F60 Flail Mower

Note: Retain all removed parts unless otherwise noted.

1. Park the machine on a level surface, disengage the PTO, move the lift arms to the lowest position, engage the parking brake, shut off the engine, and remove the key.

2. Wait for all movement to stop and allow the machine to cool before adjusting, cleaning, storing, or repairing it.

3. If a cutting unit is equipped, remove the cutting unit from the machine lift arms; refer to your cutting unit Operator’s Manual.

4. Ensure that the PTO driveshaft is aligned correctly; refer to the PTO-driveshaft alignment procedure in your traction unit Operator’s Manual.

   Important: If the markings on the driveshaft are not aligned, severe imbalance may occur in the driveline system.

5. If the lift arms for the rotary cutting unit are installed on the traction unit, remove the lift arms as follows:

   1. Raise the front of the machine and remove the front wheels from the machine; refer to your traction unit Operator’s Manual.

   2. Remove the 2 carriage bolts and 2 nuts (3/8 inch) that secure the sensor bracket to the right lift arm (Figure 3).

   3. Remove the 2 bolts (3/8 x 1-1/4 inches), 2 nuts (3/8 inch), and 2 small pins that secure the lift arms to the cylinders (Figure 3).

   4. Remove the nut and bolts securing the large pins to the lift arms as shown in Figure 4.

   5. Remove the lift arms and large pins from the machine frame (Figure 5).

      

      Figure 3

      1. Bolt (3/8 x 1-1/4 inches)
      2. Small pin
      3. Nut (3/8 inch)
      4. Carriage bolt
      5. Sensor bracket
      

      Figure 4

      Right side shown

      1. Nut
      2. Large pin
      3. Bolt
      

      Figure 5

      1. Lift arm
      2. Machine frame
      3. Large pin

Parts needed for this procedure:

1. Assemble the caster wheels to the castor fork as shown in Figure 6.

   Note: Use only the upper axle shaft hole; do not adjust the position of the caster wheel.

   

   Figure 6

   1. Castor bolt
   2. Castor fork
   3. Bearing
   4. Bearing spacer
   5. Large locknut

2. Assemble each caster arm to the cutting unit with 6 carriage bolts (M10) and 6 locknuts (M10) as shown in Figure 7; torque the locknuts to 47 to 57 N∙m (34 to 42 ft-lb).

   

   Figure 7

   Left side shown

   1. Carriage bolt
   2. Locknut
   3. Caster arm

3. Assemble the casters to the cutting unit with a shim on both sides of the caster shaft hub as shown in Figure 8.

   Note: You can adjust the height-of-cut setting by changing the amount of spacers on either side of the caster shaft hub; refer to Adjusting the Height of Cut.

   

   Figure 8

   1. Tensioning cap
   2. HoC spacers
   3. Shim
   4. Caster shaft hub
   5. Caster wheel shaft

4. Ensure that the deck is level; move the deck to a level surface and place a level horizontally across the top of the deck.

5. If the deck is not level, position the shims on the caster shaft accordingly until it is level.

Parts needed for this procedure:

Use 5 rivets to install the bracket and debris guard to the front axle (Figure 9).

Figure 9

Left side shown

1. Bracket
2. Debris guard
3. Rivet

Parts needed for this procedure:

1. Raise the front of the machine and remove the front tires from the machine; refer to your traction unit Operator’s Manual.

2. Install the lift arms and large pins to the machine frame (Figure 10).

   

   Figure 10

   Right side shown

   1. Lift arm
   2. Machine frame
   3. Large pin

3. Secure the large pin to the lift arm using a pair of nuts and bolts as shown in Figure 11.

   

   Figure 11

   1. Nut (3/8 inch)
   2. Large pin
   3. Long bolt (3/8 x 2-3/4 inches)

4. Secure each cylinder-rod end to the each lift arms with a small pins, bolts (3/8 x 1-1/4 inches), and nut (3/8 inch) as shown in Figure 12.

