Toro Groundsmaster 1200 Service Manual
  1. Manuals
  2. Brands
  3. Toro Manuals
  4. Lawn Mower
  5. Groundsmaster 1200
  6. Service manual
Toro Groundsmaster 1200 Service Manual

Toro Groundsmaster 1200 Service Manual

Pull-behind rotary mower
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
© 2018—The Toro® Company
8111 Lyndale Avenue South
Bloomington, MN 55420
Groundsmaster
Pull-Behind Rotary Mower
Form No. 18235SL Rev A
®
1200
Contact us at www.Toro.com.
Original Instructions (EN)
All Rights Reserved

Advertisement

Table of Contents
loading

Related Manuals for Toro Groundsmaster 1200

Summary of Contents for Toro Groundsmaster 1200

  • Page 1 Form No. 18235SL Rev A Groundsmaster ® 1200 Pull-Behind Rotary Mower © 2018—The Toro® Company Original Instructions (EN) 8111 Lyndale Avenue South Contact us at www.Toro.com. Bloomington, MN 55420 All Rights Reserved...
  • Page 2 Revision History Revision Date Description Initial issue. 11/2018 Revision History Page 2 Groundsmaster® 1200 Pull-Behind Rotary Mower 18235SL Rev A...
  • Page 3 Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail servicemanuals@toro.com...
  • Page 4 Notes: Notes: Page 4 Groundsmaster® 1200 Pull-Behind Rotary Mower 18235SL Rev A...
  • Page 5 Catalog for your machine and its accessories with this Service Manual for reference. Additional copies of the Operator’s Manual and Parts Catalog are available at www.toro.com. The Toro Company reserves the right to change the product specifications or this publication without notice. DANGER This safety symbol means danger.
  • Page 6 Figure 1 Groundsmaster 1200 Pull-Behind Rotary Mower Preface Page 6 Groundsmaster® 1200 Pull-Behind Rotary Mower 18235SL Rev A...
  • Page 7 Service Procedure Icons The following icons appear throughout this Service Manual to bring attention to specific important details of a service procedure. Critical Process This icon is used to highlight: • installing safety equipment (shields, guards, seat belts, brakes and R.O.P.S. components) that may have been removed.
  • Page 8 Table of Contents Preface ........................ 5 Chapter 1: Safety .................... 1–1 Safety Instructions ..................1–2 Safety and Instructional Decals ..............1–5 Chapter 2: Specifications and Maintenance ............ 2–1 Specifications ....................2–2 Torque Specifications ................... 2–5 Shop Supplies .................... 2–10 Special Tools ....................2–12 Troubleshooting ..................

  • Page 9: Table Of Contents

    Chapter 1 Safety Table of Contents Safety Instructions ..........................1–2 Before Operating the Machine ......................1–2 While Operating the Machine ......................1–3 Maintenance and Service........................1–4 Safety and Instructional Decals ......................1–5 Groundsmaster® 1200 Pull-Behind Rotary Mower Page 1–1 Safety 18235SL Rev A...

  • Page 10: Safety Instructions

    Safety Instructions The Groundsmaster 1200 Pull-Behind Rotary Mower machine is tested and certified by Toro for compliance with existing safety standards and specifications. Hazard control and accident prevention are partially dependent upon the design and configuration of the machine. They are also dependent upon awareness, concern and proper training of the personnel involved in the operation, transport, maintenance and storage of the machine.

  • Page 11: While Operating The Machine

    While Operating the Machine • Operate the machine cutting units only in well-lit areas. • Watch for holes or other hidden hazards. • Do not drive close to sand traps, ditches, creeks, or other hazards. • Reduce speed when making sharp turns. Avoid sudden stops and starts. •...

  • Page 12: Maintenance And Service

    At the time of manufacture, the machine conformed to all of the applicable safety standards. To ensure the optimum performance and continued safe use of the machine, use only genuine Toro replacement parts and accessories. Use of non-Toro replacement parts and accessories can result in non-conformance with safety standards and can potentially void the warranty.

