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(Rev. 10/1/2013) MAN0845 RD990X Tested. Proven. Unbeatable. OPERATOR'S MANUAL REARMOUNT MOWERS TO THE DEALER: Assembly and proper installation of this product is the responsibility of the Woods® dealer. Read manual instructions and safety rules. Make sure all items on the Dealer’s Pre-Delivery and Delivery Check Lists in the Operator’s Manual are completed before releasing equipment to the owner. The dealer must complete the online Product Registration form at the Woods Dealer Website which certifies that all Dealer Check List items have been completed. Dealers can register all Woods product at dealer.WoodsEquipment.com under Product Registration. Failure to register the product does not diminish customer’s warranty rights. TO THE OWNER: Read this manual before operating your Woods equipment. The information presented will prepare you to do a better and safer job. Keep this manual handy for ready reference. Require all operators to read this manual carefully and become acquainted with all adjustment and operating procedures before attempting to operate. Replacement manuals can be obtained from your dealer. To locate your nearest dealer, check the Dealer Locator at www.WoodsEquipment.com, or in the United States and Canada call 1-800-319-6637. The equipment you have purchased has been carefully engineered and manufactured to provide dependable and satisfactory use. Like all mechanical products, it will require cleaning and upkeep. Lubricate the unit as specified. Observe all safety information in this manual and safety decals on the equipment. For service, your authorized Woods dealer has trained mechanics, genuine Woods service parts, and the necessary tools and equipment to handle all your needs. Use only genuine Woods service parts. Substitute parts will void the warranty and may not meet standards required for safe and satisfactory operation. Record the model number and serial number of your equipment in the spaces provided: Model: _______________________________ Date of Purchase: _____________________ Serial Number: (see Safety Decal section for location) ____________________________________ Provide this information to your dealer to obtain correct repair parts. Throughout this manual, the term NOTICE is used to indicate that failure to observe can cause damage to equipment. The terms CAUTION, WARNING, and DANGER are used in conjunction with the Safety-Alert Symbol (a triangle with an exclamation mark) to indicate the degree of hazard for items of personal safety. 2 Introduction Gen’l (Rev. 12/5/2011) TABLE OF CONTENTS INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 OWNER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 DEALER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 DEALER CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 PARTS LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 BOLT TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 BOLT SIZE CHART & ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 44 INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 PRODUCT WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 REPLACEMENT PARTS WARRANTY . . . . . . . . . . . . INSIDE BACK COVER ! LEA EL INSTRUCTIVO! Si no lee Ingles, pida ayuda a alguien que si lo lea para que le traduzca las medidas de seguridad. MAN0845 (1/12/2010) Introduction 3 SPECIFICATIONS RD990X 3-Point Hitch Category 1 and 2 Cutting Width 90" Cutting Height Range 1-1/2" - 7" Operating Weight with Chain Shielding 1200 lbs Blade Speed (feet per minute) 17,000 Blade Speed (RPM) 2,074 Blade Spindles 3 Number of Blades 6 Universal Drive Series ASAE Cat. 4 Caster Wheels 13 x 5 x 10 Solid Rib Tire -or13 x 5 x 6 Pneumatic Tire Tractor PTO Speed RPM 540 Recommended Maximum Tractor Horsepower 75HP Mower Frame Thickness 5/16" GENERAL INFORMATION WARNING ■ Some illustrations in this manual show the mower with safety shields removed to provide a better view. The mower should never be operated with any safety shielding removed. The purpose of this manual is to assist you in operating and maintaining your mower. Read it carefully. It furnishes information and instructions that will help you achieve years of dependable performance. These instructions have been compiled from extensive field experience and engineering data. Some information 4 Introduction may be general in nature, due to unknown and varying operating conditions. However, through experience and these instructions, you should be able to develop procedures suitable to your particular situation. The illustrations and data used in this manual were current at the time of printing. However, due to possible inline production changes, your machine may vary slightly in detail. We reserve the right to redesign and change the machines as may be necessary without notification. Throughout this manual, references are made to right and left directions. These are determined by standing behind the tractor facing the direction of forward travel. MAN0845 (1/12/2011) SAFETY RULES ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Safety is a primary concern in the design and manufacture of our products. Unfortunately, our efforts to provide safe equipment can be wiped out by an operator’s single careless act. In addition to the design and configuration of equipment, hazard control and accident prevention are dependent upon the awareness, concern, judgement, and proper training of personnel involved in the operation, transport, maintenance and storage of equipment. It has been said “The best safety device is an informed, careful operator.” We ask you to be that kind of operator. TRAINING Safety instructions are important! Read all attachment and power unit manuals; follow all safety rules and safety decal information. (Replacement manuals and safety decals are available from your dealer. To locate your nearest dealer, check the Dealer Locator at www.WoodsEquipment.com, or in the United States and Canada call 1-800-3196637.) Failure to follow instructions or safety rules can result in serious injury or death. Know your controls and how to stop engine and attachment quickly in an emergency. If you do not understand any part of this manual and need assistance, see your dealer. Operators must be instructed in and be capable of the safe operation of the equipment, its attachments, and all controls. Do not allow anyone to operate this equipment without proper instructions. Never allow children or untrained persons to operate equipment. PREPARATION Check that all hardware is properly installed. Always tighten to torque chart specifications unless instructed otherwise in this manual. Always wear relatively tight and belted clothing to avoid getting caught in moving parts. Wear sturdy, rough-soled work shoes and protective equipment for eyes, hair, hands, hearing, and head; and respirator or filter mask where appropriate. Make sure attachment is properly secured, adjusted, and in good operating condition. PRD Mower (9/13/2005) Make sure spring-activated locking pin or collar slides freely and is seated firmly in tractor PTO spline groove. Make sure driveline guard tether chains are attached to the tractor and equipment as shown in the pamphlet that accompanies the driveline. Replace if damaged or broken. Check that driveline guards rotate freely on driveline before putting equipment into service. Connect PTO driveline directly to power unit PTO shaft. Never use adapter sleeves or adapter shafts. Adapters can cause driveline failures due to incorrect spline or incorrect operating length and can result in personal injury or death. Before starting power unit, check all equipment driveline guards for damage. Replace any damaged guards. Make sure all guards rotate freely on all drivelines. If guards do not rotate freely on drivelines, repair and replace bearings before putting equipment into service. Power unit must be equipped with ROPS or ROPS cab and seat belt. Keep seat belt securely fastened. Falling off power unit can result in death from being run over or crushed. Keep foldable ROPS system in “locked up” position at all times. Remove accumulated debris from this equipment, power unit, and engine to avoid fire hazard. Make sure all safety decals are installed. Replace if damaged. (See Safety Decals section for location.) Make sure shields and guards are properly installed and in good condition. Replace if damaged. A minimum 20% of tractor and equipment weight must be on the tractor front wheels when attachments are in transport position. Without this weight, front tractor wheels could raise up resulting in loss of steering. The weight may be attained with front wheel weights, ballast in tires or front tractor weights. Weigh the tractor and equipment. Do not estimate. OPERATION Full chain shielding must be installed when operating in populated areas or other areas where thrown objects could injure people or damage property. • If this machine is not equipped with full chain shielding, operation must be stopped when anyone comes within 300 feet (92 m). • This shielding is designed to reduce the risk Safety 5 SAFETY RULES ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! of thrown objects. The