   Note: Manually rotate the lift arm to align it with the cylinder-rod end.

5. Secure the sensor bracket to the right lift arm using 2 carriage bolts and 2 nuts (3/8 inch) as shown in Figure 12.

   

   Figure 12

   1. Bolt (3/8 x 1-1/4 inches)
   2. Small pin
   3. Nut (3/8 inch)
   4. Carriage bolt
   5. Sensor bracket

6. Ensure that the sensor bracket does not interfere with the sensor; refer to Adjusting the Sensor Bracket.

   When installing the sensor bracket, rotate the bracket up (as shown in Figure 12) before clamping.

7. Align the cutting unit in front of the machine frame and PTO shaft.

8. Perform the following steps to install the PTO shaft to the cutting unit:

   1. Install the PTO shaft yoke to the cutting unit gearbox shaft as shown in Figure 13.

   2. Assemble a socket-head capscrew (3/8 x 2-1/4 inches) through a washer (3/8 inch) and the hole in the driveshaft yoke (Figure 13), and secure the capscrew with a flange-locknut (3/8 inch).

   3. Assemble a socket-head capscrew (3/8 x 2-1/4 inches) through a washer (3/8 inch) and the hole in the driveshaft yoke from the opposite direction (Figure 13), and secure the capscrew with a flange-locknut (3/8 inch).

   4. Incrementally torque the locknuts to 61 N∙m (45 ft-lb) in an alternating pattern.

      Important: Ensure the PTO shaft yoke bolts are tightened to the specified torque. Failure to properly torque the bolts results in premature failure of critical parts.

      Important: Whenever you remove the PTO shaft from the gearbox, use new capscrews and locknuts to secure the shaft to the gearbox.

      

      Figure 13

      1. Flange-locknut (3/8 inch)
      2. Driveshaft yoke
      3. Washer (3/8 inch)
      4. Socket-head capscrew (3/8 x 2-1/4 inches)

9. Secure the flail to the lift arms using the lift arm pins and lynch pins (Figure 30).

Parts needed for this procedure:

Use 6 carriage bolts (M8), 6 flange nuts (M8), and the flap mount to secure the debris skirt to the axle bracket.

Note: For easier access to this area, you may remove a front wheel or both front wheels. Refer to the Setup section in the traction unit Operator’s Manual for wheel removal and installation instructions.

Figure 14

1. Flange nut (M8)
2. Flap mount
3. Debris skirt
4. Carriage bolt (M8)

Parts needed for this procedure:

Install the PTO guard assembly to the top of the gearbox as shown in Figure 15.

Figure 15

1. Washer (3/8 inch)
2. Screw (3/8 x 3/4 inch)
3. PTO guard assembly

The sensor and the sensor-bracket plate should have a 6 mm (0.24 in) clearance between them (Figure 16).

Figure 16

1. Sensor bracket
2. Locknuts
3. Sensor
4. Lift arm (right side)

If the clearance is incorrect, perform the following steps to adjust the sensor bracket:

1. Loosen the locknuts that secure the switch to the switch bracket and adjust it so that the correct clearance exists between the sensor and the sensor plate.

2. Tighten the sensor locknuts from 19 to 21 N·m (14 to 16 ft-lb).

Adjust the weight transfer of the attachment; refer to the traction unit Operator’s Manual.

Ensure that the gearbox has the correct amount of lubricant; refer to Checking the Lubricant in the Gearbox.

Ensure that the caster tires are filled to 2 to 3.5 bar (30 to 50 psi); refer to Checking the Caster Tire Pressure.

Grease the cutting unit before the first operation; refer to Lubricating the Cutting Unit. Failure to properly grease the machine will result in premature failure of critical parts.

Use the traction-unit display screen to engage Turnaround mode; refer to your traction unit Operator’s Manual.

Important: Using Turnaround mode with an equipped flail mower helps prevent premature driveline wear. You must always have Turnaround mode engaged when mowing with the flail.

