The Condor Hydrostatic Mower is a precision built machine designed for robust use, a high standard of finish and

long life. The way in which this mower is operated and maintained will have a profound effect on its performance

and reliability.

This manual contains advice on the safe operation of the Condor Hydrostatic Mower, which is offered for guid-

ance and protection of all those operating and servicing this machine.

In pursuit of continuous product development, Hayter Limited reserve the right to alter specifications without

notice.

Cutterhead Variants: The Condor Hydrostatic Drive Power Unit can be fitted with a range of cutterhead configura-

tions and optional extras:

30” Verge Attachment - 3 Blade

30” Verge Attachment - 5 Blade

30” Rotary Attachment

Optional Extras:

Narrow Wheel Kit.

Left and right: Throughout this manual the terms ‘left’ and ‘right’ refer to the machine when looking in the

direction of forward travel.

1.16 1.16

Specifications

ALL FIGURES ARE NOMINALLY QUOTED AT THE RATED ENGINE SPEED OF 2900 RPM

UNLESS OTHERWISE STATED.

Engine

Condor

Type: HONDA GX340 UT2

4 - stroke, overhead valve, 1 cylinder

Speed Rating: 2900 rpm (no load)

Power Rating: 6.5 kw (8.7 hp) @ 2900 rpm

Capacity: 337 cc

Air Cleaner: Dual element type.

Cooling System: Forced air

Oil Type: SAE 10W-30

Oil Capacity: 1.1 Litres

Fuel Type: Unleaded petrol

Fuel Capacity: 6.1 Litres

IMPORTANT - PREVENT DAMAGE: For further information regarding the engine, refer to the Engine

Manual.

Transmission System

Drive Type: Hydraulic static differential transaxle

Cutterhead Drive System

Power Unit Intermediate Drive: Single clutch V-belt drive with integral engine lockout switch sensor

Power Unit Final Drive: Twin V-belt via countershaft

Verge Drive: Triple V-belt via countershaft

Rotary Attachment: Swinging cutterblades attached to circular bottom plates on coupled gearboxes

with pulley brake.

SPECIFICATIONS

1.17 1.17

Power Unit Specifications

Ground Speed: 0 - 9 km/hr (0 - 5.6 mph) forward

0 - 5 km/hr (0 - 3 mph) reverse

Tyres Tyre Type Recommended max.

tyre pressures

Standard 16 x 6.5 - 8 4 Ply 1.9 bar (28 psi)

Option 16 x 4.00 x 8 4 ply 2.2 bar (32 psi)

Parking Brake: Lever operated integral transaxle disc brake

Safety Features: Neutral start interlock

Operator presence control

Braked cutterhead drive (rotary attachment)

Operator Controls

Cutterhead drive: Hand operated lever to engage

(Maintain by twin hand-operator pressure control levers)

Engine Speed: Hand operated lever

Parking Brake: Hand operated lever with engagement lock

Forward and Reverse: Forward and reverse twin hand operator hand/thumb levers

Ignition: On/Off switch

Bypass Valve: Hand operated lever

Weight and Dimensions

30” Rotary attachment fitted 30” Verge attachment fitted

Maximum Working Width: 844 mm 902 mm

Maximum Mowing Width: 762 mm 762 mm

Maximum Overall Length: 2040 mm 1680 mm

Overall Height: 1160 mm 1160 mm

Approx. Working Weight: 195 kg

135 kg (Power unit only)

218 kg (5 blade)

135 kg (Power unit only)

SPECIFICATIONS

1.18 1.18

Recommended Lubricants and Hydraulic Fluids

Grease Points: A good quality medium grease

Cutterhead gearbox (rotary): SAE90

Engine: SAE10W-30

Hydrostatic Unit: BP Vanellus M20W, BP Energol HLP22 or equivalent

Transaxle: SAE EP90 Transmission Oil

Should you be in any doubt please contact your Hayter Limited dealer. Using incorrect grades will cause prema-

ture wear of hydraulic components and invalidate warranty.

Verge Attachments

Code 214D Code 243D

Cylinder Drive: V-Belt/Countershaft V-Belt/Countershaft

Cutting Width: 762 mm 762 mm

Cylinder Diameter: 190 mm 190 mm

Cylinder Speed: 1250 rpm 1250 rpm

Height of Cut: 17 mm (0.7˝) to 62 mm (2.4˝) 17 mm (0.7˝) to 62 mm (2.4˝)

Number of Blades: 3 5

Smooth Rear Roller: Standard Standard

Rotary Attachments

Code 212D

Drive: V-Belt/Gearbox

Cutting Width: 762 mm

Type of Blade: 2 disc with swinging blades

Cutterbar Speed: 2860 rpm

Height of Cut: 20 mm (0.8˝) to 55 mm (2.2˝)

Number of Blades: 4 (2 on each disc)

SPECIFICATIONS

1.19 1.19

Assembling and Removing the Cutterhead Attachments - Introduction

The Condor Hydrostatic Drive Power Unit Code 510D is designed to be used with either the 30” Rotary

Cutterhead Attachment Code 212D or the 30” Verge Cutterhead Attachments Code 214D and 243D. Any of

these attachments can be quickly mounted to or removed from the power unit.

WARNING: PREVENT ACCIDENTS - Stop the engine, apply the parking brake and disconnect the

spark plug lead before attempting to remove or mount a cutterhead attachment.

WARNING: PREVENT ACCIDENTS - Do not attempt to carry out the following procedure by your-

self, another person must assist you.

Power unit with 30” Rotary Cutterhead Attachment.

ASSEMBLING THE MOWER

1.20 1.20

Assembling the Cutterhead Attachment

to the Power Unit

1. Position the cutterhead attachment on level

ground.

2. Remove the cutterhead drive cover.

3. Remove the power unit transmission guard.

4. Remove the engine drive belt from the

countershaft pulley.

5. Loosen the lock nuts (item 1) and screw the

two tensioning bolts (item 2) fully forward

to provide maximum clearance for assembly.

Refer to Fig 1.

6. Position the cutterhead attachment close to

the front of the power unit.

7. One person should tilt the power unit down

at the front by holding and raising the handles,

whilst another person assembles the twin drive

belts between the cutterhead pulley and the

power unit countershaft pulley.

8. Lower the handlebars, align the power unit

to the cutterhead mountings and connect up

using the two bolts, washers and nyloc nuts

(items 3, 4 & 5). Do not fully tighten bolts

at this stage. Refer to Fig 1.

Note: The rotary attachment has two mounting

holes. Assemble using the right hand holes. Refer

to Fig 2, item A.

9. Adjust the two tensioning bolts (item 2, Fig 1)

equally to tension the twin drive belts. The

bolts are correctly tensioned when a deflection

of 13 mm is achieved using finger pressure.