  • Page 13: Safety And Instructional Decals

    Numerous safety and instruction decals are affixed to the Groundsmaster 1200 Pull-Behind Rotary Mower. If any decal becomes illegible or damaged, install a new decal. Decal part numbers are listed in the Groundsmaster 1200 Parts Catalog. Order replacement decals from Authorized Toro Distributor.
  • Page 14 Safety: Safety and Instructional Decals Page 1–6 Groundsmaster® 1200 Pull-Behind Rotary Mower 18235SL Rev A...
  • Page 15 Chapter 2 Specifications and Maintenance Table of Contents Specifications ............................2–2 Overall Dimensions..........................2–2 Chassis .............................. 2–4 Cutting Units ............................2–4 Torque Specifications ........................... 2–5 Calculating the Torque Values When Using a Drive-Adapter Wrench ..........2–5 Identifying the Fastener........................2–6 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)..........
  • Page 16 Specifications Overall Dimensions g241347 Figure 2 Groundsmaster 1200 Pull-Behind Rotary Mower Cutting Units Lowered (Mow Position) Specifications and Maintenance: Specifications Page 2–2 Groundsmaster® 1200 Pull-Behind Rotary Mower 18235SL Rev A...
  • Page 17 Overall Dimensions (continued) g265562 Figure 3 Groundsmaster 1200 Pull-Behind Rotary Mower Cutting Units Raised (Transport Position) Groundsmaster® 1200 Pull-Behind Rotary Mower Page 2–3 Specifications and Maintenance: Specifications 18235SL Rev A...
  • Page 18 Chassis Item Description Tire size 20 x 10 - 10, 6 ply, Tubeless Tire pressure 206.8 kPa (30 psi) Wheel lug nut torque 75 to 101 N∙m (55 to 75 ft-lb) Torsion axle bolt 37 to 45 N∙m (27 to 33 ft-lb) Cutting Units Mounting Cutting units are supported by lift arms,...
  • Page 19 Torque Specifications The recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in this manual.
  • Page 20 Toro recommends replacing fasteners with a locking feature once they have been removed because the effectiveness of the locking feature diminishes with each reuse. If it is necessary to reuse a fastener with a locking feature; apply a thread locking compound (Loctite, for example) to the fastener during installation.
  • Page 21 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size Grade 1, 5 SAE Grade 1 Bolts, SAE Grade 5 Bolts, SAE Grade 8 Bolts, and 8 with Screws, and Studs with Screws, and Studs with Screws, and Studs with Thin Height Regular Height Nuts Regular Height Nuts...
  • Page 22 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws, and Class 10.9 Bolts, Screws, and Thread Size Studs with Regular Height Nuts Studs with Regular Height Nuts (Class 8 or Stronger Nuts) (Class 10 or Stronger Nuts) M5 X 0.8 57 ±...
  • Page 23 Other Torque Specifications (continued) Wheel Bolts and Lug Nuts Thread Size Recommended Torque* 7/16 - 20 UNF 65 ± 10 ft-lb 88 ± 14 N∙m Grade 5 1/2 - 20 UNF 80 ± 10 ft-lb 108 ± 14 N∙m Grade 5 M12 X 1.25 80 ±...
  • Page 24 Shop Supplies The procedures found in this Service Manual may recommend the use of commonly used shop supplies (lubricants, sealants and adhesives). A symbol denoting the use of a shop supply may appear in figures that support a procedure. Always refer to the written procedure for specific information regarding the type and the application of a shop supply.
  • Page 25 GASKET COMPOUND Used to create a seal between mating parts. Gasket compounds may be used with or without the presence of a pre-formed gasket. Gasket compounds may be solvent or silicone based, and cure when exposed to air or designed to cure in an air-less environment (anaerobic). Most gasket compounds are designed to be applied to clean surfaces free of oil, chemical residue and previously used gaskets or gasket compounds.
  • Page 26 Special Tools You can order these special tools from your Toro Distributor. Some tools may also be available from a local tool supplier. Hydraulic O-Ring Kit Toro Part No. 117-2727 This kit includes O-rings in a variety of sizes for the face seal and port seal hydraulic connections.
  • Page 27 Troubleshooting There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf conditions. Conditions such as the excessive thatch, sponginess, or attempting to cut off too much grass height may not always be overcome by adjusting the cutting unit or machine.
  • Page 28 GEARS – The Systematic Approach to Defining, Diagnosing and Solving Problems Gather Information • Information reported by the customer. • Information observed by you. • Establish the what, where, and when of the issue. Evaluate Potential Causes • Consider possible causes of the problem to develop a hypothesis. •...
  • Page 29 Chapter 3 Chassis Table of Contents General Information ..........................3–2 Service and Repairs ..........................3–3 Wheels ............................... 3–3 Wheel Bearings..........................3–5 Torsion Axle Assembly ........................3–8 Hitch Assembly ..........................3–10 Side Cutting Unit Lift Arm Assembly....................3–12 Lift Arm Joint Yoke (side cutting units only) ..................3–14 Rear Cutting Unit Lift Arm Assembly ....................