Note: Turnaround mode allows you to quickly raise the flail mower above the turf when completing a quick turn at the end of a mowing pass (or while navigating around obstacles) without disengaging the PTO.

Parts needed for this procedure:

For traction units that have a Cab Kit and a Road Light Kit equipped, the flail mower could contact the road lights. To avoid contact with the road lights, install the spacers to restrict movement of the lift arms.

1. Under the front chassis, remove the existing screws (1/4 inch) and rubber pads from the chassis (Figure 17).

   Discard the screws and retain the pads.

2. Use the new screws (1/4 x 1-1/4 inch) to secure the spacers and rubber pads to the chassis (Figure 17).

   Tighten the screws until the heads are flush with the rubber pads.

Figure 17

Several traction-unit parts removed for clarity.

1. Rubber pads
2. Existing screws (1/4 inch)
3. Spacers
4. Screws (1/4 x 1-1/4 inch)

A selection of the manufacturer approved attachments and accessories is available for use with the machine to enhance and expand its capabilities. Contact your Authorized Service Dealer or authorized the manufacturer distributor or go to www.Toro.com for a list of all approved attachments and accessories.

To ensure optimum performance and continued safety certification of the machine, use only genuine Toro replacement parts and accessories. Replacement parts and accessories made by other manufacturers could be dangerous, and such use could void the product warranty.

• Keep the flail blades sharp and in good condition to ensure good cutting performance, minimum power consumption, and good quality of cut.

• The cutting unit floats to follow ground contours.

• Before engaging the cutting unit, ensure that the engine is set to a reduced speed:

  • Traction unit models 31900, 31901, 31907, and 31909: Refer to Reducing the Engine Speed before PTO Engagement

  • Traction unit models 31902 and 31903: Refer to Engaging the Low RPM PTO Engage Mode

• Operate the cutting unit at full engine speed. Adjust the forward speed to suit the grass conditions and to not overload the cutting unit. The lower the forward speed, the better the quality of cut and after-cut appearance.

Important: Always ensure that the height of cut is set correctly according to these instructions. Ensure that both the adjuster plate and the caster fork spacers are set according to the table. Failure to do this may cause premature wear in the driveline and excessive vibration.

Note: The height of cut is determined by the rear roller and the front casters. Blade wear, tire pressure, and bent/damaged caster arms can affect the height-of-cut setting.

Figure 18

Some parts not shown for clarity.

1. Height of cut
2. Spacer
3. Height-of-cut adjuster plate

1. Position the machine on a level surface, raise the cutting unit and support it with jack stands, shut off the engine, set the parking brake, and remove the key from the ignition switch.

2. Refer to the height-of-cut setting table on the height-of-cut decal (Figure 19) for common height-of-cut settings.

   

   Figure 19

   1. Height-of-cut adjuster plate mounting positions
   2. Caster fork height-of-cut spacers

3. To adjust the position of the height-of-cut adjuster plate, remove the nuts and bolts securing the plate (Figure 20).

4. Install the bolts in the locations specified in Figure 19 for the desired height of cut; torque the nuts to 60 N∙m (44 ft-lb).

   

   Figure 20

   1. Mounting hole “L”
   2. Mounting hole "H”
   3. Mounting hole “F”
   4. Mounting hole “E”
   5. Mounting hole “D”
   6. Mounting hole “C”
   7. Mounting hole “B”
   8. Mounting hole “A”
   9. Nut
   10. Bolt

5. To adjust the position of the caster fork, remove the height-of-cut caps from the front caster shafts and adjust the amount of spacers on either side of the caster shaft hub (Figure 19).

   Note: Spacers placed above the caster shaft hub decrease the height of cut, spacers placed below the hub increase the height of cut.

6. Install the height-of-cut tensioning caps.

Important: In the event that a single blade is damaged, both that blade and the blade opposite to it should be removed and replaced as a pair to maintain balance.

1. Park the machine on a level surface, raise the cutting unit, engage the parking brake, shut off the engine, and remove the key from the ignition switch.