Refer to Fig 3.

10. Tighten the locknuts (item 1) and nuts (item

5). Refer to Fig 1.

11. Re-check the belt tensions as previously

described and readjust if necessary. The twin

drive belts are matched but it is quite normal

for there to be slight differences in tension

between them.

ASSEMBLING THE MOWER

Fig 1

Cutterhead

A A

Fig 2

1. Nut

2. Tensioning Bolt

3. Mounting Bolt

4. Washer

5. Nyloc Nut

.....................

........

"

"

13mm

""""""1" " " """"""""""2

Fig 3

1. Drive pulley attachment (cutterhead)

2. Countershaft pulley (Power unit)

1.21 1.21

Assembling the Cutterhead Attachment

to the Power Unit continued

12. Refit the drive belt from the engine to the

countershaft pulley.

13. Refit the transmission guard to the power unit

and drive cover to the cutterhead.

To remove the cutterhead attachment from the

power unit:

This is achieved by adopting the procedure. ‘To

assemble the cutterhead attachment to the

power unit’ in reverse order.

14. Route the cutterbrake cable from the rotary

attachment over the countershaft pulley shaft

on the power unit, under the support bracket

and secure with a cable tie.

15. Route the cutterbrake cable over the micro

switch bracket (fitted to the side of the

engine) and secure at the same position as the

microswitch wires with a cable tie.

16. From the microswitch bracket route the

cable to follow the cutter clutch cable up

the left hand handlebar to the anchor bracket

and secure the cable adjuster into the bracket

using the two nuts provided, refer to

MAINTENANCE - RUNNING IN

PERIOD - AT FIRST 50 HOURS OF USE

- CHECK CUTTERHEAD BRAKE

CABLE ADJUSTMENT.

17. Remove the pushfix which is secured to the

eye at the end of the cutterbrake cable inner.

18. Fit the cable eye over the pin on the cutter

clutch lever and secure into position with the

pushfix.

19. Adjust the cutterbrake cable, refer to

MAINTENANCE - RUNNING IN

PERIOD - AT FIRST 50 HOURS OF USE

- CHECK CUTTERHEAD BRAKE

CABLE ADJUSTMENT.

20. Refit the transmission guard to the power unit

and the drive cover to the cutterhead.

WARNING: PREVENT ACCIDENTS - Never

operate the mower with the transmission guard

or drive covers removed.

ASSEMBLING THE MOWER

1.22 1.22

Safety Notice

WARNING: PREVENT ACCIDENTS - Before

operating the mower it is essential that;

- The operator reads and understands this

manual.

- The daily maintenance checks have been

properly carried out and the mower is in

good working order.

- The operator should wear safety clothing

and eye protection. Failure to do so could

result in risk to health and safety.

- The area where the equipment is to be used

is inspected and all objects which may be

thrown by the machine are removed.

Operator Presence Control

The controls incorporate an operator presence

control (OPC) which is provided for the protection

of the safety and health of the operator. This system

has been designed to ensure that the cutterhead

drive and ground drive clutches are automatically

disengaged in the event of the operator releasing

hold of the handlebars for whatever reason. Each

handlebar is provided with an OPC lever and these

are mechanically linked such that operation or

either will activate the system. These levers are

lightly spring loaded and are held down by the palm

of the hand during operation. Release of the OPC

levers will cause the cutterhead clutch to disengage

(activating the brake to arrest the rotation attach-

ment cutting devices).

The travel speed rocker levers are spring loaded and

will return to the neutral position when released

thereby halting the motion of the machine.

The engine can only be started when the cutterhead

and ground speed controls are deactivated. The

integral switch sensors will not allow the engine to

be started unless this condition is satisfied.

WARNING: PREVENT ACCIDENTS - Do

not operate the mower if the operator presence

controls are defective in any way. ALWAYS

replace faulty parts and check that they function

correctly before operating the mower.

OPERATING THE MOWER

1.23 1.23

Identification of Controls

1. Transmission Bypass Valve Lever

2. Cutterhead Clutch Control Lever

3. Parking Brake Lever

4. Throttle Control

5. Operator Presence Control (OPC) Levers.

6. Travel Rocker

7. Ignition Switch

Braking System

Parking Brake: The hydrostatic axle unit incorpo-

rates an integral parking brake. This is operated by

the forward right hand lever. To operate the parking

brake, depress the lever until the spring loaded

locking catch automatically engages. To release the

parking brake, depress the lever until the locking

catch becomes free and then move it out of engage-

ment, release the brake lever.

Service Brakes: Service braking is achieved by

the hydrostatic transmission system. When the

forward and reverse travel controls are released or

the engine speed is reduced, service braking occurs

to reduce the travel speed.

WARNING: PREVENT ACCIDENTS - The

service braking system will not hold the mower

at a standstill. ALWAYS ensure that the park-

ing brake is engaged to park the mower at a

standstill.

Throttle Control

Operate the throttle control forwards to in-

crease the engine speed.

Operate the throttle control backwards to re-

duce engine speed.

Note: The engine speed dictates the speed of the

other functions, i.e. travel and cutterhead.

Travel

The forward and reverse travel rocker levers are

duplicated on each handlebar. These are mechani-

cally linked and activation of either will achieve

the desired function. The control levers are spring

centred and will automatically take up the ‘neutral’

position when deactivated.

OPERATING THE MOWER

P

Parking brake engaged

Engine speed

Fast Slow

1

2

34

5

5

6

6

7

1.24 1.24

Travel continued

Forward travel: Grip either handlebar and lay the

thumb over the travel rocker lever. Push forward

with the thumb to travel in the forward direction.

The forward speed will increase as the rocker

lever is pushed further forward or decrease as the

lever is allowed to return under the action of the

return spring. The required forward speed will be

maintained by maintaining the control lever in the

desired position.

Reverse travel: Grip either handlebar and lay the

thumb over the travel rocker lever. Pull backwards/

downwards with the base of the thumb to travel in

a reverse direction. The reverse speed will increase

as the rocker lever is further depressed or decrease

as the thumb pressure is reduced and the lever

returns under the return spring action.

Stop travel: Release the travel rocker lever and it

will automatically return to the neutral position,

thereby causing the mower to come to a standstill.

Adjustment of travel rocker levers: Both LH and

RH travel rockers levers are adjustable for operator

comfort. To adjust, slacken the appropriate bolt (1)

and move the lever assembly (3) in the required

direction. Retighten the clamp bolt securely before

operating machine.

Transmission Bypass Valve Control

When the engine is switched off, the hydrostatic

transmission is locked and acts as an effective

brake. This prevents the mower from being moved.