  • Page 30: General Information

    General Information The operators manuals provides information regarding the operation, general maintenance, and maintenance intervals for your Groundsmaster 1200 Pull-Behind Rotary Mower. Refer to the operators manual for additional information when servicing the machine. Chassis: General Information Page 3–2 Groundsmaster® 1200 Pull-Behind Rotary Mower...

  • Page 31: Service And Repairs

    3. Lift the machine from the ground and support the raised machine with a jack stand (refer to the Groundsmaster 1200 Operator’s Manual for further instructions on the proper way to use jack stands). 4. Loosen but do not remove the 5 wheel-lug nuts (2) that secure the wheel to the hub assembly.
  • Page 32 Removing the Wheel (continued) IMPORTANT Before lifting the machine with a jack, review and follow the Jacking Instructions from the Groundsmaster 1200 Operator’s Manual. 5. Jack the machine up until the wheel is off the ground. Support the machine with appropriate jack stands.

  • Page 33: Wheel Bearings

    3. Lift the machine from the ground and support the raised machine with a jack stand (refer to the Groundsmaster 1200 Operator’s Manual for further instructions on the proper way to use jack stands). 4. Remove the wheel.
  • Page 34 Disassembling the Wheel Bearings (continued) 6. Straighten and remove the cotter pin (10) from the torsion axle. 7. Remove the slotted nut (7) and spindle washer (6) that secure the wheel hub (5) to the torsion axle (1). 8. Slide and remove the wheel hub (5) from the torsion axle (1). 9.
  • Page 35 Assembling the Wheel Bearings (continued) 5. Rotate the wheel hub and tighten the slotted nut (7) to a final torque of 1.7 to 2.3 N·m (15 to 20 in-lb). After you torque the nut, ensure that the wheel hub (5) does not wobble as it turns. 6.

  • Page 36: Torsion Axle Assembly

    2. Block the wheel that you are not removing with chocks to prevent the machine from moving. 3. Lift the machine from the ground and support the raised machine with a jack stand; refer to Groundsmaster 1200 Operator’s Manual. 4. Remove the wheel; refer to Removing the Wheel (page 3–3).
  • Page 37 Removing the Torsion Axle Assembly (continued) 5. If necessary, remove the wheel bearings; refer to Disassembling the Wheel Bearings (page 3–5). 6. Remove the 6 nuts (5) and bolts (1) that secures the torsion axle (6) and flap bracket (7) to the frame assembly. 7.

  • Page 38: Hitch Assembly

    PTO. Remove the main drive shaft and disconnect the machine from the tow vehicle. Secure the machine with tow bar jack; refer to the Groundsmaster 1200 Operator’s Manual. 2. Remove the 2 bolts (1), washers (2) and nuts (5) that secures the hitch assembly (7) to the frame assembly (4).
  • Page 39 Disassembling the Hitch Assembly (continued) D. Remove the clevis assembly (12) from the hitch assembly (7). 5. If necessary, remove the 2 nuts (3) that secures the hose guide (6) to the frame assembly (4). Remove the hose guides from the frame assembly. Assembling the Hitch Assembly 1.

  • Page 40: Side Cutting Unit Lift Arm Assembly

    PTO. Remove the main drive shaft and disconnect the machine from the tow vehicle. Secure the machine with tow bar jack; refer to the Groundsmaster 1200 Operator’s Manual. 2. Remove the cutting unit covers. 3. Remove the lift cylinder (2) from the side cutting unit lift arm (3); refer to Removing the Cutting Unit Lift Cylinder (page 4–9).
  • Page 41 6. Install the cutting unit covers. 7. Lubricate the grease fittings (4) after the assembly is complete; refer to Groundsmaster 1200 Operator’s Manual. 8. Prior to returning the machine to service, raise and lower the cutting unit to verify that hydraulic hoses and fittings do not contact anything throughout the full range of movement.