2. Support the raised cutting unit using jack stands.

3. Inspect each blade for damage paying particular attention to the fasteners, cutting edge, and installation hole (Figure 21). Replace all damaged blades and fasteners.

   

   Figure 21

   1. Cutting edge
   2. Installation hole

4. Inspect each blade for excessive wear using the wear line (Figure 22). When a blade is worn down to the wear line, replace the blade.

   

   Figure 22

   1. Wear line

5. Ensure that each blade bolt is torqued to 45 N∙m (33.2 ft-lb).

6. Grip each blade and ensure that there is not more than a total of 3 mm (1/8 inch) of free movement in either direction from the rotor. If there is more than a total of 3 mm (1/8 inch) of free movement, replace the blade.

7. Check each pair of opposite blades for a weight difference between them.

   Note: Each pair of opposite blades should not have a weight difference of more than 10 g (0.4 oz).

Grease Type: No. 2 lithium grease

Replace any damaged grease fittings.

Refer to Figure 23 for the location of each pair of grease fittings on the cutting unit.

Figure 23

Left side shown

1. Caster arm fitting
2. Lift arm fitting
3. Flange bearing fitting
4. Rear roller fitting

The gearbox is designed to operate on either petroleum or synthetic SAE 80W–90 gear lube. Although the gearbox is shipped with lubricant from the factory, check the level before operating the cutting unit. The gearbox capacity is 0.33 L (11.15 fl oz).

1. Park the machine on a level surface, lower the cutting unit, engage the parking brake, shut off the engine, and remove the key.

2. Remove the breather plug from the top of the gearbox (Figure 24) and ensure that the lubricant is between the fill marks on the lower part of the breather plug. If the lubricant level is low, add enough lubricant until the level is between the marks.

   

   Figure 24

   1. Oil level fill marks on breather plug

3. Install the breather plug and torque it to 9 N∙m (84 in-lb).

1. Park the machine on a level surface, lower the cutting unit, engage the parking brake, shut off the engine, and remove the key.

2. Place a pan beneath the drain plug on the gearbox (Figure 25).

3. Remove the drain plug on the lower left side of the gearbox and drain the fluid (Figure 25).

   

   Figure 25

   1. Drain plug

4. Install the drain plug and torque to 20 to 27 N∙m (15 to 20 ft-lb).

5. Remove the breather plug from the top of the gearbox.

6. Fill the gearbox with the correct gear lube, checking periodically that the lubricant is between the lower fill marks on the breather plug; refer to Checking the Lubricant in the Gearbox.

7. When the lubricant is between the lower fill marks on the breather plug, install the breather plug and torque it to 9 N∙m (84 in-lb).

1. Park the machine on a level surface, lower the cutting unit, engage the parking brake, shut off the engine, and remove the key.

2. Loosen the 4 captive bolts that secure the top and bottom of the belt cover to the machine (Figure 26).

   

   Figure 26

   1. Belt cover captive bolts
   

   Figure 27

   1. Idler pulley nut
   2. Idler pulley post nut

3. Loosen, but do not remove, the idler pulley nut (Figure 27).

   Note: To loosen the idler pulley nut, you will need to hold the bolt that secures it in place on the inside of the deck.

4. Adjust the nut on the idler pulley post to tension the belt (Figure 27).

5. Using a single-barrel tension meter, push down on the belt to check the tension as follows (Figure 28):

   • For a new belt, you should be able to push the belt down 5 mm (1/5 inch) using 6.0 to 6.4 kg (13.2 to 14.1 lb) of force.

   • For a used belt, you should be able to push the belt down 5 mm (1/5 inch) using 5.1 to 5.6 kg (11.2 to 12.3 lb) of force.

   

   Figure 28

   1. Belt without force
   2. Belt deflected 5 mm (0.2 inches)

6. Adjust the nut on the idler pulley post as necessary to tighten or loosen the belt.

7. Rotate the rotor manually a couple of turns and check the belt tension again; if the tension is incorrect, check and adjust until it is correct.

8. Tighten the idler pulley nut; torque to 100 N∙m (74 ft-lb).

9. Install the belt cover (Figure 26).

1. Park the machine on a level surface, lower the cutting unit, engage the parking brake, shut off the engine, and remove the key.

2. Remove the belt cover (Figure 26).

3. Tighten the set screws securing the taper-lock bushings to 30 N∙m (41 ft-lb).

   

   Figure 29

   1. Taper-lock bushing
   2. Set screws

4. Install the belt cover.

1. Park the machine on a level surface, lower the cutting unit, engage the parking brake, shut off the engine, and remove the key.

2. Disconnect the PTO-shaft yoke from the cutting-unit gearbox shaft as shown in Figure 13.

   Important: Whenever you remove the PTO shaft from the gearbox, use new capscrews and locknuts to secure the shaft to the gearbox.

3. Remove the fasteners that attach the debris skirt to the front-axle bracket on the traction unit (Figure 14).

4. Remove the lynch pins and pins securing the cutting unit to the lift arms (Figure 30).

   

   Figure 30

   1. Lift arm pin
   2. Lynch pin

5. Move the machine away from the cutting unit.

The caster arms have bushings pressed into the top and bottom of the tube, and after many hours of operation, the bushings wear.

To check the bushings, move the caster fork back and forth and from side to side. If the caster spindle is loose inside the bushings, the bushings are worn; replace them.

1. Park the machine on a level surface, raise and support the cutting unit with jack stands, engage the parking brake, shut off the engine, and remove the key.

2. Remove the tensioning cap, spacer(s), and thrust washer from the top of the caster spindle.

3. Pull the caster spindle out of the mounting tube. Allow the thrust washer and spacer(s) to remain on the bottom of the spindle.

4. Insert a pin punch into the top or bottom of the mounting tube and drive the bushing out of the tube (Figure 31). Also, drive the other bushing out of the tube. Clean the inside of the tubes to remove dirt.

   

   Figure 31

   1. Caster arm tube
   2. Bushings

5. Apply grease to the inside and outside of the new bushings. Use a hammer and flat plate to drive the bushings into the mounting tube.

6. Inspect the caster spindle for wear and replace it if damaged.

7. Push the caster spindle through the bushings and mounting tube, slide the thrust washer and spacer(s) onto the spindle, and install the tensioning cap on the caster spindle.

1. Park the machine on a level surface, raise and support the cutting unit with jack stands, engage the parking brake, shut off the engine, and remove the key.

2. Remove the locknut from the bolt holding the caster wheel assembly between the caster fork (Figure 32). Grasp the caster wheel and slide the bolt out of the fork or pivot arm.

3. Remove the bearing from the wheel hub and allow the bearing spacer to fall out (Figure 32). Remove the bearing from the opposite side of the wheel hub.

4. Check the bearings, spacer, and inside of the wheel hub for wear. Replace any damaged parts.

5. To assemble the caster wheel, push the bearing into the wheel hub. When installing the bearings, press on the outer race of the bearing.

   

   Figure 32

   1. Caster bolt
   2. Caster fork
   3. Bearings
   4. Bearing spacer
   5. Large locknut

6. Slide the bearing spacer into the wheel hub. Push the other bearing into the open end of the wheel hub to captivate the bearing spacer inside the wheel hub.

7. Install the caster wheel assembly between the caster fork and secure it in place with the bolt and locknut.

Ensure that all blade bolts are torqued to 45 N∙m (33 ft-lb).

Ensure that all flaps are undamaged and free to rotate; replace any and all damaged flaps.

1. Set the PTO switch to the OFF position.

2. Park the machine on level ground, set the throttle control to the slow engine-speed position, and engage the parking brake.

3. Raise the cutting unit as necessary to access the blockage.

4. Shut off the engine, remove the ignition key, and wait for all moving parts to stop.

5. Support the raised cutting unit with jack stands.

6. Use a wooden pole to carefully remove the blockage.

   Important: The flail rotor may rotate when you release the blockage.