Activation of the bypass valve lever will unlock the

transmission and allow the machine to be moved

in a forward or reverse direction. Depress and hold

the bypass valve lever before attempting to move

the mower and release it on completion of the

manoeuvre.

IMPORTANT: PREVENT DAMAGE - Do not

operate the bypass valve lever while the engine

is running as this will cause a rapid temperature

rise in the hydrostatic system.

OPERATING THE MOWER

1.25 1.25

Ignition Switch

The engine may only be started when the ignition

switch is in the ‘on’ position (B).

WARNING: PREVENT ACCIDENTS - Always

switch the ignition key to the ‘off’ position (A)

and remove the key when the mower is not in

use.

Cutterhead Drive Operation

The cutterhead drive engagement mechanism is

protected by the Operator Presence Control (OPC)

system.

To engage cutterhead drive: Push the cutterhead

clutch control lever forwards with the left hand

while pushing downwards on the OPC lever with

the palm of the right hand, release the cutterhead

clutch control lever and the cutterhead drive will

remain engaged until such time as the OPC levers

are released. The OPC levers are duplicated on

each handlebar and operation of either (or both)

will keep the system activated.

To disengage cutterhead drive: Release the OPC

levers. Observe that the cutterhead clutch control

lever automatically returns backwards to the disen-

gaged position.

WARNING: PREVENT ACCIDENTS - Do not

operate the mower if the handlebar controls of

the operator presence control system are defec-

tive in any way. ALWAYS replace faulty parts

and check that they function correctly before

operating the mower.

Starting the Engine

This machine is fitted with an Engine Start

Lockout, refer to OPERATOR PRESENCE

CONTROL.

WARNING: PREVENT ACCIDENTS - Before

starting the engine check that:

- The area is clear of bystanders.

- The cutterhead drive is disengaged.

- The parking brake is engaged.

- The travel controls are in neutral.

- You have read and understood the Safety

Precautions Section in this manual.

OPERATING THE MOWER

2

12

STOP

A

B

STOP

A

B

Engage Cutterhead Drive

Disengage Cutterhead Drive

1.26 1.26

OPERATING THE MOWER

Starting the Engine continued

CAUTION: PREVENT DAMAGE - Before

attempting to start the engine, ensure that the

crankcase oil level is correct and check the fuel

level.

Starting a cold engine: Turn the fuel valve and

the engine switch to the ‘on’ position. Set the

throttle control lever to approximately 70% full

throttle and close the choke lever.

Turn the ignition key to the ‘on’ (B) position.

Pull the start grip with a steady motion to start the

engine.

Gradually return the choke lever to the open posi-

tion as the engine warms up.

Once the engine has warmed up increase the throt-

tle setting as required for operation.

CAUTION: PREVENT DAMAGE - Do not

allow the start grip to snap back against the

engine. Return it gently to prevent damage.

Starting a warm engine: Follow the procedure

for ‘Starting a cold engine’ except the use of the

choke will not normally be required when starting

a warm engine.

Stopping the Engine

To stop the engine: Turn the ignition key to the

‘off’ (A) position.

In normal use bring the mower travel to a stop,

disengage the cutterhead drive and engage the

parking brake before stopping the engine.

WARNING: PREVENT ACCIDENTS - If the

engine fails to stop when the ignition switch

is switched to the ‘off’ position (A), turn the

engine to the ‘off’ position and close the fuel

valve. The engine may also be stalled by closing

the choke and opening the throttle control or

removing the spark plug lead.

STOP

A

B

STOP

A

B

1. Fuel Valve

2. On

3. O

1. Engine Switch

2. On

3. O

1. Choke Lever

2. Close

3. Open

1.27 1.27

OPERATING THE MOWER

General Operating Hints

1. The rotational speed of the cutterhead should

always be kept as high as possible to maintain

the highest quality of cut. This in turn requires

the mower engine speed to be kept as high as

possible.

2. The quality of cut will deteriorate if the

forward speed is too high. Always balance the

quality of cut with the work rate required and

set the forward speed accordingly.

3. Never let the mower labour. Reduce the

forward speed or increase the height of cut.

If a verge attachment is used, ensure that the

cutting cylinder is not in heavy contact with

the bottom blade. Regularly check the cutting

cylinder to bottom blade adjustment every few

hours even though cutting performance seems

satisfactory. Rapid wear will take place if the

bottom blade is in heavy or zero contact with

the cutting cylinder.

4. Rotary attachment. Ensure that the

cutterblade and bottom plates are maintained

in good condition.

5. Always disengage the cutterhead drive

when transporting across ungrassed areas.

Verge attachment: Grass will lubricate the cutting

edges in work. Excess heat will build up if the

cutting cylinder is run out of work which will

cause rapid wear to place. For this reason it is also

wise to reduce the cutting cylinder speed when

mowing lightly grassed areas or when the grass is

dry.

6. Cutting performance is best when cutting

against the lie of the grass. In order to take

advantage of this fact the operator should

attempt to alternate the direction of

mowing between cuts.

Adjusting Height of Cutter

Verge attachment

Remove the set screw ‘A’ at each end and use a

suitable tommy bar to reposition the height adjust-

ments quadrants ‘B’ and align with the desired hole

locations. Ensure that the same hole locations are

selected at each end. Finally refit the setscrew and

tighten securely.

1.28 1.28

OPERATING THE MOWER

Adjusting Height of Cutter continued

30’’ Rotary Attachment.

Loosen hand knob (1) sufficiently to allow lever

(2) to be moved to the required height of cut posi-

tion. Retighten the hand knob to secure the height

of cut lever in position.

Handlebar Height Adjustment

The height of the handlebar may be adjusted at the

connection between the handlebar stays (1) and

the plate on the handlebar (2). Adjustment holes

(3) provide 3 alternative handlebar settings. Ensure

that the handlebars are set at the same level on each

side of the mower.

Note: The length of the connecting rods to the

travel control rocker levers must be re adjusted as

necessary to ensure correct operation.

1. Hand knob

2. Height of Cut Lever

1. Handlebar Stay

2. Handlebar

3. Adjustment Holes

1.29 1.29

Maintenance

WARNING: PREVENT ACCIDENTS - When carrying out maintenance procedures it is

essential that:

- The engine is switched off, the spark plug lead removed and the ignition switch is in the ‘off’

position.

- The parking break is applied.

- You have read and understood the

maintenance section of the Operator’s Manual.

IMPORTANT: PREVENT DAMAGE - Regular maintenance is essential for the continued safe

operation of the mower. Correct servicing will prolong the working life of the mower and safeguard the

“Hayter Warranty”. Always fit genuine ‘Hayter service parts’ as these are accurately matched to the

required duty.

