Rail Ramp Conversion Kit

Parts needed for this procedure:

1. Raise the trailer with jacks or blocks so that the wheels are not touching the ground.

2. If necessary, remove the 4 lug nuts securing the tires and remove the tires to access the wheel rods.

3. If equipped, remove the fasteners securing the standard inserts to the bottom of the ramp and remove the inserts (Figure 1).

   

   Figure 1

   1. Trailer stop
   2. Standard insert
   3. Wheel rod
   4. Brackets

4. Remove the existing trailer stops, wheel rods, and brackets from the trailer (Figure 1).

   Note: Save the trailer stops, brackets, and hardware for later installation.

5. Secure the tube assembly mounting brackets to the square holes in each side of the trailer with 4 carriage bolts and locknuts (Figure 2).

   Position the tube assemblies so that the cross tubes are to the rear.

   Note: On trailers with serial numbers prior to 220000001: To mount the tube assemblies you will need to drill 3 holes in each side of the trailer as follows:

   • Secure the top-rear hole of the tube assembly mounting bracket (with the cross-tube to the rear) to the top-rear square hole in the inside of the trailer (Figure 2).

   • Position the tube assembly so it is parallel to the top of the trailer.

   • Using the tube assembly mounting brackets as templates, locate, mark, and drill 3 holes (9.9 mm or 0.390 inch) at each mounting bracket hole.

   • Secure the tube assembly mounting brackets to each side of the trailer with 3 hex-head screws (3/8 x 3/4 inch) in place of the carriage bolts.

6. Mount a load ramp to the rear of each tube assembly with a hex-head bolt (3/8 x 2-1/2 inches), spacer, and locknut (Figure 2).

7. Install a hex-head bolt (5/16 x 2-1/2 inches) through each of the center holes in the load ramps and through the 2 rubber tubes (Figure 4).

   

   Figure 2

   1. Tube assembly
   2. Cross tube
   3. Load ramp
   4. Rubber tube
   5. Spacer
   6. Locking bracket
   7. Trailer stop
   8. Narrow wheel rod

Parts needed for this procedure:

1. Position a locking bracket onto each side of the ramp so that they align with the underside of the load ramps, engage with the rubber tubes in the load ramps, and align with the holes in the ramp (Figure 2 and Figure 4).

   Note: Use only 1 set of mounting holes per locking bracket.

2. Loosely mount each locking bracket to the ramp with flange head screws (5/16 x 3/4 inch) and flange nuts (Figure 2 and Figure 4).

   Note: If the ramp handle interferes with the mounting fastener of the locking bracket, grind off the end of the handle to expose the hole as required (Figure 3). Touch up any exposed metal surfaces with paint.

   

   Figure 3

   1. Ramp handle
   2. Grind the handle here.

3. Raise and lock the ramp. Adjust the locking brackets so they are engaged on the rubber tubes and tighten the flange screws and nuts (Figure 2 and Figure 4).

   

   Figure 4

   1. Locking bracket
   2. Load ramp
   3. Ramp

4. Point the narrow wheel rods upward and mount them to the mounting holes in each side of the trailer, using the brackets and fasteners removed in step 4 (Figure 2).

   Note: Ensure that the brackets are flush with the top of the trailer frame.

   Note: On trailers with serial numbers prior to 220000001: Purchase 2 new rod brackets (Part No. 105-5395) and 2 new retaining clips (Part No. 99-6204) to replace the existing components on the trailer.

5. Raise and lower the narrow wheel rods to ensure that they are installed correctly; the rods should move smoothly and not be able to slide out of the brackets.

6. Install the tires that were removed in step 2; torque the lug nuts to 80 ft-lb (108.5 N·m).

7. Remove any blocks or jacks and lower the trailer to the ground.

Parts needed for this procedure:

1. Remove the existing standard transport wheels from the wheel axles on the greensmower (if equipped).

2. Remove the existing wheel axles from the sides of the greensmower by unscrewing them.

   Note: The right wheel axle has left-hand threads; remove the right axle by rotating clockwise.

3. Install the new right wheel axle to the right side of the machine.

   Note: The right wheel axle has left-hand threads; install the right axle by rotating counterclockwise.

4. Install the appropriate left axle to your machine:

   • Greensmaster 800/1000/1600 machines: install the 13.3 cm (5.25 inches) left axle

   • Greensmaster 1800/2100 series machines: install the 14.2 cm (5.6 inches) left axle

   • Greensmaster 1018/1021 series machines: install the 13.8 cm (5.4 inches) left axle

5. Perform the following step for Greensmaster Flex 18 or 21 machines only:

   • Remove the right side drum cover from the machine (Figure 5).

     

     Figure 5

     1. Right side drum drive cover
     2. Felt seal
     3. Rubber grommet

   • Remove and discard the rubber grommet from the axle hole in the drum cover (Figure 5).

   • Affix the felt seal to the inside of the cover positioning it around the axle hole (Figure 5).

   • Install the cover to the machine.

6. Insert a rail wheel onto each shaft with the channel facing outward and secure it with a wheel clip (Figure 6).

   

   Figure 6

   1. Wheel shaft
   2. Rail wheel (channel facing outward)
   3. Wheel clip

Parts needed for this procedure:

Use 2 shoulder bolts, 2 washers, and 2 nuts (1/4 inch) to secure the tie-down straps to the ramp (Figure 7).

Note: There are existing rivets in the hardware installation locations shown in Figure 7. Remove these rivets.

Figure 7

1. Shoulder bolt
2. Washer
3. Tie-down strap
4. Nut (1/4 inch)

1. Connect the trailer securely to the traction unit.

2. Lower the load ramps, roll the machines onto the rails, and secure the wheels in the wheel stops (Figure 8).

   

   Figure 8

   Note: When trailering only 1 machine, mount the wheel rods to the middle set of mounting holes in the trailer.

3. Connect the straps to the cutting-unit grass basket holder.