mower deck and protective devices cannot prevent all objects from escaping the blade enclosure in every mowing condition. It is possible for objects to ricochet and escape, traveling as much as 300 feet (92 m). Inspect and clear area of stones, branches, or other hard objects that might be thrown, causing injury or damage. Never direct discharge toward people, animals, or property. attachments are in transport position. Without this weight, front tractor wheels could raise up resulting in loss of steering. The weight may be attained with front wheel weights, ballast in tires or front tractor weights. Weigh the tractor and equipment. Do not estimate. Do not operate or transport on steep slopes. Do not operate or transport equipment while under the influence of alcohol or drugs. Keep bystanders away from equipment. Always comply with all state and local lighting and marking requirements. Do not operate or transport equipment while under the influence of alcohol or drugs. Never allow riders on power unit or attachment. Operate only in daylight or good artificial light. MAINTENANCE Keep hands, feet, hair, and clothing away from equipment while engine is running. Stay clear of all moving parts. Always comply with all state and local lighting and marking requirements. Never allow riders on power unit or attachment. Always sit in power unit seat when operating controls or starting engine. Securely fasten seat belt, place transmission in neutral, engage brake, and ensure all other controls are disengaged before starting power unit engine. Before working underneath, carefully read Operator’s Manual instructions, disconnect driveline, raise mower, securely block up all corners with jackstands, and check stability. Secure blocking prevents equipment from dropping due to hydraulic leak down, hydraulic system failures, or mechanical component failures. Do not modify or alter or permit anyone else to modify or alter the equipment or any of its components in any way. Do not operate or transport on steep slopes. Always wear relatively tight and belted clothing to avoid getting caught in moving parts. Wear sturdy, rough-soled work shoes and protective equipment for eyes, hair, hands, hearing, and head; and respirator or filter mask where appropriate. Do not stop, start, or change directions suddenly on slopes. Make sure attachment is properly secured, adjusted, and in good operating condition. Use extreme care and reduce ground speed on slopes and rough terrain. Keep all persons away from operator control area while performing adjustments, service, or maintenance. Operate tractor PTO at 540 RPM. Do not exceed. Look down and to the rear and make sure area is clear before operating in reverse. Watch for hidden hazards on the terrain during operation. Stop power unit and implement immediately upon striking an obstruction. Dismount power unit, using proper procedure. Inspect and repair any damage before resuming operation. TRANSPORTATION Use additional caution and reduce speed when under adverse surface conditions, turning, or on inclines. Do not operate PTO during transport. A minimum 20% of tractor and equipment weight must be on the tractor front wheels when 6 Safety Make certain all movement of equipment components has stopped before approaching for service. Never go underneath equipment (lowered to the ground or raised) unless it is properly blocked and secured. Never place any part of the body underneath equipment or between moveable parts even when the engine has been turned off. Hydraulic system leak down, hydraulic system failures, mechanical failures, or movement of control levers can cause equipment to drop or rotate unexpectedly and cause severe injury or death. Follow Operator's Manual instructions for working underneath PRD Mower (9/13/2005) SAFETY RULES ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! and blocking requirements or have work done by a qualified dealer. Make sure shields and guards are properly installed and in good condition. Replace if damaged. Frequently check blades. They should be sharp, free of nicks and cracks, and securely fastened. Wear gloves when installing belt. Be careful to prevent fingers from being caught between belt and pulley. Do not handle blades with bare hands. Careless or improper handling may result in serious injury. Your dealer can supply genuine replacement blades. Substitute blades may not meet original equipment specifications and may be dangerous. Tighten all bolts, nuts, and screws to torque chart specifications. Check that all cotter pins are installed securely to ensure equipment is in a safe condition before putting unit into service. Make sure all safety decals are installed. Replace if damaged. (See Safety Decals section for location.) Use care when installing or removing belt from spring-loaded idler. Springs store energy when extended and, if released suddenly, can cause personal injury. STORAGE Follow manual instructions for storage. Keep children and bystanders away from storage area. PRD Mower (9/13/2005) Safety 7 SAFETY & INSTRUCTIONAL DECALS ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Replace Immediately If Damaged! DANGER DANGER 6 - 15503 SHIELD MISSING DO NOT OPERATE PUT SHIELD ON 5 - 18867 18867--B ROTATING BLADES AND THROWN OBJECTS Do not put hands or feet under or into mower when engine is running. Before mowing, clear area of objects that may be thrown by blade. Keep bystanders away. Keep guards in place and in good condition. MODEL NO. SERIAL NO. Woods Equipment Company Oregon, Illinois, U.S.A. 1 - Serial Number Plate BLADE CONTACT OR THROWN OBJECTS CAN CAUSE SERIOUS INJURY OR DEATH. 15503-C 9 - 57123 9" Red Rear Reflector BE CAREFUL! Use a clean, damp cloth to clean safety decals. Avoid spraying too close to decals when using a pressure washer; high-pressure water can enter through very small scratches or under edges of decals causing them to peel or come off. Replacement safety decals can be ordered free from your Woods dealer. To locate your nearest dealer, check the Dealer Locator at www.woodsonline.com, or in the United States and Canada call 1-800-319-6637. 8 Safety (Rev. 10/1/2013) MAN0845 (1/12/2011) SAFETY & INSTRUCTIONAL DECALS ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Replace Immediately If Damaged! WARNING WARNING DO NOT EXCEED PTO SPEED OF 540 RPM PTO speeds higher than 540 RPM can cause equipment failure and personal injury. 18866-D FALLING OFF CAN RESULT IN BEING RUN OVER. Tractor must be equipped with ROPS (or ROPS CAB) and seat 4 - 18866 belt. Keep foldable ROPS systems in “locked up” position at all times. Buckle Up! Keep seat belt securely fastened. DANGER Allow no riders. RAISED EQUIPMENT CAN DROP AND CRUSH. Before working underneath, follow all instructions and safety rules in operator’s manual and securely block up all corners of equipment with jack stands. Securely blocking prevents equipment dropping from hydraulic leak- down, hydraulic system failures or mechanical component failures. ROTATING DRIVELINE CONTACT CAN CAUSE DEATH KEEP AWAY! FALLING OFF OR FAILING TO BLOCK SECURELY CAN RESULT IN SERIOUS INJURY OR DEATH. 18865--C 2 - 18865 DO NOT OPERATE WITHOUT All driveline guards, tractor and equipment shields in place DANG NGER ER Drivelines securely attached at both ends Driveline guards that turn freely on driveline If shaft connection is visible, shield is missing. Replace shield before operating equipment. 1004114 18864-C 7 - 18864 10 - 1004114 8 - 33347 DANGER 3 - 18877 11 - 1003751 WARNING WARNING TO AVOID SERIOUS INJURY OR DEATH: Read Operator's Manual (available from dealer) and follow all safety precautions. Keep all shields in place and in good condition. GUARD MISSING. DO NOT OPERATE. DANGER Operate mower from tractor seat only. Lower mower, stop engine and remove key before dismounting tractor. Allow no children or untrained persons to operate equipment. Do not transport towed or semi-mounted units over 20 mph. FAILURE TO OPERATE SAFELY CAN RESULT IN INJURY OR DEATH. 18877-C MAN0845 (1/12/2011) CRUSHING AND PINCHING HAZARD GUARD MISSING. DO NOT OPERATE. 33347E DANGER Be extremely careful handling various parts of the machine. They are heavy and hands, fingers, feet, and other body parts could be crushed or pinched between tractor and implement. Operate tractor controls from tractor seat only. Do not stand between tractor and implement when tractor is in gear. Make sure parking brake is engaged before going between tractor and implement. Stand clear of machine while in operation or when it is being raised or lowered. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN SERIOUS INJURY OR DEATH. 