Dirt and contamination are the enemies of any hydraulic system. When carrying out maintenance pro-

cedures on the transmission system always ensure that the work area and components are thoroughly

clean before, during and after refitting.

The recommended service intervals are based on normal operating conditions. Severe or unusual con-

ditions will necessitate shorter service intervals.

WARNING: PREVENT ACCIDENTS - Remember the engine and transmission oil is hot after mower

use. Allow to cool before carrying out maintenance procedures.

WARNING: PREVENT ACCIDENTS - Use hazardous substances carefully. The following fluids are

identified as being hazardous;

Substances Assessed risk

Petrol High

Lubricating Oil Low

Transmission Oil Low

Gear box oil Low

Grease Low

When using any of the above fluids it is recommended that the eye protection and gloves are worn and care

is taken to prevent spillage.

Avoid contact with skin; wash off spillage with soap and water.

In case of petrol, keep away from all sources of ignition and wash with soap and water. Remove any con-

taminated clothing and wash thoroughly before use.

Avoid contact with eyes; wash with running water and

seek medical attention.

Avoid ingestion; If swallowed seek medical attention.

CAUTION: PREVENT ENVIRONMENTAL DAMAGE - Dispose of hazardous substances correctly.

MAINTENANCE

1.30 1.30

MAINTENANCE

Engine

Refer to the engine manual for engine maintenance

information. The engine is governed to run at a

maximum speed of 2900 r.p.m. Under no circum-

stances must this speed be modified.

Running In Period - At First 50 Hours of

Use

Check wheel nut torque: Power unit wheel nut

torque setting 80Nm (60lbs ft).

Check belt tension - Engine / Countershaft

drive: Ensure that the cutterhead drive is disen-

gaged and check the free play at the centre of the

belt as shown using finger pressure. If adjustment

is required, slacken the engine securing bolts and

move the engine towards the rear of the mower

until the correct tension is obtained. Finally tighten

the engine securing bolts.

Check cutterhead drive clutch cable adjust-

ment: Ensure that the cutterhead drive is disen-

gaged. Adjust the clutch cable by slackening off

the locknuts at the anchor plate on the left hand

handlebar and moving the adjuster to obtain 3mm

free movement of the cable. Retighten the locknut.

Note: The cutterhead drive clutch cable adjuster

is positioned to the left of the cutterhead brake

adjuster when fitted with a rotary cutterhead attach-

ment.

Check belt guide clearance: Engage the cutter-

head drive and check the clearance between the

belt guides and the belt as shown. If adjustment

is required slacken the idler pulley mounting bolt

and move the belt guides into the correct position.

Retighten the bolt.

Check cutterhead brake cable adjustment (Ro-

tary attachment only): Ensure that the cutterhead

drive is disengaged. Adjust the cutterhead brake

cable by slackening off the locknuts at the anchor

plate on the left hand handlebar and moving the

adjuster to obtain 6mm free movement of the cable.

Retighten the locknut.

Note: The cutterhead brake cable adjuster is po-

sitioned to the right of the cutterhead drive clutch

cable adjuster.

1. Countershaft Pulley

2. Engine Pulley

1. Anchor Plate on Handlebars

2. Locknut

3. Adjuster

1. 6mm Gap

2. Belt Guides

3. Engine Pulley

4. Idler Pulley

5. Countershaft pulley

1. Anchor Plate on Handlebars

2. Locknut

3. Adjuster

1.31 1.31

MAINTENANCE

Running In Period - At First 50 Hours of

Use continued

Check belt tension - Cutterhead input drive:

Check the free play at the centre of the drive belt

span as shown using finger pressure. If adjustment

is required, refer to MOUNTING OF CUTTER-

HEAD ATTACHMENT.

Check belt tension - Main engine drive: Check

the free play at the centre of the drive belt as shown

using finger pressure. If adjustment is required

adjust the jockey pulley bracket until the correct

belt tension is obtained.

Daily and Before Use

Check engine oil: If the oil level is below the

upper mark on the dipstick, top up with the correct

grade of engine oil, refer to ENGINE OWNER’S

MANUAL.

Air cleaner (Dual element type): Check the air

cleaner elements for holes or tears and replace if

damaged. Clean the paper element.

CAUTION: PREVENT DAMAGE - Always

replace a damaged air cleaner or damage to the

engine will result. NEVER run the engine with-

out the air cleaner correctly fitted.

Check fuel level: Top up as necessary with

unleaded petrol. Always top up before storing the

mower over night to prevent water condensation

from contaminating the fuel.

WARNING: PREVENT ACCIDENTS - Never

use petrol or low flash point solvents when

cleaning the air cleaner elements. A fire or

explosion could result.

WARNING: PREVENT ACCIDENTS - Petrol

is highly flammable. Observe all relevant safety

precautions. Refer to SAFETY PRECAUTIONS

- PREPARATION.

.....................

........

"

"

13mm

""""""1" " " """"""""""2

1. Drive Pulley Attachment (Cutterhead)

2. Countershaft Pulley (Power unit)

1

2

3

1. Drive Pulley Attachment (Cutterhead)

2. Countershaft Pulley (Power unit)

1.32 1.32

MAINTENANCE

Daily and Before Use continued

Check hydrostatic unit oil level: Always check,

prior to starting, when the mower is cold. Remove

the reservoir cap and check the fluid level. The

level should not be above the ‘cold’ mark. Top up,

if necessary to the cold mark with the

recommended grade of transmission fluid, refer

to SPECIFICATIONS, and replace the reservoir

cap. If the natural colour of the transmission fluid

has become ‘milky’ or black, it is possible that an

overheating or water contamination problem exists.

In such cases, the mower should be checked by a

Hayter dealer and the oil should be changed, refer

to MAINTENANCE - EVERY 200 HOURS.

IMPORTANT: PREVENT DAMAGE - Do not

overfill as this will reduce the expansion vol-

ume in the reservoir and leakage may occur

at operating temperature. If frequent topping

up is required, locate and repair any leaks.

Operation at a low fluid level may result in

permanent internal damage.

Check the operator presence controls: Stop the

engine.

Check the operation of the microswitches, ensure

the operation arm is free of any debris and that

the roller rotates freely. Spray the hydrostatic unit

neutral detent microswitch with a water repellent

lubricant.

Engage the cutterhead drive and operate the OPC

levers. The engine should not start when the

normal starting procedures are followed.

Start the engine, engage the cutterhead drive and

operate the OPC levers. Release the OPC levers

and ensure that the cutterblades cease to rotate

within 5 seconds.

Operate and hold the travel rocker lever in the

forward travel direction. The engine should not

start when normal starting procedures are fol-

lowed. Carry out a similar check for reverse travel.