   Important: Avoid using excessive force when you remove the blockage.

7. Remove the wooden pole from the cutting unit before you start the engine.

8. Repair or adjust the cutting unit if necessary.

Ensure that the caster tires are filled to 2 to 3.5 bar (30 to 50 psi).

To check for any unusual vibration of the rotor, run the cutting unit at full-engine speed.

1. Start the engine and move the machine to a level, open area away from bystanders.

2. Lower the cutting unit and engage the parking brake.

3. Engage the PTO and run the engine at full throttle while watching for any unusual rotor vibration.

4. If the rotor vibration is unusual, perform the following:

   1. Set the throttle to idle, shut off the PTO, and raise the cutting unit.

   2. Shut off the engine, remove the key, and wait for all moving parts to stop.

   3. Check the cutting unit for the following:

      • Debris preventing the rotor or blades operating correctly and remove any blockages; refer to Clearing a Blocked Rotor.

      • A damaged rotor or worn rotor bearings; refer to Checking the Rotor Bearings.

      • Missing, damaged, unbalanced, or excessively worn blades; refer to Sharpening the Blades and Replacing the Blades.

        Important: All opposing blade pairs must have a similar amount of wear; unbalanced blades may affect the balance of the rotor.

   Important: If you cannot correct the cause of unusual rotor vibration, contact your authorized Toro distributor.

Important: Wear gloves when checking the rotor bearings.

1. Move the machine onto a level surface and engage the parking brake.

2. Raise cutting unit, shut off the engine, remove the key, and wait for all moving parts to stop.

3. Support the cutting unit with jack stands.

4. Grip the rotor at each end and check for excessive end play; if the rotor has excess end play, it may need to be replaced; contact your authorized Toro distributor.

Visually inspect the debris skirt for any damage and remove any debris that has collected on the debris skirt.

Use an angle grinder to sharpen the angled grinding surface on the back of the flail blade (Figure 33).

Important: Do not grind the front face of the flail blade.

While grinding the blade, keep the cutting edge perfectly horizontal and the angled surface flat to the ground (Figure 33).

Use the grinder gently and ensure that the flail does not get hot; otherwise, the steel will lose its hardness.

Do not sharpen the blades past the wear line that is indicated by the 5 dots (Figure 33). Ensure that all the flail blades are sharpened equally to maintain the balance of each rotor.

Keep a new blade as a reference and refer to it when grinding.

Figure 33

1. Surface to grind
2. Wear indicators

To maintain balance, replace blades only as an opposed pair or a whole rotor at a time. Also replace the bushing, the bolt, and the locknut when you replace a blade. There are 2 service kits available for blade replacement; refer to the Parts Catalog.

1. Raise the cutting unit and secure it with jack stands.

2. Engage the parking brake, shut off the engine, and remove the key.

3. Turn the rotor slowly by hand so that each row of flails are in the desired position and you can easily access them.

4. Remove any debris from the bolt head and the nut and clean the protruding threads with a wire brush.

5. Mark the position of the bolt head so that you can replace the bolts from the same side.

6. Holding the blade in a rag or padded glove, remove the nut, bolt, bushing, and blade (Figure 34).

   Note: If needed, apply penetrating oil to the threads to make the nut easier to remove.

   

   Figure 34

   1. Nut
   2. Bolt
   3. Bushing
   4. Blade

7. Discard the blade, bushing, nut, and bolt.

8. Install a new blade and bushing with a new nut and blade bolt (Figure 34).

   Note: Pay attention to the bolt-head-position markings so that you replace the bolt in the same direction.

9. Torque the fasteners to 45 N∙m (33 ft-lb).

Remove the grass buildup under the cutting unit daily.

1. Park the machine on a level surface, raise the cutting unit to the TRANSPORT position, engage the parking brake, shut off the engine, and remove the key.

2. Thoroughly clean the underside of the cutting unit with water.