1003751-A Safety 9 OPERATION The operator is responsible for the safe operation of the mower. The operator must be properly trained. Operators should be familiar with the mower, the tractor, and all safety practices before starting operation. Read the safety rules and safety decals on pages 5 to 9. This mower is designed for light brush shredding and grass mowing. It is especially useful in cane, berry, grape and vegetable crops for mowing and shredding prunings. Recommended mowing speed for most conditions is from 2 to 5 mph. DANGER Full chain shielding must be installed when operating in populated areas or other areas where thrown objects could injure people or damage property. • If this machine is not equipped with full chain shielding, operation must be stopped when anyone comes within 300 feet (92 m). • This shielding is designed to reduce the risk of thrown objects. The mower deck and protective devices cannot prevent all objects from escaping the blade enclosure in every mowing condition. It is possible for objects to ricochet and escape, traveling as much as 300 feet (92 m). Stop power unit and implement immediately upon striking an obstruction. Dismount power unit, using proper procedure. Inspect and repair any damage before resuming operation. CAUTION Always wear relatively tight and belted clothing to avoid getting caught in moving parts. Wear sturdy, rough-soled work shoes and protective equipment for eyes, hair, hands, hearing, and head; and respirator or filter mask where appropriate. TRACTOR STABILITY WARNING A minimum 20% of tractor and equipment weight must be on the tractor front wheels when attachments are in transport position. Without this weight, front tractor wheels could raise up resulting in loss of steering. The weight may be attained with front wheel weights, ballast in tires or front tractor weights. Weigh the tractor and equipment. Do not estimate. WARNING Never allow children or untrained persons to operate equipment. Keep bystanders away from equipment. Make sure spring-activated locking pin or collar slides freely and is seated firmly in tractor PTO spline groove. Before working underneath, carefully read Operator’s Manual instructions, disconnect driveline, raise mower, securely block up all corners with jackstands, and check stability. Secure blocking prevents equipment from dropping due to hydraulic leak down, hydraulic system failures, or mechanical component failures. Keep all persons away from operator control area while performing adjustments, service, or maintenance. CAUTION 10 Operation Figure 1. Tractor Stability ATTACHING MOWER TO TRACTOR WARNING Make sure spring-activated locking pin or collar slides freely and is seated firmly in tractor PTO spline groove. The standard 1-3/8" 6B-spline driveline with a QD yoke is used to connect the mower to the tractor. MAN0845 (1/12/2011) Refer to Figure 2 1. For Category 1 hitch, position mower hitch arms (E) with offset toward center of mower. For Category 2 hitch, position mower hitch arms (E) with offset toward outside of mower. 2. Attach the mower hitch pins (B) to lower tractor lift arms and secure. Tether Chain 3. Attach tractor top link (1) to mower top link bracket attachment point A. Connect driveline to tractor PTO shaft. CM906 Figure 3. Attaching Mower to Tractor 4. Attach tether chain to tractor drawbar if drive equipped with chain, (Figure 3). 5. Adjust the tractor lower 3-point arm anti-sway devices to prevent mower from swinging side to side during transport. CUTTING HEIGHT ADJUSTMENT WARNING Keep all persons away from operator control area while performing adjustments, service, or maintenance. NOTICE ■ Avoid low cutting heights. Striking the ground with blades produces one of the most damaging shock loads a mower can encounter. Allowing blades to contact ground repeatedly will cause damage to mower and drive. 1. Level mower from side to side. Check by measuring from mower frame to the ground at each deck rail. 2. Verify that the same amount of spacers are under all caster arms. 3. Loosen cap screws that attach caster arm assembly to deck. 4. Set mower on the ground. 1. A. B. C. D. E. Tractor top link Mower top link attachment point Mower hitch pin Category 2 sleeve Lower hitch arm attachment point Mower hitch arm Figure 2. Attachment Points MAN0845 (1/12/2011) 5. Retighten cap screws. This clearance in the bolt holes. equalizes the 6. Adjust front of mower level with or slightly lower than the rear to obtain best mowing results. See Figure 4. 7. Control cutting height by adjusting front and rear caster wheels. 8. To raise rear of mower, move caster adjustment spacers under rear caster arms. See Figure 6. Operation 11 9. To raise front of mower, move spacers under front caster wheel arms. TRACTOR TOP LINK ADJUSTMENT When the cutting height is set, adjust tractor top link until mower top link attachment point (A) is aligned vertically with mower hitch pin (B), Figure 7. Adjust tractor top link so mower is level between caster wheel and ground (dimension C), Figure 8. This will allow the mower to follow ground contour. The mower has three lower hitch plate attachment points (D), Figure 7. It may be necessary to change the mower hitch plate attachment point to obtain proper tire clearance and/or lift height. Figure 4. Cutting Height Adjustment Remember, measurement at location A (Figure 4) should not be less than location B and should not be over 1/2" greater than location B. Spacers under caster arm pivot tube Cut Height Axle Position 1/2" Spacer 3/4" Spacer 1" Spacer 1-1/2" A 2" A 2-1/2" A 3" A 3-1/2" A 4" A 1 2 4-1/2" A 2 2 5" A 5-1/2" A 6" 1 1 1 1 2 2 2 1 2 2 A 2 2 2 6-1/2" B 1 2 2 7" B 2 2 2 Figure 5. Cutting Height Chart 1. A. B. C. D. E. Figure 6. Height Adjustment with Caster Arm Spacers 12 Operation Tractor top link Mower top link attachment point Mower hitch pin Category 2 sleeve Lower hitch arm attachment point Mower hitch arm Figure 7. Top Link Adjustment (Rev. 10/1/2013) MAN0845 (1/12/2011) FRONT CASTER WHEEL INTERFERENCE CHECK using proper procedure. Inspect and repair any damage before resuming operation. NOTICE Power for operating mower is supplied by tractor PTO. Operate PTO at 540 rpm. Know how to stop tractor and mower quickly in an emergency. ■ Do not operate tractor and mower until this interference check has been performed. If you change tractors, you must perform the check for that mounting. If mower becomes plugged causing belt to slip for over two seconds follow these steps: 1. Maneuver equipment into a previously cut area and allow mower to clear accumulated material. 2. Continue running at least two minutes, allowing pulleys to cool. Stopping the mower in contact with a very hot pulley will bake and ruin belt. Proper ground speed will depend upon the terrain, the height, and type and density of material to be cut. Normally, ground speed will range from 2 to 5 mph. Tall dense material should be cut at a low speed; thin medium-height material can be cut at a faster ground speed. Always operate tractor PTO at 540 rpm to maintain proper blade speed and produce a clean cut. Figure 8. Front Caster Wheel Interference Check Perform this check with all of the spacers above caster wheel arm. This will place caster wheels in their highest position and provide lowest cutting height for mower. 1. Raise mower with tractor hydraulics to 16" at dimension C or maximum height of tractor lift, whichever is less. 2. Pivot both front caster wheels forward and check that there is clearance between caster wheels and tractor tires. 3. If there is interference adjust mower hitch arm (E) as shown in Figure 7. NOTE: If interference continues, see tractor operator's manual and adjust tractor wheels to narrower spacing. FRONT ROLLER (OPTIONAL) The caster wheels and side skids effectively reduce scalping in most cases. However, you may encounter areas where the caster wheels and/or side skids drop into depressions and allow center of the mower to contact ground and scalp. An optional front roller may be installed to minimize scalping. See page 32. OPERATING TECHNIQUE Under certain conditions, tractor tires may roll some grass down and prevent it from being cut at the same height as the surrounding area. When this occurs, reduce your ground speed, but maintain PTO at 540 rpm. The lower ground speed will permit grass to partially rebound. In general, lower cutting heights give a more even cut and leave less tire tracks. However, it is better to cut grass frequently rather than too short. Short grass deteriorates rapidly in hot weather and invites weed growth during growing seasons. Follow local recommendations for the suitable cutting height in your area. Operating Tips WARNING Inspect and clear area of stones, branches, or other hard objects that might be thrown, causing injury or damage. Extremely tall material should be cut twice. Set mower at a higher cutting height for the first pass. Then cut at desired height, 90 degrees to the first pass. Remember, sharp blades produce cleaner cuts and require less power. CAUTION Stop power unit and implement immediately upon striking an obstruction. Dismount power unit, MAN0845 (1/12/2011) Analyze area to be cut to determine the best procedure. Consider height and type of grass and terrain type: hilly, level, or rough. Operation 13 Plan your mowing pattern to travel straight forward whenever possible. Mow with uncut grass to the right. This will distribute the clippings over the cut area. Uneven Terrain WARNING Do not operate or transport on steep slopes. Do not stop, start, or change directions suddenly on slopes. Use extreme care and reduce ground speed on slopes and rough terrain. Watch for hidden hazards on the terrain during operation. Pass diagonally through sharp dips and avoid sharp drops to prevent hanging up tractor and mower. Practice will improve your skills in maneuvering rough terrain. MOWER REMOVAL & STORAGE ___ Check that all safety decals are installed and in good condition. Replace if damaged. ___ Check that all shields and guards are properly installed and in good condition. Replace if damaged. ___ Check that chain shielding is in good condition and replace any damaged chain links. ___ Check that all hardware and cotter pins are properly installed and secured. ___ Check to ensure blades are sharp, in good condition, and installed correctly. Replace if damaged. ___ Check that equipment is properly and securely attached to tractor. ___ Make sure driveline spring-activated locking pin or collar slides freely and is seated firmly in tractor PTO spline groove. ___ Make sure the driveline guards and tether chains are in good condition. Guards must rotate freely on driveline. Fasten tether chains to the tractor and the equipment as instructed. 