WARNING: PREVENT ACCIDENTS - Keep

bystanders away when checking the opera-

tor presence control system. DO NOT use the

mower unless the operator presence controls

work correctly as described below. Consult your

Hayter dealer if the system malfunctions.

1.33 1.33

Daily And Before Use continued

Check travel controls: Start the engine.

Engage forward travel and operate at maximum

speed over level ground, release the travel controls

and ensure that the mower comes to a stop.

Engage reverse travel and operate at maximum

speed over level ground, release the travel controls

and ensure that the mower comes to a stop.

Check fasteners: Check that all nuts, bolts, pins

and linkages are secured correctly in place and are

in good order.

Check tyres: Examine the condition of the tyres

and check that the inflation pressures are correctly

set, refer to SPECIFICATIONS.

Verge attachment: Examine the condition

of the cutting cylinder and the bottom blade,

adjust as necessary, refer to MAINTENANCE

- CUTTERHEAD CYLINDER TO BOTTOM

BLADE ADJUSTMENT.

Rotary attachment: Check the condition of the

cutterblades and mounting arrangement for signs

of wear, damage or looseness. Ensure that the

cutterblades are not bent or cracked and that the

cutterblade securing bolts are tight. Damaged or

excessively worn cutterblades may be out of

balance which will cause excessive vibration this

may lead to breakage or result in serious damage

to the machine.

WARNING: PREVENT ACCIDENTS - Never

use the mower if the cutterblades and mounting

arrangement are seriously worn, damaged, out

of balance or loose.

Remove all grass cuttings and build up of debris

from the cutterhead area, the cooling air intake

areas/external surfaces of the engine and the inter-

lock microswitches.

WARNING: PREVENT ACCIDENTS - Check

all guards and safety devices. Never operate the

mower unless the guards are securely in posi-

tion, in good condition and all safety devices are

in place and in good working order.

MAINTENANCE

1.34 1.34

MAINTENANCE

Every 50 Hours

Perform routine checks: Refer to DAILY

BEFORE USE.

Check power unit wheel nut torque: Wheel nut

torque setting - 80 Nm (60lbs ft)

Rotary attachment: Inspect the chain couplings

between the cutter headgear boxes. Inspect sprock-

et teeth and chains for signs or wear.

IMPORTANT: PREVENT DAMAGE - If the

chains / countershaft are removed for any reason,

ensure that the cutterhead phasing is correct after

refitting.

Lubrication

Transaxle: Check oil level on dipstick. This

should be level with the hole indicator on the dip-

stick. Top up if necessary with the correct grade of

transmission fluid, refer to SPECIFICATIONS.

Top up fluid should be introduced through the dip-

stick tube.

Cutterhead Gearbox (Rotary Attachment):

Remove filler plug on top of the gearbox and

check oil level. Gearbox should be 3/4 full. If nec-

essary top up with the correct grade of oil, refer to

SPECIFICATIONS.

General: Lightly apply a good quality general

purpose lubricating oil to the following points;

All linkage pivot points

All inner cables

Rear roller quadrant pivot bushes (Verge

Attachment).

Apply a good quality medium grade grease to the

following points:

Front wheels (Rotary Attachments).

Carrier pivot (Verge Attachments).

Cylinder bearing housings (Verge Attachments).

Chain couplings - between cutterhead gearboxes

(Rotary Attachment).

1.35 1.35

MAINTENANCE

Every 200 Hours

Perform routine checks: Refer to DAILY

BEFORE USE, EVERY 50 HOURS USE.

Change transmission fluid: Hydrostatic Unit.

IMPORTANT: PREVENT DAMAGE - Dirt and

contamination are the enemies of any hydraulic

system. Ensure that the work area and the com-

ponents are thoroughly clean before during and

after refitting. Do not allow debris to become

entrained within the hydraulic system.

It is recommended that the following procedure is

adopted when carrying out an oil change.

- Remove the lower left hand cover and the rear

fan guard screen to gain access to the hydro

static unit.

- Disconnect the ball joint from the lower

actuating lever by removing the 5/16” UNF hex,

nut and spring washer.

- Slacken the main engine drive belt by loosening

the jockey pulley bracket.

- Remove the ¼” UNC Setscrew and retaining

washer and remove the fan.

- Remove the 4 mounting bolts and support the

hydrostatic unit.

- Remove the connecting pipe from the top of the

hydrostatic unit and allow the residual oil to

drain into a suitable can.

- Lift the unit and unhitch the drive belt.

- Lower the hydrostatic unit and remove from the

machine.

- Thoroughly clean dirt and debris from around

the hydrostatic unit.

- Remove the drain plug and allow the oil to

drain into a suitable can. Rotate the input shaft

to assist the draining procedure. Finally replace

the drain plug and tighten securely.

- Turn the unit the right way up and remove the

plastic cup (Note this has a left hand thread) and

the upper bleed plug.

1.36 1.36

MAINTENANCE

Every 200 Hours continued

- Carefully refill the unit with fresh

transmission oil of the recommended grade,

refer to SPECIFICATIONS, until fluid is seen

to flow from the bleed plug aperture. Replace

the cap securely and hand tighten the bleed

plug.

- Remove the plastic reservoir (note this has a left

had thread), from the power unit. Thoroughly

clean and ensure that the mesh screen is fully

open.

- Refit the hydrostatic unit following the

dismantling procedure in reverse order. Torque

the 4 mounting bolts and the fan mounting bolt

to 10.2 - 11.3Nm (7.5 - 8.3 lbs ft).

- Retention the engine drive belt, refer to

RUNNING IN PERIOD.

- Reconnect the connecting pipe.

- Reconnect the ball joint to the actuating lever.

- Replace lower cover and fan guard screen.

- Do not replace the plastic reservoir at this stage.

- Remove the bleed plug from the top of the

hydrostatic unit. Top up through the reservoir

base until oil flows from the bleed plug

aperture and keep topped up during the

following procedure.

WARNING: PREVENT ACCIDENTS - Do not

proceed to the next stage unless all guards have

been replaced and fully secured.

- Start the engine and maintain as low a throttle

setting as possible.

- Ease the machine forwards and backwards

until all residual air has bled from the bleed

plug aperture. Ensure that the reservoir cup is

kept topped up during this process.

- Stop the engine and set the parking brake.

- Replace the bleed plug and secure.

- Replace the reservoir cap and hand tighten.

1.37 1.37

MAINTENANCE

Every 200 Hours continued

- Top up the reservoir to the ‘’COLD’ level and

replace the cap. Clean off any surplus oil from

around the reservoir and the hydrostatic unit to

prevent a build up of debris.

The procedure has now been completed.

Note - The oil change procedure can be accom-

plished without removing the hydrostatic unit but

it will take an exceptionally long period to refill

the unit through the small diameter feed pipe.

