Hayter CONDOR 510D Operator's Manual
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Hayter CONDOR 510D Operator's Manual

Hayter CONDOR 510D Operator's Manual

Hydrostatic drive power unit
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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: 20.02.2012

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  • Page 1 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 Original Instructions (EN) Part  No.
  • Page 3 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.

  • Page 5: Table Of Contents

    CONTENTS CONTENTS Page No. Safety Precautions 1.7 - 1.12 Training 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...
  • Page 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...
  • Page 7 SAFETY PRECAUTIONS 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.

  • Page 8: Safety Precautions

    SAFETY PRECAUTIONS 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.
  • Page 9 SAFETY PRECAUTIONS 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’...

  • Page 10: Safety Precautions 1.7

    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.

  • Page 11: Decals 1.11

    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.

  • Page 12: Decals Continued

    1.12 SAFETY PRECAUTIONS 1.12 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)
  • Page 13 1.13 EC CONFORMITY INFORMATION 1.13 Noise Levels Operator Daily Personal Noise Exposure: HAYTER LIMITED have no control over site SPELLBROOK, BISHOP'S STORTFORD, conditions, duration of use, state of maintenance or HERTS. CM23 4BU. ENGLAND. CONDOR - HYDRO adjustment of the mower. All of these factors will affect POWER UNIT the operator’s daily personal noise exposure level - L EP,d...

  • Page 14: Ec Conformity Information 1.13

    1.14 EC CONFORMITY INFORMATION 1.14 EC DECLARATION OF CONFORMITY Manufactured by: HAYTER LIMITED, Address: Spellbrook, Bishop s Stortford, Herts. CM23 4BU. ENGLAND declare that the lawnmower : Condor Condor Condor Model name: Hydrostatic Power Unit Hydrostatic Power Unit Hydrostatic Power Unit Type: Pedestrian lawnmower Pedestrian lawnmower...

  • Page 15: Introduction

    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.

  • Page 16: Engine

    1.16 SPECIFICATIONS 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...

  • Page 17: Power Unit

    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...

  • Page 18: Recommended Lubricants And Hydraulic Fluids

    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.

  • Page 19: Assembling The Mower 1.19

    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.
  • Page 20 1.20 ASSEMBLING THE MOWER 1.20 Fig 1 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.
  • Page 21 1.21 ASSEMBLING THE MOWER 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.

  • Page 22: Operating The Mower 1.22

    1.22 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.

  • Page 23: Identification Of Controls

    1.23 OPERATING THE MOWER 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- Parking brake engaged rates an integral parking brake.

  • Page 24: Transmission Bypass Valve Control

    1.24 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.

  • Page 25: Ignition Switch

    1.25 OPERATING THE MOWER 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.

  • Page 26: Stopping The Engine

    1.26 OPERATING THE MOWER 1.26 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’...

  • Page 27: General Operating Hints

    1.27 OPERATING THE MOWER 1.27 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.

  • Page 28: Handlebar Height Adjustment

    1.28 OPERATING THE MOWER 1.28 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.

  • Page 29: Maintenance

    1.29 MAINTENANCE 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.

  • Page 30: Engine

    1.30 MAINTENANCE 1.30 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 Check wheel nut torque: Power unit wheel nut torque setting 80Nm (60lbs ft).

  • Page 31: Daily And Before Use 1.31

    1.31 MAINTENANCE 1.31 Running In Period - At First 50 Hours of 13mm Use continued   .....   ..Check belt tension - Cutterhead input drive: Check the free play at the centre of the drive belt            1    ...
  • Page 32 1.32 MAINTENANCE 1.32 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...
  • Page 33 1.33 MAINTENANCE 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.

  • Page 34: Every 50 Hours

    1.34 MAINTENANCE 1.34 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.

  • Page 35: Every 200 Hours 1.35

    1.35 MAINTENANCE 1.35 Every 200 Hours P erform 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.
  • Page 36 1.36 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.
  • Page 37 1.37 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 accom- plished without removing the hydrostatic unit but it will take an exceptionally long period to refill...
  • Page 38 1.38 MAINTENANCE 1.38 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 1.6mm increased if the maximum speed of the machine is min.
  • Page 39 1.39 MAINTENANCE 1.39 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.
  • Page 40 1.40 MAINTENANCE 1.40 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...

  • Page 41: Rotary Attachment 1.41

    MAINTENANCE 1.41 1.41 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.

  • Page 42: Cutterblades

    MAINTENANCE 1.42 1.42 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.

  • Page 43: Preparing The Mower For Storage

    PREPARING THE MOWER FOR STORAGE 1.43 1.43 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.

  • Page 44: Grass Cutting Faults

    GRASS CUTTING FAULTS 1.44 1.44 Rotary Attachment FAULT POSSIBLE CAUSE REMEDY Undulating ground contours Uneven cut 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 Height of cut too low Raise the height of cut Scalping...

  • Page 45: Trouble Shooting 1.45

    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’...
  • Page 46 TROUBLE SHOOTING 1.46 1.46 FAULT POSSIBLE CAUSE REMEDY Incorrect parking brake Worn brake discs Replace brake discs. Consult your authorised operation dealer. Incorrect cable adjustment Re adjust the cable setting Excessive noise in Hydrostatic unit oil level low Fill reservoir to the correct level transmission system Air in hydrostatic system Carry out ‘bleeding’...

  • Page 47: Electrical Circuit Diagram

    ELECTRICAL CIRCUIT DIAGRAM 1.47 1.47 Black Stop  Switch Engine  Stop (Mounted  on  handlebar) Switch  Wire Black Engine  Stop Stop  Switch Switch Wire (Mounted  On   Engine) Control Module Black Engine  Stop Switch  Wire Yellow Yellow Switch  Link  Wire Blue Cutter  Clutch Microswitch Blue Transmission...

  • Page 48: Warranty

    WARRANTY 1.48 1.48 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.

  • Page 49: Notes 1.49

    NOTES 1.49 1.49...
  • Page 50 1.50 NOTES 1.50...

  • Page 51: Customer Information

    1.51 CUSTOMER INFORMATION 1.51 Machine Details Engine Serial No: ......... Hydrostatic Unit Serial No: .

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