1. Disengage PTO, place tractor and mower on solid, level surface. Raise mower with 3-point hitch. ___ Inspect area and remove stones, branches or other hard objects that might be thrown, causing injury or damage. 2. Place blocks under mower side skids. Lower mower onto blocks. ___ Do not allow riders. 3. Set parking brake, stop engine and remove key. Disconnect mower driveshaft from tractor PTO. ___ Check all lubrication points and grease as instructed in “Lubrication Information” on page 15. Make sure the PTO slip joint is lubricated and that the gearbox fluid levels are correct. 4. Collapse driveshaft as far as possible and store in driveshaft hanger bracket to prevent ground contact. 5. Disconnect mower from tractor 3-point hitch. Start tractor and carefully drive away from mower. 6. Before extended storage, see page 18 for cleaning instructions. OWNER PRE-OPERATION CHECK LIST (OWNER'S RESPONSIBILITY) ___ Set tractor PTO at 540 rpm. ___ Make sure tractor ROPS or ROPS cab and seat belt are in good condition. Keep seat belt securely fastened during operation. ___ Before starting engine, operator must be in tractor seat with seat belt fastened. Place transmission in neutral or park, engage brake, and disengage tractor PTO. ___ Review and follow all safety rules and safety decal instructions on pages 5 to 9. 14 Operation MAN0845 (1/12/2011) OWNER SERVICE The information in this section is written for operators who possess basic mechanical skills. If you need help, your dealer has trained service technicians available. For your protection, read and follow the safety information in this manual. WARNING Never allow children or untrained persons to operate equipment. Keep bystanders away from equipment. Before working underneath, carefully read Operator’s Manual instructions, disconnect driveline, raise mower, securely block up all corners with jackstands, and check stability. Secure blocking prevents equipment from dropping due to hydraulic leak down, hydraulic system failures, or mechanical component failures. Keep all persons away from operator control area while performing adjustments, service, or maintenance. Operate tractor PTO at 540 RPM. Do not exceed. CAUTION Always wear relatively tight and belted clothing to avoid getting caught in moving parts. Wear sturdy, rough-soled work shoes and protective equipment for eyes, hair, hands, hearing, and head; and respirator or filter mask where appropriate. BLOCKING METHOD Do not work underneath mower unless it is properly attached to the tractor and blocked securely. When properly attached, the unit will be anchored to minimize front to rear movement. Raise mower completely, set tractor brakes, turn engine off, remove key, block tractor wheels front and rear, and disconnect mower driveline from tractor. The only approved blocking device for this mower is a jackstand with a load rating of 1000 pounds or more. One jackstand under each corner of the mower (four total) must be installed before working underneath. See Figure 9. When blocking, you must consider overall stability of the unit. Just blocking under the unit will not ensure your safety. The working surface must be level and solid to support the loaded weight of the jackstands. Test jackstands stability before working under any portion of the mower. (Rev. 10/1/2013) MAN0845 (1/12/2011) Figure 9. Blocking Method LUBRICATION INFORMATION Do not let excess grease collect on or around parts, particularly when operating in sandy areas. Figure 10 shows the lubrication points. The accompanying chart gives the frequency of lubrication in operating hours, based on normal operating conditions. Severe or unusual conditions may require more frequent lubrication. Some reference numbers have more than one location; be sure you lubricate all locations. Use a lithium grease of #2 consistency with a MOLY (molybdenum disulfide) additive for all locations. Be sure to clean fittings thoroughly before attaching grease gun. When applied according to the lubrication chart, one good pump of most guns is sufficient. Use SAE 90W gear lube in the gearbox. Fill to plug on side of gearbox. Check gearbox daily for evidence of leakage at both seals and the gasket between the housing and cover. If leakage is noted, repair immediately. There may be a small amount of lube emitted from the vent plug; this is not considered leakage. Overfilling the gearbox will cause the excess gear lube to blow out vent plug and ruin the belt. Driveshaft Lubrication Lubricate the driveshaft slip joint every 8 operating hours. Failure to maintain proper lubrication could result in damage to U-joints, gearbox, and driveshaft. 1. Lower mower to ground. 2. Apply grease at three locations shown in Figure 10. 3. Raise and lower mower several times to distribute grease. Owner Service 15 REF DESCRIPTION FREQUENCY 1 Driveline U-Joints 8 Hours 2 Gearbox (Fill to center of horizontal shaft with SAE 90W gear lube) Check for leaks daily 3 Caster Wheel (Four Wheels) 8 Hours 4 Caster Pivot (Four Yokes) 8 Hours 5 Slip Joint 8 Hours 6 Shield Bearing 8 Hours 7 Blade Spindles (Access through hole) 8 Hours Figure 10. Lubrication Points & Chart 16 Owner Service (Rev. 10/1/2013) MAN0845 (1/12/2011) NOTICE ■ Use care when installing or removing belt from spring-loaded idler at step 6. Springs store energy when extended and, if released suddenly, can cause personal injury. 7. Adjust belt guide G to provide 1/8" to 3/16" clearance from belt. Tighten bolt to 85 lbs-ft. BLADE SERVICE WARNING Figure 11. Belt Routing BELT SERVICE Belt Replacement One of the major causes of belt failure is improper installation. Before installing a new belt, check the following: Before dismounting power unit or performing any service or maintenance, follow these steps: disengage power to equipment, lower the 3-point hitch and all raised components to the ground, operate valve levers to release any hydraulic pressure, set parking brake, stop engine, remove key, and unfasten seat belt. 1. Check pulley shafts and bearings for wear. 2. Check pulley grooves for cleanliness. 3. Make sure spindles turn freely and without wobble. If grooves require cleaning, moisten a cloth with a nonflammable, non-toxic degreasing agent or commercial detergent and water. Avoid excessive force during installation. Do not use tools to pry belt into pulley groove. Do not roll belt over pulleys to install. This can cause hidden damage and premature belt failure. Keep all persons away from operator control area while performing adjustments, service, or maintenance. Blade Removal 1. Remove Nylok bolt (5). 2. Remove blade lock (4) from groove in blade pin. 3. Remove blade (2) and pin (3) from spindle assembly (1). Belt Installation 1. Disconnect idler spring from deck lug I. 2. Slide belt under drive pulley A and over idler arm. Position belt around drive pulley A. 3. Route belt around pulley B, idler C and pulley D as shown. 4. Make sure belt is on drive pulley A, route around idler E, and connect idler spring to lug I on deck. 5. Loosen bolt holding belt guide G and swing it away from pulley F. 6. Grasp belt between spindle pulley F, spring loaded idler E and spindle pulley D. Pull spring loaded idler with belt to obtain enough belt length to route it over pulley F. Make sure spring-loaded idler pivots freely with belt installed. MAN0845 (1/12/2011) 1. 2. 3. 4. 5. Blade Spindle Blade Blade Pin Blade Lock 1/2NC x 3/4 Nylok Bolt Figure 12. Blade Removal Owner Service 17 Blade Installation CAUTION Your dealer can supply genuine replacement blades. Substitute blades may not meet original equipment specifications and may be dangerous. 1. Always sharpen both blades at the same time to maintain balance. Follow original sharpening pattern. 2. Do not sharpen blade to a razor edge. Leave at least a 1/16" blunt edge. 3. Do not sharpen back side of blade. CHAIN SHIELDING DANGER 1. 2. 3. 4. 5. Blade Spindle Blade Blade Pin Blade Lock 1/2NC x 3/4 Nylok Bolt Figure 13. Blade Assembly 1. Install blade pin (3) thru blade (2) and blade spindle (1). 2. Make sure blade cutting edge is positioned to lead in a clockwise rotation, as viewed from top of mower. 3. Insert blade lock (4) into groove of blade pin (3). 