Check all belt tensions: Refer to RUNNING IN

PERIOD.

Check cutterhead drive clutch cable adjust-

ment: Refer to RUNNING IN PERIOD.

Check condition of cutterhead drive brake pad:

Replace if excessively worn.

Check cutterhead drive brake adjustment:

Refer to RUNNING IN PERIOD.

Power Unit General Maintenance

Transmission bypass valve: The lever should be

adjusted so that the bypass valve plunger on the

hydrostatic unit is fully depressed when the lever

is just touching the handlebar cross-tube.

To adjust setting slacken adjuster nuts at end of

cable. Adjust cable setting and lock the adjuster

nuts. Check that the machine can be moved with

the engine switched off when the bypass valve

lever is operated.

Parking brake - cable adjustment: To adjust the

cable, slacken off the locknut and turn the cable

adjuster. A correctly set cable should have no

slack. When the brakes are applied, the brake lever

should operate smoothly and lock at the end of its

travel.

Check that the parking brake has been applied by

depressing the transmission bypass valve lever and

try to pull or push the machine. The wheels should

be locked. Re adjust the cable if the machine is

able to be moved. Tighten the cable adjuster lock-

nuts.

1.38 1.38

MAINTENANCE

Power Unit General Maintenance

continued

Travel Speed: The forward and reverse stops re-

strain the hydrostatic unit actuating lever from be-

ing moved excessively and prevent internal compo-

nents from being damaged. The setting dimensions

shown should be used. These dimensions may be

increased if the maximum speed of the machine is

to be reduced, but the dimensions should never be

less than those indicated.

To set the forward / reverse stops correctly for min-

imum travel speeds, loosen the adjuster locknuts

and screw the adjuster screws away from the actu-

ating lever. Operate the actuating lever by hand to

its extreme / full travel position for forward travel

and move the adjuster screw to stop the actuating

lever 1.6mm before the extreme / full travel posi-

tion is reached. Repeat this procedure for reverse

travel except move the adjuster screw to stop the

actuating lever 5mm before the extreme / full travel

position is reached. Tighten the locknuts.

IMPORTANT: PREVENT DAMAGE - The

hydrostatic unit may sustain permanent damage

if the forward and reverse stops allow greater

travel than the limits indicated.

Neutral detent mechanism: Should the mower

creep forwards or backwards when the travel speed

control levers are in the neutral position it will be

necessary to adjust the neutral detent setting.

Slacken hex. nuts (1) and adjust the bracket on the

slots until the actuating lever (2) of the hydrostatic

unit is parallel with the side of the engine deck

(Neutral position).

Retighten the hex nuts securely.

Recheck the mower operation and make further

adjustments is necessary.

1

2

3

5mm

min.

1.6mm

min.

1. Forward stop / Adjuster

2. Reverse stop / Adjuster

3. Hydrostatic unit actuating lever

1. Hex nuts

2. Actuating lever (view from under the machine)

1.39 1.39

MAINTENANCE

Power Unit General Maintenance

continued

Adjustment of engine lockout switches: The

micro switch must be positioned such that when

the actuating levers (transmission neutral detent

lever or cutter clutch idler arm) are in the neutral/

disengaged position the switches must be fully

closed. To adjust, set the appropriate lever in the

neutral/disengaged position, slacken off the switch

mounting bolts and slide the switch along its

mounting slots until the switch is heard to click

shut. Retighten mounting bolts.

Check the operation of the operator presence con-

trols, refer to DAILY BEFORE USE.

Verge Attachment

IMPORTANT: PREVENT DAMAGE - It is

essential that the relationship between the

bottom blade and the cutting cylinder is kept in

good adjustment in order to ensure good

cutting performance, minimum power con-

sumption and prolonged life for the cutting

edges.

Cutterhead cylinder to bottom blade adjust-

ment: Carry out the following procedure before

commencing work and re-check the settings every

few hours.

Check that the cutting cylinder is correctly set to

the bottom blade by holding a thin piece of paper

between the cutting cylinder and the bottom blade

as shown. Carefully rotate the cylinder and check

that the paper is cut cleanly at all points along the

length of the blade. Hold the paper at 90 degrees

(right angles) to the bottom blade to obtain the cor-

rect cutting action.

If adjustment is necessary proceed as follows:

Slacken the nearside and offside setscrews ‘A’.

Slacken both locknuts ‘B; and turn the adjusting

nuts ‘C’ in a clockwise direction. The adjust-

ing nuts should be rotated one flat of the nut at

a time, alternating end to end, while rotating the

cutting cylinder backwards until it is felt to be in

‘fleeting’ contact with the bottom blade along its

entire length. Re check the cutting action along the

length of the bottom blade using a thin piece of

paper and making marginal adjustments as neces-

sary.

1

2

3

1. Transmission micro switch

2. Transmission neutral detent lever

3. Chassis

1. Cutter clutch idler arm

2. Cutter clutch micro switch

1.40 1.40

MAINTENANCE

Verge Attachment continued

Finally tighten locknuts ‘B’ using 2 spanners to

avoid inadvertent movement of adjuster nuts ‘C’

and tighten setscrews ‘A’. Recheck the cutting

action as previously described to ensure that the

setting has not moved.

If it is impossible to obtain a good clean paper

cut across the entire length of the bottom blade it

will be necessary to remove any high spots on the

spirals/bottom blade with a stone. In severe cases

it will be necessary to regrind the cutting cylinder

and the bottom blade, refer to GRINDING.

Do not be tempted to over adjust causing heavy

contact between the cylinder and bottom blade

as this will cause very rapid uneven wear to take

place leading to tram lining and waviness of the

cutting edges. The frictional losses will be high

and a significant amount of power will be absorbed

thus reducing the power available for cutting. The

heating effect due to friction will cause excessive

expansion to take place which will further aggra-

vate the situation by increasing the contact pres-

sure.

If the cutterhead is allowed to operate for more

than a few hours without adjustment the running

wear will eventually cause the cylinder to run out

of contact with the bottom blade. At this stage very

rapid rounding of the cutting edges will occur as

grass and abrasive particles pass through the clear-

ance between the blades.

Lack of attention to adjustment can therefore

be foolhardy as maintenance costs will escalate.

Quality of cut will also be seriously affected as

will the health and growth of the grass.

An experienced operator will notice when a cutter-

head starts to go out of adjustment, when the grass

ceases to be cut cleanly and the cut ends become

ragged.

Cutterhead grinding: It will be necessary to

carry out a grinding operation to correct cylinder

spiral edges or a bottom blade edge which have

become excessively rounded or distorted. A bot-

tom blade which is nearing the end of its wear life

should be replaced and this should be ground on

its holder prior to fitting, refer to CUTTERHEAD

BOTTOM BLADE REPLACEMENT.