  • Page 42: Lift Arm Joint Yoke (Side Cutting Units Only)

    1. Park the machine on a level surface, lower the cutting units and disengage the PTO. Remove the main drive shaft and disconnect the machine from the tow vehicle. Secure the machine with tow bar jack; refer to the Groundsmaster 1200 Operator’s Manual. 2. Remove the cutting unit covers. Chassis: Service and Repairs Page 3–14...
  • Page 43 Removing the Lift Arm Joint Yoke (continued) 3. Remove the cotter pin (1), slotted hex nut (2), hardened washer (3) and thrust washers (4 and 17) from joint yoke shaft. 4. Remove the 8 bolts (11), hardened washers (12) and 2 bolt plates (13) that secure the base mounts to the deck mount assembly (14).
  • Page 44 Disassembling the Joint Yoke (continued) D. Repeat process for remaining bearing. E. Thoroughly clean and inspect all components. Assembling the Joint Yoke 1. Apply a coating of grease to the bearing bores of the yoke and base mounts. Also, apply grease to the bearings and seals of the cross assembly. 2.
  • Page 45 Installing the Lift Arm Joint Yoke (continued) 3. Install the shims (8) between the cutting unit connection and base mounts and secure the base mounts with 8 cap screws (11), hardened washers (12) and 2 bolt plates (13). Tighten the bolts (11) from 53 to 64 N·m (39 to 47 ft−lb). 4.

  • Page 46: Rear Cutting Unit Lift Arm Assembly

    PTO. Remove the main drive shaft and disconnect the machine from the tow vehicle. Secure the machine with tow bar jack; refer to the Groundsmaster 1200 Operator’s Manual. 2. Remove the cutting unit covers. 3. Remove the lift cylinders from the cutting unit lift arms; refer to...
  • Page 47 Removing the Rear Cutting Unit Lift Arm Assembly (continued) 6. Remove the nuts, bolts and washers that secures the hub support assembly to the cutting unit assembly. 7. Remove the cutting unit lift arm assembly from the machine. 8. As required, disassemble the lift arm assembly: A.
  • Page 48 5. Install the cutting unit covers. 6. Lubricate the grease fittings after the assembly is complete; refer to Groundsmaster 1200 Operator’s Manual. 7. Before returning the machine to service, raise and lower the cutting unit to verify that hydraulic hoses and fittings do not contact anything throughout the full range of movement.

  • Page 49: Impact Arm Assembly

    1. Park the machine on a level surface, lower the cutting units and disengage the PTO. Remove the main drive shaft and disconnect the machine from the tow vehicle. Secure the machine with tow bar jack; refer to the Groundsmaster 1200 Operator’s Manual. Groundsmaster® 1200 Pull-Behind Rotary Mower Page 3–21...
  • Page 50 Removing the Impact Arm Assembly (continued) g254260 Figure 18 Impact arm assembly Hardened washer Deck mount assembly Bolt Thrust washer Nut (4 each) Spindle spacer (2 each) Nut (2 each) Carriage bolt (4 each) Lock nut Bolt (2 each) Cutting unit Lift arm assembly 2.
  • Page 51 Disassembling the Impact Arm Assembly 1. Disassemble the impact arm assembly (15) and pivot hub (18) as required. 2. Thoroughly clean the impact arm components and inspect for worn parts. Replace components as needed. Assembling the Impact Arm Assembly 1. Slide the washer (5), compression spring (6), second washer (5), plastic bearing (7), third washer (5), flat washer (8) and one jam nut (9) onto the spring shaft (3).
  • Page 52 Assembling the Impact Arm Assembly (continued) g241353 Figure 19 10. Thread rod end (1) with jam nut (2) into end of the spring shaft so that distance from center of the impact housing mounting hole is from 73.4 to 73.7 cm (28.91 to 29.03 in); refer to Figure 19.