4. Secure lock (4) with Nylok bolt (5). Blade Sharpening Figure 14. Blade Sharpening NOTICE ■ When sharpening blades, grind the same amount on each blade to maintain balance. Replace blades in pairs. Unbalanced blades will cause excessive vibration, which can damage gearbox bearings. Vibration may also cause structural cracks to cutter. 18 Owner Service Full chain shielding must be installed when operating in populated areas or other areas where thrown objects could injure people or damage property. • If this machine is not equipped with full chain shielding, operation must be stopped when anyone comes within 300 feet (92 m). • This shielding is designed to reduce the risk of thrown objects. The mower deck and protective devices cannot prevent all objects from escaping the blade enclosure in every mowing condition. It is possible for objects to ricochet and escape, traveling as much as 300 feet (92 m). Check that chain shielding is in good condition and replace any damaged chain links. CLEANING After Each Use ● Remove large debris such as clumps of dirt, grass, crop residue, etc. from machine. ● Inspect machine and replace worn or damaged parts. ● Replace any safety decals that are missing or not readable. Periodically or Before Extended Storage ● Clean large debris such as clumps of dirt, grass, crop residue, etc. from machine. ● Remove the remainder using a low-pressure water spray. 1. Be careful when spraying near scratched or torn safety decals or near edges of decals as water spray can peel decal off surface. 2. Be careful when spraying near chipped or scratched paint as water spray can lift paint. 3. If a pressure washer is used, follow the advice of the pressure washer manufacturer. ● Inspect machine and replace worn or damaged parts. ● Sand down scratches and the edges of areas of missing paint and coat with Woods spray paint of matching color (purchase from your Woods dealer). ● Replace any safety decals that are missing or not readable (supplied free by your Woods dealer). See Safety Decals section for location drawing. MAN0845 (1/12/2011) TROUBLE SHOOTING MOWING CONDITIONS PROBLEM POSSIBLE CAUSE SOLUTION Grass cut higher in center of swath than at edge Height of mower higher at rear than at front Adjust mower height and attitude so that mower rear and front are within 1/2 inch of same height. See instructions on page 11. Grass cut lower in center of swath than at edge Height of mower lower at rear than at front Adjust mower height and attitude so that mower rear and front are within 1/2 inch of same height. See instructions on page 11. Streaking conditions in swath Conditions too wet for mowing Allow grass to dry before mowing. Blades unable to cut that part of grass pressed down by path of tractor tires Slow ground speed of tractor but keep engine running at full PTO rpm. Cutting lower will help. Adjust tractor tire spacing if possible. Dull blades Sharpen or replace blades. Material too high and too much material Reduce ground speed but maintain 540 rpm at tractor PTO, or make two passes over material. Raise mower for the first pass and lower for the second and cut at 90 degrees to first pass. Raise rear of mower high enough to permit material to discharge, but not so high that conditions listed above occur. Grass wet Allow grass to dry before mowing. Slow ground speed of tractor but keep engine running at full PTO rpm. Rear of mower too low, trapping material under mower Adjust mower height and attitude. Material discharges from mower unevenly; bunches of material along swath MAN0845 (1/12/2011) Troubleshooting 19 TROUBLE SHOOTING BELT CONDITIONS PROBLEM Belt slippage POSSIBLE CAUSE SOLUTION Mower overloading; Material too tall or heavy Reduce tractor ground speed but maintain full PTO rpm. Cut material twice, one high pass and then mow at desired height. Cut at 90 degrees to first pass. Oil on belt from over lubrication Be careful not to over-lubricate. Clean lubricant from belt and pulleys with clean rag. Replace oil-soaked belt. Belt hung up or rubbing Check belt position in pulleys and idlers. Check belt for free travel in pulleys. Check under mower and around blade spindle shaft for wire, rags, or other foreign material. Clean all material from under mower. Belt misaligned or belt rubbing guide Re-align belt. Be sure belt does not rub any other part while running. Pulley misaligned Inspect to ensure belt is running in center of backside idler. Shim idler as necessary to align. Damaged belt Rollover, high shock loads or installation damaged Replace belt.* Belt breakage High shock loads Avoid abusive mowing. Avoid hitting the ground or large obstructions. Belt came off drive Check pulleys for foreign material in grooves. Avoid hitting solid objects or ground. Frayed edges on belt cover * Check belt for damage by laying it flat on the floor. A belt that does not lie flat (has humps or twists, indicating broken or stretched cords) must be replaced. 20 Troubleshooting MAN0845 (1/12/2011) NOTES MAN0845 (1/12/2011) Troubleshooting 21 DEALER SERVICE The information in this section is written for dealer service personnel. The repair described here requires special skills and tools. If your shop is not properly equipped or your mechanics are not properly trained in this type of repair, you may be time and money ahead to replace complete assemblies. WARNING Before working underneath, read manual instructions, securely block up, and check stability. Secure blocking prevents equipment from dropping due to hydraulic leak down, hydraulic system failure, or mechanical component failure. 4. Disassemble split taper bushing (13) (located on top of pulley) by removing the two bolts and key (14). 5. Insert bolts into the threaded holes of bushing flange. 6. Tighten bolts alternately to remove split taper bushing. 7. Remove pulley (12). 8. Remove bolts that attach spindle to mower frame and remove spindle. 9. Remove grease fitting (17) from top of shaft. Keep all persons away from operator control area while performing adjustments, service, or maintenance. CAUTION 5. Spindle Housing 7. Spindle Shaft and Crossbar Always wear relatively tight and belted clothing to avoid getting caught in moving parts. Wear sturdy, rough-soled work shoes and protective equipment for eyes, hair, hands, hearing, and head; and respirator or filter mask where appropriate. 8. Blade Lock 9. Blade Pin 10. 1/2NC x 3/4 Nylock HHCS 11. Blade 12. Sheave BLOCKING METHOD See "Blocking Method" instructions on page 15. BLADE SPINDLE SERVICE 13. Bushing 14. Key 15. 1" Lock Washer 16. 1NC Jam Nut 17. Grease Fitting Spindle repair requires special skills and tools. If your shop is not properly equipped or your mechanics are not trained in this type of repair, you may be time and money ahead to use a new spindle assembly. For reference, the grease fitting is in the top of the spindle shaft. Permatex® 3D Aviation Form-A-Gasket or equivalent is recommended as a sealant. Spindle Removal 1. Remove blade (11) from spindle (7). 2. Remove belt from pulleys. 3. Remove jam nut (16) and washer (15) from top of spindle shaft, Figure 15. 22 Dealer Service Figure 15. Sheave and Blade Assembly Spindle Disassembly 1. Place spindle assembly in press and press shaft down through housing. 2. Remove seals from housing. 3. Remove bearing cups from housing by placing a punch in the slots provided and driving them out. Alternate punch positions from side to side. Take care to prevent housing damage. MAN0845 (1/12/2011) NOTICE ■ Improper positioning of seals can cause seal damage. An improperly installed seal will leak and could cause bearing failure. 3. Identify the open side of the seal (3) containing the spring. 4. Apply a thin coat of Permatex to the area of housing where seals seat. 3. Seal 5. Spindle Housing 7. Spindle Shaft and Crossbar 5. Install bottom seal (3) with spring up toward center of housing. 6. Place seal squarely on housing and select a piece of pipe or tubing with an OD that will set on outside edge of seal. A tubing with an OD that is too small will bow seal cage. Figure 16. Spindle Disassembly Spindle Assembly Refer to Figure 17. Bearing cones and cups are designed to work together. It is important to position them so bearing cone taper mates with cup taper. 1. Lubricate new cups (6) with a light oil. Place them in spindle housing (5) so they will mate with bearing cones (4). Cups (6) and cones (4) are a press fit to minimize wear. Seat cups (6) securely with a press or place a large drift in the flat lip and drive them into housing (5) until cup seats against machined shoulder of housing. 2. Place bottom bearing cone (4) into spindle with taper positioned to mate with cup (6). 7. Carefully press seal into housing, to prevent distortion to metal seal cage. Bottom seal should seat firmly and squarely against machined shoulder in housing. 8. Make sure seal lip did not roll under. Distortion to seal cage or damage to seal lip will cause seal to leak. Damaged seals must be replaced. 9. Insert shaft (7) through bottom of housing (5). 10. Fill housing cavity with a medium grade grease. 11. Install top bearing (4) on shaft (7) to mate with top cone (6). 