1.41 1.41

MAINTENANCE

Verge Attachment continued

Cutterhead grinding continued: When grinding

operations are necessary it is essential that both

cylinder and bottom blade are ground at the same

time. The only exception to this rule is when a new

cylinder is fitted in which case it is only neces-

sary to grind the bottom blade. All such grinding

operations should be carried out by your dealer on

a quality, well maintained cylinder / bottom blade

grinding machine.

Cutterhead bottom blade replacement: Remove

the bottom blade holder by removing the three

fixing bolts at each end and withdrawing from the

cutterhead. Remove the worn bottom blade and

discard the countersunk retaining screws. Fit the

new blade to the holder and loosely assemble with

new retaining screws. Tighten the centre retaining

screws to a torque of 54 Nm (40 lbs ft). Continue

by tightening the remaining fasteners to the same

torque by working from the centre out towards the

blade ends.

The new bottom blade must be ground on its hold-

er prior to refitting to the cutterhead.

Adjust the cutting cylinder position to give ade-

quate clearance for fitting the new bottom blade

holder. Refit the bottom blade holder assembly

using new fixing bolts and tighten securely. Finally

adjust the cylinder to the bottom blade, refer to

CUTTERHEAD CYLINDER TO BOTTOM

BLADE ADJUSTMENT.

Rotary Attachment

WARNING: PREVENT ACCIDENTS - NEVER

work on the cutterblades unless the spark plug

lead has been removed. The cutterblades have

sharp edges. ALWAYS wear strong gloves to

protect your hands when working on the cutter-

blades. DO NOT operate tools towards the cut-

ting edges to avoid the risk of injury should the

tool slip. ALWAYS use genuine Hayter replace-

ment parts.

WARNING: PREVENT ACCIDENTS -

ALWAYS renew both cutterblades on each bot-

tom plate to ensure the cutting mechanism is

balanced, NEVER replace cutterblades individ-

ually. ALWAYS use new bolts, nuts and washers

when fitting new cutterblades.

1.42 1.42

MAINTENANCE

Rotary Attachment continued

PREVENT DAMAGE: A damaged cutterblade

will cause the cutting mechanism to be out

of balance and excessive vibration will occur

which may lead to breakage. DO NOT use an

unbalanced cutting mechanism.

Replace the cutterblades every 2 years or sooner

if excessively worn or damaged.

WARNING: PREVENT ACCIDENTS - It is

wise to seek assistance when removing and

inverting the cutterhead attachment.

The condition of the cutterblades and the

mounting arrangement should be checked regu-

larly for signs of wear or damage. Ensure that

the cutterblades are not bent or cracked.

Regularly check that the bolts securing the cut-

terblades and bottom plate are secure.

To remove the cutterblades: Remove the cutter-

blade nut (2) and bolt (5).

How to assemble the cutterblades: Assemble cut-

terblades (4) such that they are below and pointing

away from the bottom plate (1). Tighten the cut-

terblade nuts (2) and bolts (5) to a torque of 19Nm

(14 lbs. ft.).

Tighten the bottom plate bolt (7) to a torque of

54Nm (40lbs. ft).

Always replace the tab washer (6) before re-assem-

bly,

Cutterblades

Cutterblade phasing: IMPORTANT: PREVENT

DAMAGE - The cutterheads must be correctly

phased. Ensure that the cutterblades are fitted

into the correct mounting holes the underdeck

as shown.

Part No

HY590

Part No

2779

111"3904"A

1.43 1.43

PREPARING THE MOWER FOR STORAGE

Preparing the Mower for storage

Storage for long periods: To ensure that the mower is

maintained in good working order it is important that

the following procedure is adopted when the mower is

stored for periods in excess of one month. Refer to the

maintenance section and engine handbook as neces-

sary.

WARNING: PREVENT ACCIDENTS - Ensure

that the mower is outdoors, away from all possible

sources of ignition and that the engine is cool prior

to carrying out the following procedure.

Drain fuel from the engine and carburettor.

Disconnect the spark plug lead. Change the engine oil.

Remove the engine spark plug and pour a tablespoon

of clean engine oil into the spark plug aperture. Do not

exceed the stated volume of oil as engine damage may

occur on restarting. Operate the engine start grip sev-

eral times to crank the engine. This will distribute the

oil. Replace the spark plug.

Pull the engine start - grip slowly until resistance is

felt. Continue pulling until the notch on the starter pul-

ley aligns with the hole on the recoil starter as shown

in the engine Owner’s Manual. At this point, the intake

and the exhaust valves are closed and this will help to

protect the engine from internal corrosion.

Clean all areas of the power unit, engine and cutter-

head attachment.

Lubricate the mower.

Treat bare metal parts with a water repellent anti-

corrosion product.

Rest the machine on wooden blocks to remove the

weight of the mower from its wheels.

Cover the mower with a protective sheet and store it in

a dry, ventilated area.

1.44 1.44

GRASS CUTTING FAULTS

FAULT POSSIBLE CAUSE REMEDY

Uneven cut Undulating ground contours Change direction of cut

Cutterblades worn or damaged Sharpen or replace as necessary

Cutterblades out of balance Replace as necessary

Wheel damaged Inspect and replace as necessary

Scalping Height of cut too low Raise the height of cut

Rotary Attachment

Verge Attachments

FAULT POSSIBLE CAUSE REMEDY

Ridge lines in the cut

across the direction of

travel over full width

Forward speed too high Reduce forward speed

Cylinder speed too low Increase mower engine speed

Height of cut too low Raise the height of cut

Clutch system out of adjustment Adjust as necessary

Some uncut or poor cut

strands of grass

Cutting cylinder is partially out of contact

with the bottom blade

Re adjust cutting cylinder to the bottom

blade

Cutting cylinder is in heavy contact with the

bottom blade

Re adjust cutting cylinder to the bottom

blade

Height of cut is too high Lower the height of cut setting

Cutting edges of cutting cylinders / bottom

blades are rounded

Re grind to restore the cutting edges

Lines of uncut or badly

cut grass in direction of

travel

Tram lining of cutting edges due to heavy

contact caused by incorrect cutting cylinder

to bottom blade adjustment

Re grind to restore the cutting edges

Bottom blade in ground contact Raise the height of cut

Scalping Height of cut too low Raise the height of cut

Excessive bottom blade

wear

Bottom blade in heavy ground contact Raise the height of cut

Cutting edges of the cutting cylinder / bot-

tom blade are rounded

Re grind to restore cutting edges

Cylinder is in heavy contact with the bottom

blade

Re adjust the cutting cylinder to the bottom

blade

1.45 1.45

When using the following chart it may be found that overhaul of major components are necessary. In this

case it is recommended that your authorised dealer make these repairs as they are properly equipped to

do this work.