  • Page 53: Latch Linkage Assembly

    Latch Linkage Assembly g243402 Figure 20 Side Cutting Unit Assembly (shown) Latch spacer Wing latch pin assembly Hex nut (left or right-hand thread) (2 each) Wing latch Quadrant linkage rod Washer head bolt Latch spacer Flat head nut Yoke linkage Rod end (left-hand thread) Lock washer (2 each) Clevis spring pin...
  • Page 54 Latch Linkage Assembly (continued) g243403 Figure 21 Rear Cutting Unit Assembly (shown) Rear latch Flat washer Bolt Washer head bolt Linkage brake yoke Rod end (left or right-hand thread) Latch pin assembly Hex nut (left or right-hand thread) Lock washer (2 each) Thrust washer Flat head nut...
  • Page 55 Chapter 4 Hydraulic System Table of Contents General Information ..........................4–2 Hydraulic Hoses..........................4–2 Installing Hydraulic Hoses and Tubes (O-Ring Face Seal) ..............4–3 Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings)..........4–5 Hydraulic Schematic..........................4–8 Service and Repairs ..........................4–9 Cutting Unit Lift Cylinder ........................

  • Page 56: General Information

    Note: If the hose has an elbow at one end, tighten the swivel nut on the elbow end before you tighten the nut on the straight end of the hose. For more hydraulic hose information, refer to the Toro Basics Series Training Book Hydraulic Hose Servicing (Part No. 94813SL).

  • Page 57: Installing Hydraulic Hoses And Tubes (O-Ring Face Seal)

    Installing Hydraulic Hoses and Tubes (O-Ring Face Seal) g212099 Figure 22 Tube or hose Swivel nut O-ring Fitting body 1. Ensure that all the threads, the sealing surfaces of the hose/tube, and the fitting are free of burrs, nicks, scratches, or unwanted material. 2.
  • Page 58 Installing Hydraulic Hoses and Tubes (O-Ring Face Seal) (continued) Hose/Tube Installation Torque Table Fitting Dash Size Hose/Tube Side Thread Size Installation Torque (inch(es)—threads per inch) 9/16—18 25 to 29 N∙m (18 to 22 ft-lb) 11/16—16 37 to 44 N∙m (27 to 33 ft-lb) 13/16—16 51 to 63 N∙m (37 to 47 ft-lb) 1—14...

  • Page 59: Installing The Hydraulic Fittings (Sae Straight Thread O-Ring Fittings)

    Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) Installing a Non-Adjustable Fitting g212226 Figure 24 Fitting O-ring 1. Ensure that all the threads, the sealing surfaces of fitting, and the component port are free of burrs, nicks, scratches, or unwanted material. 2.
  • Page 60 Installing an Adjustable Fitting g212224 Figure 25 Locknut Back-up washer O-ring g212225 Figure 26 Step 1: clearance the lock nut Step 3: align the fitting Step 2: seat the back-up washer Step 4: tighten the lock nut 1. Ensure that all the threads, the sealing surfaces of fitting, and the component port are free of burrs, nicks, scratches, or unwanted material.
  • Page 61 Installing an Adjustable Fitting (continued) 7. Tighten the fitting lock nut (Step 4 in Figure 26): A. Hold the fitting in the correct alignment with a wrench and use a torque wrench and tighten the lock nut to the recommended torque value within the specified range of torque values;...

  • Page 62: Hydraulic Schematic

    Hydraulic Schematic g267285 Figure 27 Hydraulic System: Hydraulic Schematic Page 4–8 Groundsmaster® 1200 Pull-Behind Rotary Mower 18235SL Rev A...

  • Page 63: Service And Repairs

    PTO. Remove the main drive shaft and disconnect the machine from the tow vehicle. Secure the machine with tow bar jack; refer to the Groundsmaster 1200 Operator’s Manual. Note: Read the general precautions for removing and installing the hydraulic system components.
  • Page 64 Removing the Cutting Unit Lift Cylinder (continued) WARNING Ensure that the cutting units are fully lowered before loosening any of the machine hydraulic lines. If cutting units are not fully lowered as the hydraulic lines are loosened, the cutting unit may drop unexpectedly.

  • Page 65: Servicing The Cutting Unit Lift Cylinder

    Servicing the Cutting Unit Lift Cylinder g241356 Figure 29 Side Cutting Unit Cylinder (shown) Lock nut Barrel assembly External collar Piston Shaft assembly BT seal O-ring Head Dust seal Piston seal O-ring Square O-ring O-ring Back−up ring Set screw (2 each) Disassembly of the Cutting Unit Lift Cylinder Note: Refer to Figure 29...
  • Page 66 Disassembly of the Cutting Unit Lift Cylinder (continued) IMPORTANT Prevent damage when clamping the cylinder’s barrel into a vise; clamp on the barrel clevis only. Do not close vise on barrel. 2. Mount the lift cylinder in vise equipped with the soft jaws by clamping in the barrel clevis.
  • Page 67 Assembly of the Cutting Unit Lift Cylinder (continued) C. Secure the piston (2) to the shaft with the lock nut (1). Tighten lock nut: • Side cutting unit cylinder 5/8 in. lock nut to 102 Nm (75 ft-lb). • Rear cutting unit cylinder 1/2 in. lock nut to 54 Nm (40 ft-lb). 4.