12. Apply a thin coat of Permatex to shaft area where sleeve will seat. 13. Install sleeve (2) on shaft and press sleeve and bearing into housing until all free play is removed and there is a very light drag on bearings (similar to adjusting front wheel bearings on an automobile). Check by spinning spindle. It should turn freely. 14. Be careful not to overtighten bearings. Proper bearing adjustment is essential to good bearing life. 15. If you overtighten bearings, hold spindle housing and rap spindle shaft with a lead hammer. 16. Carefully press top seal (3) in with spring up. Top seal should be flush with or to within 1/16" above the housing. 17. Rotate housing on spindle shaft, checking for free movement. 2. 3. 4. 5. 6. 7. 17. Sleeve Seal Bearing Cone Spindle Housing Bearing Cup Spindle Shaft & Crossbar Grease fitting Figure 17. Spindle and Shaft Assembly MAN0845 (1/12/2011) 18. Install grease fitting (17) in spindle shaft. Spindle Installation NOTICE ■ Pulley installation sequence is very important for bearing life. Follow the sequence exactly. 1. Install spindle through bottom of mower and secure with four mounting bolts. Dealer Service 23 2. Install pulley (12) and split taper bushing (13) with integral key (14) on spindle shaft. Make sure bushing is in contact with sleeve on spindle shaft. 4. Install lock washer and nut on spindle shaft. Tighten nut until snug, but do not over-tighten. Check shaft to make sure it spins freely.. 3. Alternately tighten split taper bushing cap screws to 20 lbs-ft. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Crown gear Gearbox housing Input shaft Output shaft Gear pinion Bearing Bearing Protective flat washer Cotter pin Snap ring Snap ring Spacer Shim Castle nut Castle nut M24 x 2 Shim Flat washer Oil seal (40 x 80 x 12 mm) Oil seal (35 x 72 x 10 mm) 20. 21. 22. 23. 24. 25. 26. 27. Cap Snap ring Top cover Bolt M8 x 14 mm Breather level plug Cotter pin Bearing Ball bearing Figure 18. Gearbox Assembly GEARBOX REPAIR Read this entire section before starting any repair. Many steps are dependent on each other. Repair to this gearbox is limited to replacing bearings, seals, and gaskets. Replacing gears, shafts, and a housing is not cost effective. It is more economical to purchase a complete gearbox if repair to anything other than replacement of bearings, seals or gaskets is required. Fill gearbox with SAE 80W or 90W gear lube until it runs out the side level plug. Bearing failure is indicated by excessive noise and side to side or end play in gear shafts. Seal Replacement Recommended sealant for gearbox repair is Permatex® Aviation 3D Form-A-Gasket or equivalent. Leakage can occur at the vertical or horizontal gaskets and shaft seals. Leakage at the horizontal gasket or seal can be repaired without removing the gearbox from the cutter. Inspect gearbox for leakage and bad bearings. Seal Installation Leakage is a very serious problem and must be corrected immediately. NOTE: Proper seal installation is important. An improperly installed seal will leak. 24 Dealer Service MAN0845 (1/12/2011) 1. Clean area in housing where seal outer diameter (OD) seats. Apply a thin coat of Permatex. 2. Inspect area of shaft where seal seats. Remove any burrs or nicks with an emery cloth. 3. Lubricate gear shaft and seal lips. 4. Place seal squarely on housing, spring-loaded lip toward housing. Select a piece of pipe or tubing with an OD that will sit on the outside edge of the seal but will clear the housing. Tubing with an OD that is too small will bow seal cage and ruin seal. 5. Carefully press seal into housing, avoiding distortion to the metal seal cage. 1. 2. 3. 4. 3. If the leak occurred at either end of horizontal shaft, remove oil cap (20) and/or oil seal (19). Replace with new one (see Seal Replacement, page 24). Horizontal seal should be pressed flush with outside of housing. 4. Fill gearbox with SAE 80W or 90W gear lube until it runs out the level plug Gearbox Removal from Mower Refer to Figure 20. Seal Pipe or tube Seal seat Casting Pipe or tube must press at outer edge of Incorrect Installation Figure 19. Seal Installation 1. 2. 3. 4. 5. 6. Vertical Shaft Seal Replacement 1. Disconnect and remove the driveline from the gearbox. 2. Remove vent plug (24). Figure 18, and siphon gear lube from housing through this opening. 3. Remove gearbox stand from mower deck. 4. Remove gearbox and pulley from gearbox stand. 5. Remove vertical shaft seal (18). Replace with new seal (see Seal Replacement, page 24). Vertical seal should be recessed in housing. NOTE: Distortion to seal cage or damage to seal lip will cause seal to leak. 7. 8. 9. 11. 12. 13. 14. 15. Gearbox Vent Plug Gearbox Stand Sheave Shield 1/2NC X 2 HHCS 5/8NC x 1-3/4 Flange HHCS 5/8NC Flange Lock Nut M8 x 1.25P x 16mm HHCS 5/16 Flat Washer 1/4 x 1/4 x 1-1/4 Key 25 x 44 x 4mm Flat Washer M24 x 2 Castle Nut 3/16 x 2 Cotter Pin 6. Fill gearbox with SAE 80W or 90W gear lube until it runs out the level plug. 7. Assemble gearbox and pulley to gearbox stand. Attach gearbox stand to mower deck. Horizontal Shaft Seal Replacement Figure 20. Gearbox Stand Assembly 1. Disconnect and remove the driveline from the gearbox (1). 1. Disconnect and remove the driveline from the gearbox. 2. Remove vent plug (2) and siphon gear lube from housing through this opening. 2. Remove vent plug (24), Figure 18, and siphon gear lube from housing through this opening. 3. Remove gearbox stand (3) from mower deck rails by removing four cap screws (6). MAN0845 (1/12/2011) Dealer Service 25 4. Remove four cap screws (9), flat washer (11), and remove shield (5) from gearbox. 5. Remove castle nut (14) and hardware from output shaft of gearbox. 6. Remove sheave (4) from gearbox. 7. Remove four bolts (9) that attach gearbox to gearbox stand and remove gearbox. Gearbox Disassembly Refer to Figure 18. 1. Remove top cover (22) from housing. Turn gearbox upside down and pour out remaining gear oil from gearbox. 2. Remove oil cap (20) (to be replaced). 3. Remove snap ring (10) and shim (13) from input shaft (3). 4. Support gearbox in hand press and push on input shaft (3) to remove bearing (7). 5. Remove gear (1) from inside housing. 6. Remove oil seal (19) from front of housing (to be replaced). 7. Remove snap ring (10) and shim (13) from front of housing (2). 8. Remove input bearing (7) by using a punch and hammer from outside of housing. 9. Support housing in vise in a horizontal position. 10. The castle nut (15) and cotter pin (25) are already removed with the drive sheave. Remove snap ring (21), washer (8), and seal (18). 11. Remove cotter pin (9), castle nut (14), and washer (17) from output shaft (4). 12. Remove output shaft (4) by using a punch and hammer and tap on top to drive down. 13. Remove gear (5) and shim (16) from inside housing. 14. Remove bearing (26) by using a punch and hammer from the top, outside the housing. 15. Support housing upside down (top cover surface) and remove bearing (6) by using a punch and hammer from the bottom side of the housing. 16. Inspect gears for broken teeth and wear. Some wear is normal and will show on loaded side. Forged gear surfaces are rough when new. Check that wear pattern is smooth. 17. Inspect vertical and horizontal shafts for grooves, nicks, or bumps in the areas where the seals seat. Resurface any damage with emery cloth. 18. Inspect housing and caps for cracks or other damage. 26 Dealer Service Gearbox Reassembly Refer to Figure 18. NOTE: Repair to this gearbox is limited to replacing bearings, seals, and gaskets. Replacing gears, shafts, and a housing is not cost effective. Purchasing a complete gearbox is more economical. 1. Clean housing, paying specific attention to areas where gaskets will be installed. 2. Wash housing and all components thoroughly. Select a clean area for gearbox assembly. Replace all seals, bearings, and gaskets. All parts must be clean and lightly oiled before reassembling. 3. Insert output bearings (6 & 26) in the housing, using a round tube of the correct diameter and a hand press. 4. Slide output shaft (4) through both bearings (6 & 26) until it rests against bearing (6). 5. Slide shim (16) over output shaft (4). 6. Press gear (5) onto output shaft (4) and secure with washer (17), castle nut (14), and cotter pin (9). 7. Apply grease to lower seal lips (18) and press seal over output shaft (4), using a tube of the correct diameter. Be sure not to damage the seal lip. Press in housing so that seal is recessed. 8. Insert protective washer (8) by hand. Install snap ring (21) and position it together with dual lip seal (18) by pressing it into position. Verify that snap ring is seated correctly. 9. Press bearing (7) into the housing, using a round tube of the correct diameter and a hand press. Secure with shim (13) and snap ring (10). 10. Secure snap ring (11) on input shaft (3) if not already secure. 11. Place gear (1) through top of housing and align gear (1) and gear (5) so that gear teeth are a match. 12. While holding gear (1) in place, slide input shaft (3) through gear (1) and bearing (7). Align splines on shaft (3) and gear (1). 13. Slide spacer (12) over input shaft (3) and press bearing onto input shaft (3), using a round tube of the correct diameter and a hand press. 14. Slide shim (13) over input shaft (3) and secure with snap ring (10). 