WARNING: PREVENT ACCIDENTS - ALWAYS switch off the mower engine, turn the ignition

controls to the ‘off’ position and apply the parking brake before attempting to work on the mower.

TROUBLE SHOOTING

FAULT POSSIBLE CAUSE REMEDY

Engine will not start Travel control interlock switch sensor not

energised

Ensure travel control levers are in the neutral

position

Check setting of interlock switch sensor

Ignition control switched off Turn ignition control to the ‘on’ position

Engine switch in the ‘off’ position Turn the ignition switch to the ‘on’ position

Cutterhead drive interlock switch sensor not

engaged

Check setting of cutterhead interlock switch

sensor

Disengage the cutterhead drive

Fuel valve closed Turn the fuel valve to the ‘on’ position

Insufficient ‘choke’ Reset the choke lever

For all other engine problems; refer to ENGINE HANDBOOK

Lack of transmission

drive

Parking brake engaged Release parking brake

Low oil level Fill reservoir to correct level

Air in system Carry out ‘bleeding’ procedure

Incorrect oil used Drain reservoir and refill with correct oil

Drive belt incorrectly tensioned Re tension drive belt

Broken drive belt Replace drive belt

Bypass valve open Close bypass valve

Incorrect linkage adjustment Re adjust linkage setting

Defective hydrostatic unit or transaxle Consult your authorised dealer

Forward / backward

transmission creep in

neutral

Neutral adjustment incorrectly set Re adjust neutral detent mechanism

Transmission system

overheating

Blocked cooling fins Clean fins

Hydrostatic unit oil level low Check reservoir and top up as necessary

Air in hydrostatic system Carry out ‘bleeding’ procedure

Transaxle oil level low Check the dipstick and fill to the correct level

Parking brake engaged Disengage parking brake

Cutterhead drive brake engaged Re adjust brake settings

Defective cooling fan or fan drive Check fan operation and service as required

1.46 1.46

TROUBLE SHOOTING

FAULT POSSIBLE CAUSE REMEDY

Incorrect parking brake

operation

Worn brake discs Replace brake discs. Consult your authorised

dealer.

Incorrect cable adjustment Re adjust the cable setting

Excessive noise in

transmission system

Hydrostatic unit oil level low Fill reservoir to the correct level

Air in hydrostatic system Carry out ‘bleeding’ procedure

Transaxle oil level low Check the dipstick and fill to the correct level

Incorrect belt tension Re adjust as necessary

Excessive oil viscosity due to too cold

conditions

Allow system to warm up

Low cutterhead power Incorrect belt tensions Re adjust belt tensions

Incorrect cutterhead drive clutch adjustment Re adjust as necessary

Lack of cutterhead drive Broken drive belt Replace drive belt

Incorrect cutterhead drive clutch adjustment Re adjust as necessary

After initial satisfactory

operation the machine

loses power

Worn hydrostatic unit Replace as necessary

Hydrostatic unit oil level low Fill reservoir to correct level

Incorrect oil viscosity Drain system and refill with correct grade

of oil

Air in hydrostatic unit Carry out ‘bleeding’ procedure

Overheating Refer to TRANSMISSION SYSTEM

OVER HEATING

Cylinder ‘knocks’ while

rotating (Verge attach-

ment only)

Incorrect belt tensions Re adjust belt tensions

High spot on cylinder or bottom blade due

to contact with a foreign object

Remove the high spot with a stone to restore

cutting edges. Serious damage will neces-

sitate re grinding.

Worn cylinder bearings Replace as necessary

Cutterhead vibrates

excessively (Rotary at-

tachment only)

Worn, damaged or loose cutterblades Replace, re sharpen or tighten immediately

Damaged or loose bottom plate Replace, re sharpen or tighten immediately

1.47 1.47

ELECTRICAL CIRCUIT DIAGRAM

Black

Black

Stop*Switch

(Mounted*on*handlebar)

Control

Module

Stop*Switch

Wire

Red

Red

Engine*Stop

Switch*Wire

Engine*Stop

Switch

(Mounted*On*

Engine)

Engine*Stop

Switch*Wire

Red

Black

On

OFF

Yellow

Yellow

Switch*Link*Wire

Red

Transmission

Microswitch

Cutter*Clutch

Microswitch

Blue

Red

Blue 4

6

5

1

2

7

Item No. Description Part No.

1 Switch Assembly C/W Keys 510224

2 Control Module Assy 111-5820

4 Cable Assy Microswitch 510116

5 Cutterclutch Microswitch 510068

6 Transmission Microswitch 510069

7 Cable Assy Engine Stop 510227

1.48 1.48

WARRANTY

HAYTER LIMITED Warrants to the original user / purchaser that this unit shall be free from defects in mate-

rial and workmanship for a period of 12 calendar months from the date of delivery. This warranty excludes

proprietary items which have the benefit of the supplying manufacturers warranty.

Engine manufacturers furnish their own warranties and provide services through their authorised network. If

you experience any difficulty please contact your specialist Hayter dealer.

It is the end user / purchasers responsibility to ensure that the service schedule and service record book as

applied are acted upon. HAYTER LIMITED reserve the right to request inspection of a service record book,

where relevant at any reasonable time. Failure to keep the service schedule up to date may invalidate the

warranty. Owners should therefore satisfy themselves that the products are operated and serviced correctly,

particularly where they are operated on a contract or hire basis.

This warranty which is not capable of assignment does not apply to any unit that has been tampered with,

altered, misused or abused and will become invalid if non genuine Hayter parts are fitted. This warranty

does not cover minor adjustments unless they are due to defective materials or workmanship. Consult the own-

ers handbook or your authorised Hayter dealer for assistance when making these

adjustments.

To make a warranty claim contact your authorised Hayter dealer through whom the machine was originally

supplied, indicating the machine serial number and purchase date. Subject to the conditions and exclusions in

this warranty, the authorised dealer will at our option, repair or replace any warranted part within the duration

of the warranty period.

This warranty gives you specific legal rights and is in addition to any statutory rights to which you may be

entitled and your statutory rights are not affected by this warranty. If you need additional information concern-

ing this written warranty or assistance in obtaining services please write or telephone: HAYTER LIMITED,

Service Department, Spellbrook, Bishop’s Stortford, Herts., CM23 4BU. Telephone: ( 01279 ) 723444.

1.49 1.49

NOTES

1.50 1.50

NOTES

1.51 1.51

CUSTOMER INFORMATION

Machine Details

Engine Serial No: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydrostatic Unit Serial No: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transaxle Serial No: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

P.U Serial No: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Verge Attachment Serial No: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rotary Attachment Serial No: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .