Operator’s Manual 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 Part No. 111-5824 Rev A Original Instructions (EN) Date: 20.02.
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 CONTENTS 1.5 CONTENTS Page No.
1.6 1.6 CONTENTS CONTENTS Page No. MAINTENANCE Maintenance Engine Running in period - at First 50 Hours of Use Daily and before use Every 50 hours Every 200 hours Rotary Attachment Cutterblades Preparing the Mower for Storage GRASS CUTTING FAULTS - Both Types of Attachments TROUBLE SHOOTING ELECTRICAL CIRCUIT DIAGRAM WARRANTY NOTES CUSTOMER INFORMATION 1.29 - 1.43 1.29 1.30 1.30 - 1.31 1.31 - 1.33 1.34 1.35 - 1.37 1.41 - 1.42 1.42 1.43 1.44 1.45 - 1.46 1.47 1.48 1.49 - 1.50 1.
SAFETY PRECAUTIONS 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. Training Read the instructions carefully.
1.8 SAFETY PRECAUTIONS 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.
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.
1.10 SAFETY PRECAUTIONS 1.10 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.
SAFETY PRECAUTIONS 1.11 1.11 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.
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.
1.13 EC CONFORMITY INFORMATION 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.
EC CONFORMITY INFORMATION 1.14 1.14 EC DECLARATION OF CONFORMITY Manufactured by: HAYTER LIMITED, Address: Spellbrook, Bishop s Stortford, Herts. CM23 4BU.
1.15 INTRODUCTION 1.15 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.
SPECIFICATIONS 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.
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.
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 premature wear of hydraulic components and invalidate warranty.
1.19 ASSEMBLING THE MOWER 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.
1.20 ASSEMBLING THE MOWER Assembling the Cutterhead Attachment to the Power Unit 1.20 Fig 1 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.
1.21 ASSEMBLING THE MOWER 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.
OPERATING THE MOWER 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.
OPERATING THE MOWER 1.23 1.23 Identification of Controls 1. 2. 3. 4. 5. 6. 7. Transmission Bypass Valve Lever Cutterhead Clutch Control Lever Parking Brake Lever Throttle Control Operator Presence Control (OPC) Levers. Travel Rocker Ignition Switch 2 1 3 7 5 Braking System Parking brake engaged P Service Brakes: Service braking is achieved by the hydrostatic transmission system.
1.24 OPERATING THE MOWER 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.
OPERATING THE MOWER 1.25 Ignition Switch 1.25 B A ST O P 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 1 The cutterhead drive engagement mechanism is protected by the Operator Presence Control (OPC) system.
1.26 OPERATING THE MOWER Starting the Engine continued 1.26 B A ST O P 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. 1.
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.
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 position. Retighten the hand knob to secure the height of cut lever in position. 1. Hand knob 2. Height of Cut Lever 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).
MAINTENANCE 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.
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 circumstances 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 disengaged and check the free play at the centre of the belt as shown using finger pressure.
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 CUTTERHEAD 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.
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.
1.33 MAINTENANCE 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.
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 sprocket 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.
MAINTENANCE 1.35 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 components 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.
MAINTENANCE 1.36 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.
MAINTENANCE 1.37 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 accomplished 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.
1.38 MAINTENANCE Power Unit General Maintenance continued Travel Speed: The forward and reverse stops restrain the hydrostatic unit actuating lever from being moved excessively and prevent internal components 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.
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.
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.
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 necessary 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.
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.
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 necessary.
1.44 GRASS CUTTING FAULTS 1.
TROUBLE SHOOTING 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 1.46 1.46 FAULT POSSIBLE CAUSE REMEDY Incorrect parking brake operation Worn brake discs Replace brake discs. Consult your authorised dealer.
ELECTRICAL CIRCUIT DIAGRAM 1.47 Black Engine Stop Switch (Mounted On Engine) OFF 1 Stop Switch (Mounted on handlebar) Black Engine Stop Switch Wire 1.47 7 Stop Switch Wire Red On 2 Control Module Red Black Engine Stop Switch Wire Red Yellow Yellow Red Blue 5 Cutter Clutch Microswitch Switch Link Wire 4 Red Blue 6 Transmission Microswitch Item No. Description Part No.
1.48 WARRANTY 1.48 HAYTER LIMITED Warrants to the original user / purchaser that this unit shall be free from defects in material 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.
1.49 NOTES 1.
1.50 NOTES 1.
1.51 CUSTOMER INFORMATION 1.51 Machine Details Engine Serial No: ......................................... Hydrostatic Unit Serial No: ......................................... Transaxle Serial No: ......................................... P.U Serial No: ......................................... Verge Attachment Serial No: ......................................... Rotary Attachment Serial No: .........................................