15. Check input shaft end float by moving the input shaft (3) by hand. If end float is higher than 0.012”, insert shim between input shaft (3) and rear bearing (7). Repeat until end float is less than 0.012”. Check rotational torque by hand. The torque should be less than 2.2 lbs-inch. MAN0845 (1/12/2011) 16. Check that the gear backlash is between 0.006” and 0.016”. You should not have to adjust the backlash. UNIVERSAL JOINT REPAIR 1. 2. 3. 4. 17. Press in input oil seal (19), using tube of correct diameter. Be careful not to damage seal lip. 18. Press oil cap (20) on to cover the rear of housing, using a tube of the correct diameter. Yoke Cup and bearings Snap ring Journal cross 19. Check gearbox housing for leaks by plugging all holes except one. Apply 4 psi compressed air and immerse the gearbox in water to verify that there are no leaks. 20. Remove gearbox from water and dry off with compressed air. Add SAE 80W or 90W EP oil until it runs out of side level hole. Tighten all plugs. Figure 22. U-Joint Exploded View Gearbox Installation NOTE: Gearbox is heavy: do not attempt to move without mechanical assistance. U-Joint Disassembly 1. Remove external snap rings from yokes in four locations as shown in Figure 23. 1. Set gearbox on gearbox stand and fasten with bolts and nuts. Torque bolts to 175 lbs-ft. . 2. Attach drive sheave to output shaft. Secure using castle nut and hardware previously removed. Torque castle nut to 170 lbs-ft. 3. Attach gearbox stand to mower using four flanged 1/2" cap screws. Drive Sheave Installation Refer to Figure 21. 1. When gear stand is installed on mower, the distance from the top of the mower deck to the center line of the lower groove on the drive pulley must be 2-21/32" (±1/32"). This is a critical dimension and must be carefully adjusted for proper belt life. 2. Tighten gear stand hardware. Figure 23 3. Fill gearbox half full with SAE 90W gear lube. 4. Check level after waiting five minutes to permit lube to work through bearings. Add lube, if necessary, until gearbox is half full. 5. Replace driveline shield. Attach driveline to gearbox. Figure 24 Figure 21. Drive Sheave Installation MAN0845 (1/12/2011) 2. With snap rings removed, support drive in vise, hold yoke in hand and tap on yoke to drive cup up out of yoke. See Figure 24. Dealer Service 27 3. Clamp cup in vise as shown in Figure 25 and tap on yoke to completely remove cup from yoke. Repeat Step 2 and Step 3 for opposite cup. final removal. Drive remaining cup out with a drift and hammer. U-Joint Assembly 1. Place seals securely on bearing cups. Insert cup into yoke from outside and press in with hand pressure as far as possible. Insert journal cross into bearing cup with grease fitting away from shaft. Be careful not to disturb needle bearings. Insert another bearing cup directly across from first cup and press in as far as possible with hand pressure. 2. Trap cups in vise and apply pressure. Be sure journal cross is started into bearings and continue pressure with vise, squeezing in as far as possible. Tapping the yoke will help. 3. Seat cups by placing a drift or socket (slightly smaller than the cup) on cup and rap with a hammer. See Figure 27. Install snap ring and repeat on opposite cup. 4. Repeat Step 1 & Step 2 to install remaining cups in remaining yoke. Figure 25 5. Move both yokes in all directions to check for free movement. If movement is restricted, rap on yokes sharply with a hammer to relieve any tension. Repeat until both yokes move in all directions without restriction. Figure 26 4. Place universal cross in vise as shown in Figure 26 and tap on yoke to remove cup. Repeat Step 3 for 28 Dealer Service Figure 27 MAN0845 (1/12/2011) ASSEMBLY INSTRUCTIONS DEALER SET-UP INSTRUCTIONS Assembly of this mower is the responsibility of the Woods dealer. If should be delivered to the owner completely assembled, lubricated, and adjusted for normal cutting conditions. Complete Dealer Check Lists on page 34 when you have completed the assembly. The mower is shipped partially assembled. Assembly will be easier if components are aligned and loosely assembled before tightening hardware. Recommended torque values for hardware are located on page 43. Select a suitable working area. Open parts boxes and lay out parts and hardware to make location easy. Refer to illustrations, accompanying text, parts lists and exploded view drawings. WARNING Before working underneath, carefully read Operator’s Manual instructions, disconnect driveline, raise mower, securely block up all corners with jackstands, and check stability. Secure blocking prevents equipment from dropping due to hydraulic leak down, hydraulic system failures, or mechanical component failures. CAUTION Always wear relatively tight and belted clothing to avoid getting caught in moving parts. Wear sturdy, rough-soled work shoes and protective equipment for eyes, hair, hands, hearing, and head; and respirator or filter mask where appropriate. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Wood Blocks Chain Shielding Rear Shipping Bracket Front Shipping Bracket PTO Hanger Diagonal Brace A-Frame Bar U-Link Sleeve Caster Arms Hitch Arms 1/2 NC x 1-1/2 HHCS 1/2 NC x 4 HHCS 1/2 NC x 6-1/2 HHCS 1/2 NC Flange Lock Nut 5/8 NC x 3-1/2 HHCS 5/8 NC Flange Lock Nut Lug 1/2 NC x 4-1/2 HHCS Figure 28. Shipping Unit Disassemble Shipping Unit (Figure 28) 1. Remove all parts that are wired and strapped to mower. 2. Remove wood blocks (1) and chain shielding (2) attached to front of mower. Discard blocks. 4. Remove cap screw (14) and lock nuts (15) from front shipping bracket (4). Discard bracket and replace hardware through PTO hanger (5), diagonal braces (6), A-frame bars (7), U-link (8) and sleeve (9). Do not over tighten lock nut against the PTO hanger. PTO hanger should rotate freely. 3. Remove cap screws (12) and lock nuts (15) from rear shipping bracket (3). Discard bracket. (Rev. 10/1/2013) MAN0845 (1/12/2011) Assembly 29 Install Front Casters ( Figure 28 & 29) 1. Remove cap screws (12 & 13) and lock nuts (15) from outer caster arms (10). 2. Place arms inside of pockets in front corners of deck. Replace hardware. 10. 12. 13. 15. 18. 19. Caster arm 1/2 NC x 1-1/2 HHCS 1/2 NC x 4 HHCS 1/2 NC Flange lock nut Lug 1/2 NC x 4-1/2 HHCS Figure 29. Caster Arm Assembly Torque Caster Arms 1. Place mower on a hard level surface. 2. Loosen cap screws and lock nuts on all four caster wheel arms. This allows clearance in the caster wheel assemblies to be equalized. 1. A. B. C. D. E. Tractor top link Mower top link attachment point Mower hitch pin Category 2 sleeve Lower hitch arm attachment point Mower hitch arm Figure 30. Hitch Arm Installation 3. Torque all cap screws and nuts to 85 lbs-ft. Install Hitch Arms 1. Remove cap screws, lock nuts and hitch arms (E) from lower hitch arm attachment point (D). 2. Position arms according to Figure 30 and replace hardware. 30 Assembly MAN0845 (1/12/2011) Install Driveshaft 1. Pull locking collar (B) back and, at the same time, push driveline onto gearbox shaft until locking device engages. 2. Rotate PTO hanger forward. Rest driveline on PTO hanger. 3. If so equipped, hook anti-rotation chain (C) on shield (2). Fill Gearbox NOTICE ■ Gearbox is not filled at the factory. Prior to delivery, make sure each gearbox is filled half-full with 80W or 90W API GL-4 or GL-5 gear lube. 1. Make sure vent plug hole is clear. Fill gearbox halffull with high quality gear oil that has a viscosity index of 80W or 90W and an API service rating of GL-4 or GL-5. 2. Fill gearbox until oil runs out the side plug on gearbox. 3. Pour in one pint of gear lube, wait five minutes and add additional gear lube until it just comes out of side hole. 4. Allow an additional five minutes for the lube to flow through bearings, then check to make sure oil level is at bottom of side hole. Replace side plug. Install vent plug. A. B. C. 1. 2. 3. 4. 5. Gearbox input shaft Locking collar Anti-rotation chain Gearbox Shield Driveline Washer, flat standard 5/16 Screw, HHCS 8 mm x 1.25P x 16 mm Figure 31. Driveshaft Installation MAN0845 (1/12/2011) Assembly 31 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Front chain shield plate Rear corner chain shield plate Left corner chain shield plate Right rear chain shield plate Left rear chain shield plate 1/4 Chain - 3 link 1/4 Chain - 4 link Pin, 28 to 30 Chains Pin, 7 to 9 Chains Pin 40 to 42 Chains 3/8 NC x 1 Carriage Bolt 3/8 NC Flange Lock Nut Figure 32. Chain Shield Installation Install Chain Shielding DANGER Full chain shielding must be installed when operating in populated areas or other areas where thrown objects could injure people or damage property. • If this machine is not equipped with full chain shielding, operation must be stopped when anyone comes within 300 feet (92 m). • This shielding is designed to reduce the risk of thrown objects. The mower deck and protective devices cannot prevent all objects from escaping the blade enclosure in every mowing condition. It is possible for objects to ricochet and escape, traveling as much as 300 feet (92 m). 1. Install front and rear chain shields with hardware shown. Install Front Roller (Optional) 1. Remove center belt shield from mower. 2. Insert four carriage bolts (8) through top of deck plate. 