  • Page 68: Hydraulic Hoses

    Hydraulic Hoses g251725 Figure 30 Cylinder assembly (2 each) Hose assembly (2 each) Tube assembly Straight fitting Flat head nut Tube clamp Orifice straight fitting Tube assembly Flat head screw Hydraulic hose (2 each) Flat head screw (2 each) Hydraulic hose (2 each) Tee fitting (2 each) Manifold Hydraulic hose (2 each)
  • Page 69 Chapter 5 Cutting Unit Drive Table of Contents General Information ..........................5–2 Service and Repairs ..........................5–3 Main Drive Shaft ..........................5–3 Cutting Unit Drive Shafts........................5–5 Servicing the Drive Shaft........................5–9 Cutting Unit Gear Box ........................5–11 Center Gear Box ..........................5–15 Groundsmaster®...

  • Page 70: General Information

    The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your Groundsmaster 1200 Pull-Behind Rotary Mower. Refer to the Operator’s Manual for additional information when servicing the Groundsmaster 1200 Pull-Behind Rotary Mower. Cutting Unit Drive: General Information Page 5–2 Groundsmaster®...

  • Page 71: Service And Repairs

    PTO. Remove the main drive shaft and disconnect the machine from the tow vehicle. Secure the machine with tow bar jack; refer to the Groundsmaster 1200 Operator’s Manual. WARNING Support the drive shaft (weighs approximately 39 Kg (86 lb)) to prevent it from dropping and causing personal injury when removing.
  • Page 72 Installing the Main Drive shaft g263851 Figure 32 Yoke Outer shield tube Inner tube yoke Shield cone Outer cardan tube Shield cone Central body Inner shield tube Yoke Outer tube yoke Inner cardan tube Shield chain IMPORTANT If the drive shaft tube and shaft were separated, ensure that the slip shaft yoke and slip tube yoke are aligned when the tube and shaft are assembled.

  • Page 73: Cutting Unit Drive Shafts

    PTO. Remove the main drive shaft and disconnect the machine from the tow vehicle. Secure the machine with tow bar jack; refer to the Groundsmaster 1200 Operator’s Manual. WARNING Support the drive shaft (weighs approximately 16 Kg (36 lb)) to prevent it from dropping and causing personal injury when removing.
  • Page 74 Removing the Cutting Unit Drive Shafts (continued) g263855 Figure 34 Cutting unit gear box Cutting unit drive shaft Clamp (2 each) Main gear box 2. Disconnect the cutting unit drive shaft (3) from the centre gear box shaft (4) as follows: A.
  • Page 75 Installing the Cutting Unit Drive Shafts g263852 Figure 35 Yoke Slip tube Shield cone Shield cone Inner shield tube Yoke Slip tube yoke Slip shaft Shield chain Outer shield tube Slip shaft yoke IMPORTANT If the cutting unit drive shaft tube and shaft were separated, ensure that the slip shaft yoke and slip tube yoke are aligned when the tube and shaft are assembled.
  • Page 76 Installing the Cutting Unit Drive Shafts (continued) A. Align the splines on the cutting unit gear shaft (1) to the cutting unit drive shaft and press the quick release pin (2) and slide the cutting unit drive shaft onto the cutting unit gear shaft. B.

  • Page 77: Servicing The Drive Shaft

    Servicing the Drive Shaft g241349 Figure 36 Cutting Unit Drive Shaft (shown) End yoke Grease fitting Slip tube yoke Universal joint kit (cross and Slip shaft yoke End yoke bearings) (2 each) Disassembling the Drive Shaft 1. Remove the cutting unit drive shaft from the machine; refer to Removing the Cutting Unit Drive Shafts (page 5–5).
  • Page 78 Assembling the Drive Shaft g241348 Figure 37 Cutting Unit Drive Shaft (shown) End yoke Retaining ring Grease fitting Cross and bearing kit Shaft yoke 1. Install new cross and bearings as follows: A. Apply a thick layer of grease to the bearing bores in the end yoke and shaft yoke.

  • Page 79: Cutting Unit Gear Box

    PTO. Remove the main drive shaft and disconnect the machine from the tow vehicle. Secure the machine with tow bar jack; refer to the Groundsmaster 1200 Operator’s Manual. 2. Disconnect the drive shaft from the cutting unit gear box; refer to...
  • Page 80 Removing the Cutting Unit Gear Box (continued) 5. Remove the drive pulley (7) from the gear box shaft (1) as follows: A. Remove the 2 set screws (5) that secure the taper lock bushing (6) to the drive pulley (7) on the cutting unit gear box shaft. g266928 Figure 39 Set screw installation position...
  • Page 81 Left cutting unit gear box Center cutting unit gear box 1. If removed, fill the cutting unit gear box (1) with 1.06 L (1.13 qt) of Toro premium tractor fluid or Mobil 424. 2. If oil seals were removed from the cutting unit gear box, install new seals to the cutting unit gear box (1).
  • Page 82 11. Install the deck mount assembly (3) to the cutting unit assembly (8); refer to Installing the Deck Mount Assembly (page 6–7). 12. Install the drive belt: refer to the Groundsmaster 1200 Operator’s Manual. 13. Connect the drive shaft to the cutting unit gear box; refer to Installing the Cutting Unit Drive Shafts (page 5–7).

  • Page 83: Center Gear Box

    PTO. Remove the main drive shaft and disconnect the machine from the tow vehicle. Secure the machine with tow bar jack; refer to the Groundsmaster 1200 Operator’s Manual. 2. Disconnect the main drive shaft from the center gear box; refer to...
  • Page 84 1. If oil seals were removed from the center gear box, install new seals to the center gear box. Make sure that the center gear box is filled with 2.48 L (2.6 qt) of Toro premium tractor fluid or Mobil 424. 2. Position the center gear box assembly (item 2 in...
  • Page 85 Chapter 6 Cutting Units Table of Contents General Information ..........................6–2 Operator's Manual..........................6–2 Adjustments ............................6–3 Service and Repairs ..........................6–4 Cutting Unit ............................6–4 Deck Mount Assembly ........................6–5 Idler Assemblies..........................6–8 Blade Spindles ..........................6–11 Rollers.............................. 6–19 Kicker Roller (Side cutting units only)....................

  • Page 86: General Information

    General Information Operator's Manual The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for the cutting unit on your machine. Refer to the Operator’s Manual for additional information when servicing the cutting unit. Cutting Units: General Information Page 6–2 Groundsmaster®...

  • Page 87: Adjustments

    Adjustments CAUTION Do not work on the cutting unit or lift arms with the tow vehicle engine running. Always shut off the engine and remove the key from the key switch of the tow vehicle before working on the cutting unit. Refer to the Operator’s Manual for cutting unit adjustment procedures.

  • Page 88: Service And Repairs

    Always shut off the engine and remove the key from the key switch of the tow vehicle before working on the cutting unit. Cutting Unit Refer to Groundsmaster 1200 Operator’s Manual for cutting unit blade and belt removal and installation procedure. Cutting Units: Service and Repairs Page 6–4...

  • Page 89: Deck Mount Assembly

    PTO. Remove the main drive shaft and disconnect the machine from the tow vehicle. Secure the machine with tow bar jack; refer to the Groundsmaster 1200 Operator’s Manual. 2. Remove the cutting unit drive shafts; refer to Removing the Cutting Unit Drive Shafts (page 5–5).
  • Page 90 Removing the Deck Mount Assembly (continued) 5. Disconnect the impact arm assembly (1) from cutting unit assembly (14) by removing the nut (3), spacers (3) and bolt (2); refer to Removing the Impact Arm Assembly (page 3–21). 6. Remove the lift arm assembly (10) from the cutting unit assembly (14); refer Removing the Lift Arm Joint Yoke (page 3–14) Removing the Rear Cutting Unit Lift Arm Assembly (page...
  • Page 91 Removing the Deck Mount Assembly (continued) 11. If necessary, remove the 2 screws (5 in Figure 45) that secures the bumper pad (4) to the deck stop assembly (3). Remove the bumper pad from the deck stop assembly. Installing the Deck Mount Assembly 1.

  • Page 92: Idler Assemblies

    PTO. Remove the main drive shaft and disconnect the machine from the tow vehicle. Secure the machine with tow bar jack; refer to the Groundsmaster 1200 Operator’s Manual. 2. Remove the cutting unit covers from the top of the cutting unit.
  • Page 93 Removing the Idler Assembly (continued) 4. Remove the retaining ring (2) that secures the idler assembly to the idler pivot (14). CAUTION The torsion spring (5) is under heavy load and can cause personal injury. Be careful when removing the tension from the torsion spring of the idler arm.
  • Page 94 Installing the Idler Assembly 1. Assemble the idler components as shown in Figure 2. If removed, install the flat washer (6) over the idler pivot (14). CAUTION The spring is under heavy load and can cause personal injury. Be careful when applying the tension from the torsion spring of the idler arm.

  • Page 95: Blade Spindles

    PTO. Remove the main drive shaft and disconnect the machine from the tow vehicle. Secure the machine with tow bar jack; refer to the Groundsmaster 1200 Operator’s Manual. 2. Remove the cutting unit covers from the top of the cutting unit.
  • Page 96 Removing the Blade Spindle (continued) CAUTION Contact with a sharp blade can cause serious injury. Wear gloves or wrap sharp edges of the blade with a rag. IMPORTANT The cutting unit blades rotate counterclockwise when viewed from overhead. The blade bolts (5) have left hand threads. 4.
  • Page 97 Disassembling the Blade Spindle g241361 Figure 49 Low Spindle Assembly (shown) Locknut Bearing set Large snap ring Special hardened washer Bearing spacer Spacer ring Pulley Ribbed neck bolt (8 each) 13. Shaft spacer O-ring Spindle housing Spindle shaft Oil seal (2 each) Grease fitting Note: Refer to Figure 49...
  • Page 98 Disassembling the Blade Spindle (continued) 6. Discard the spindle shaft O−ring (4). 7. Use an arbor press to remove the 2 bearing sets (6) and bearing spacer (7) from the spindle housing. Note: The large retaining ring can remain inside the spindle housing. Removing the large retaining ring is very difficult.
  • Page 99 Assembling the Blade Spindle (continued) g266961 Figure 51 Bearing cups Arbor press Large snap ring Support Large spacer Arbor press base 3. Use an arbor press to push the bearing cups into the top and bottom of the spindle housing. The top bearing cup must contact the outer spacer that was previously installed, and the bottom bearing cup must contact the snap ring.
  • Page 100 Assembling the Blade Spindle (continued) IMPORTANT If you are replacing the bearings, ensure that you use the spacer ring that is included with a new bearing set; refer to Figure 7. Slide the spacer ring and inner bearing spacer into the spindle housing, then install the upper bearing cone and oil seal into the top of the housing.
  • Page 101 Assembling the Blade Spindle (continued) IMPORTANT A pneumatic grease gun can produce high pressure inside the spindle housing that can damage the spindle seals. Thus, do not use a pneumatic grease gun for greasing of the spindle housings. 12. Attach a hand pump grease gun to the grease fitting on the housing and fill the housing cavity with grease until the grease starts to come out of the lower seal.
  • Page 102 Installing the Blade Spindle (continued) 2. Attach the spindle assembly to the cutting unit with the 8 ribbed neck bolts (item 1 in Figure 48) and 8 flange nuts (13). IMPORTANT The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting.

  • Page 103: Rollers

    PTO. Remove the main drive shaft and disconnect the machine from the tow vehicle. Secure the machine with tow bar jack; refer to the Groundsmaster 1200 Operator’s Manual. 2. Loosen the set screws in the collars of the roller bearings.
  • Page 104 Installing the Rollers 1. If removed, install the grease fittings (6) on the flange bushing (4). IMPORTANT Replacement roller bearings include straight grease fittings. Fit 90° grease fittings in bearings prior to installation. Position grease fitting toward the outside of the cutting unit. 2.

  • Page 105: Kicker Roller (Side Cutting Units Only)

    Park the machine on a level surface, lower the cutting units and disengage the PTO. Remove the main drive shaft and disconnect the machine from the tow vehicle. Secure the machine with tow bar jack; refer to the Groundsmaster 1200 Operator’s Manual.

Table of Contents