32 Assembly 3. Place roller bracket (1) over bolts; then install flange lock nuts (9) on bolts and tighten. 4. Place front roller (2), two bearings (4), spacer (3) and two SAE flat washers (6) between roller bracket as shown in Figure 33. 5. Insert cap screw (5) through bracket and roller. 6. Secure with flanged lock nut (7). Do not overtighten, roller must spin freely. 1. 2. 3. 4. 5. 6. 7. 8. 9. Roller Bracket Roller Spacer Bearing 1/2 NC x 9 HHCS 1/2 SAE Flat Washer 1/2 NC Flange Lock Nut 3/8 NC Carriage Bolt 3/8 NC Flange Lock Nut Figure 33. Front Roller Installation MAN0845 (1/12/2011) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. A-Frame Arm Sleeve, .94 x 1.44 x 2.75 (Cat 2 Only) Sleeve, .94 x 1.44 x 1.94 (Cat 1 Only) Sleeve, .81 x 1.25 x 2.12 Sleeve, .88 x 1-1/8 x 19/32 3/4 Flat Washer 3/4 NC x 5-1/2 HHCS GR5 3/4 NC Hex Nut 1/2 Flat Washer 1/2 NC x 6 HHCS 1/2 NC x 2 HHCS 3/8 Chain, 38-Link Figure 34. Quick Hitch Kit Installation (Optional) Install Quick Hitch (Optional) NOTE: This kit allows mower to fit Category 1 or Category 2 standard quick hitches. 1. Lower hitch arms must be located in center attachment hole. See Figure 34 for adjustment. 2. For use with Category 1 quick hitch, lower hitch arms should be positioned with offset toward inside of mower. For use with Category 2 quick hitch, lower hitch arms should be positioned with offset toward outside of the mower. 3. Remove clevis pins from lower hitch arms. Pins will not be used for quick hitch. 4. Attach A-Frame arms (1) and sleeve (2) to lower hitch arms using cap screws (7), sleeve (5), washers (6) and hex nut (8). MAN0845 (1/12/2011) 5. Attach upper end of A-Frame arms (1) and sleeve (4) to U-bracket, using cap screw (7), washers (6) and hex nut (8). 6. Remove rear offset links. They will be replaced with chains (12). 7. Attach chains (12) to top of A-frame on both sides as shown, using cap screw (10), washers (9), and flange lock nut. 8. Attach opposite ends of chains (12) to rear mower frame using cap screws (11), washers (9), and flange lock nut. Vary length slightly as desired. Twist chain to make finite adjustments in length until unit lifts level. 9. Tighten all hardware. Assembly 33 DEALER CHECK LISTS PRE-DELIVERY CHECK LIST (DEALER’S RESPONSIBILITY) Inspect the equipment thoroughly after assembly to ensure it is set up properly before delivering it to the customer. The following check lists are a reminder of points to inspect. Check off each item as it is found satisfactory or after proper adjustment is made. ___ Check that all safety decals are installed and in good condition. Replace if damaged. ___ Check that shields and guards are properly installed and in good condition. Replace if damaged. ___ Check all bolts to be sure they are properly torqued. ___ Check that all cotter pins and safety pins are properly installed. Replace if damaged. ___ Check and grease all lubrication points as identified in “Lubrication Information” on page 15.” ___ Gearboxes are not filled at the factory. Prior to delivery, fill as specified in the “Owner Service, lubrication information” on page 15 and check to see that there are no leaking seals. ___ Check that blades have been properly installed. DELIVERY CHECK LIST (DEALER’S RESPONSIBILITY) ___ Show customer how to make adjustments and select proper PTO speed. ___ Instruct customer how to lubricate and explain importance of lubrication. ___ Point out the safety decals. Explain their meaning and the need to keep them in place and in good condition. Emphasize the increased safety hazards when instructions are not followed. ___ Present Operator's Manual and request that customer and all operators read it before operating equipment. Point out the manual safety rules, explain their meanings and emphasize the increased safety hazards that exist when safety rules are not followed. ___ Explain to customer the potential crushing hazards of going underneath raised equipment. Instruct that before going underneath to disconnect the driveline, securely block up all corners with jack-stands and to follow all instructions in the “Owner Service, Blocking Methods” section of the Operator’s Manual. Explain that blocking up prevents equipment dropping from hydraulic leak down, hydraulic system failures or mechanical component failures. ___ Show customer how to make sure driveline is properly installed and that spring-activated locking pin or collar slides freely and is seated in groove on tractor PTO shaft. ___ For mounted units, add wheel weights, ballast in front tires, and/or front tractor weight to enhance front end stability. A minimum 20% of tractor and equipment gross weight must be on front tractor wheels. When adding weight to attain 20% of tractor and equipment weight on front tractor wheels, you must not exceed the ROPS weight certification. Weigh the tractor and equipment. Do not estimate! ___ Show customer the safe, proper procedures to be used when mounting, dismounting, and storing equipment. ___ Make customer aware of optional equipment available so that customer can make proper choices as required. ___ Point out all guards and shields. Explain their importance and the safety hazards that exist when not kept in place and in good condition. 34 Notes MAN0845 (1/12/2011) PARTS INDEX Rearmount Mower: RD990X MAIN FRAME ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 - 37 GEARBOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 DRIVESHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 BLADE & SPINDLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 CHAIN SHIELDING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 FRONT ROLLER ASSEMBLY (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . 42 QUICK HITCH KIT (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 MAN0845 (1/12/2011) Parts 35 RD990X MAIN FRAME ASSEMBLY 36 Parts (Rev. 10/1/2013) MAN0845 (1/12/2011) RD990X MAIN FRAME ASSEMBLY REF PART QTY DESCRIPTION REF PART QTY DESCRIPTION 1 ----- 1 Deck (not sold separately) 50 1266 * 3/16 x 1-1/2 Cotter Pin 2 1032786 2 Lower Hitch Arm 51 64803 * 3/16 x 2 Cotter Pin 3 56598 2 Sleeve .885 x 1.125 x 2.62 51 18270 * 3/16 Safety Pin 4 19524 2 Sleeve .64 x 1.00 x 2.09 HT 53 29792 * 1/4 x 1/4 x 1-1/4 Key 5 1032795 2 A-Frame Arm 54 12296 * 1/4-28 Grease Fitting 6 1032798 1 Sleeve .62 x .94 x 3.13 55 39254 7 1032797 1 U-Link 56 14562 8 1032796 2 Rear Offset Link 58 4378 * 5/16 SAE Flat Washer 9 1032811 1 PTO Hanger 59 14139 * 5/16 NC Flange Lock Nut 10 1032789 1 Idler Arm 60 14350 * 3/8 NC Flange Lock Nut 11 35141 2 Retaining Ring 61 27542 12 35193 2 Bearing 62 3379 * 1/2 NC x 1-1/2 HHCS GR5 13 27211 1 Sleeve .63 x .88 x 1.18 63 3699 * 1/2 NC x 2 HHCS GR5 14 19570 2 Flat Pulley (includes item 15) 64 10380 * 1/2 NC x 4 HHCS GR5 15 6095 2 .626 x 1.85 Ball Bearing 65 22205 * 1/2 NC x 6-1/2 HHCS GR5 16 28928 1 Ext. Spring .187 x 1.3 x 8.17 66 29604 17 ----- 3 Spindle Assembly (see page 40) 67 29893 * 1/2 NC x 1-1/2 Carriage Bolt 18 1032808 1 Belt Guide 68 1093 19 1032799 1 2V Powerband Belt 2W174.5 69 11900 M8 x 1.25P x 16mm HHCS * 5/16 NC x 1 HHCS GR5 7/16 Klik Pin 1/2 NC x 8 HHCS GR5 1/2 NC Hex Nut * 1/2 NC Flange Lock Nut 20 1032779 1 Gearbox Stand 70 19024 21 1002499 1 Gearbox 1:1.92 (see page 38) 71 902 22 1032751 1 Sheave, 11.50 PD, 2B 72 23141 5/8 NC x 3-1/2 HHCS GR5 23 1002048 1 Clutch Shield 73 20419 5/8 NC x 3 Carriage Bolt GR5 5/8 NC x 1-3/4 Flange HHCS GR5 * 5/8 NC x 2 HHCS GR5 24 ----- 1 Driveline (see page 39) 74 1517 25 1032809 1 Belt Shield, Inner 75 19025 26 1032810 2 Belt Shield, Outer 76 302178 27 1026530 1 Manual Tube 77 1032818 28 1037965 4 Caster Arm (includes item 29) 78 51946 29 31780 8 Bronze Bushing 1-1/4 x 1-1/2 x 1/2 79 7163 30 1032782 4 Caster Yoke 80 20893 31 WP20718G 4 13 x 5 x 10 Solid Tire, gray (includes item 32) -or- 81 1032834 1 Complete Decal Set 82 53591 1 Safety Decal Set 31 WP19744G 4 13 x 5 x 6 Pneumatic Tire, gray (includes item 32) 83 3508 * 1/2 NC x 4-1/2 HHCS GR5 32 2306 8 Bearing Cup 84 1037959 6 Lug 33 2304 8 Bearing Cone 34 5624 8 Seal 1.13 x 1.78 x .47 35 52744 8 Bushing .752 x 1.125 x .625 HT 36 20714 4 Sleeve .525 x .75 x 5.80 HT 37 52853 8 Sleeve 1.25 x 1.90 x .50 38 52854 8 Sleeve 1.25 x 1.90 x .75 39 52855 8 Sleeve 1.25 x 1.90 x 1.00 40 1032812 2 Skid Shoe (Rev. 10/1/2013) MAN0845 (1/12/2011) HHCS * .625 x 1.38 x 7GA Flat Washer * 5/8 NC Flange Lock Nut 5/8 NF Castle Nut 7/8 x 3.9 Clevis Pin M24 x 2 Castle Nut * 1-1/4 Stand Flat Washer 25 x 44 x 4 mm Flat Washer Hex Head Cap Screw Standard Hardware, Obtain Locally Parts 37 RD990X GEARBOX ASSEMBLY REF PART QTY DESCRIPTION A 1002499 1 57458 2 NSS 3 1005320 1 Shaft, Input 1-3/8 -6 4 1005321 1 Shaft, Output 1-1/4 5 57491 1 Pinion Gear 13T M5.3 6 57476 1 Bearing Cup & Cone 7 57462 1 Bearing Cup & Cone 8 20888 1 Washer, 1.58 x 3.13 x .04 Protective Flat 9 1 Gearbox Assembly, Complete 1 Gear, Crown 25T M5.3 1 Gearbox Housing * 1 Pin, Cotter B4 x 50 10 57466 2 Snap Ring 11 20895 1 Snap Ring, 45 mm 12 57373 1 Spacer, 35.3 x 48 x 2.5 13 57328 2 Kit, Shim 60.3 x 71.6 14 57468 1 Nut, Castle 15 51946 1 Nut, Castle M24 x 2 16 57328 1 Kit, Shim 30.3 x 44 17 57473 1 Washer, 21 x 37 x 3 mm Flat 18 20900 1 Seal, Oil 40 x 80 x 12 mm 19 57463 1 Seal, Oil 35 x 72 x 10 mm 20 57374 1 Oil Cap 38 Parts REF PART QTY DESCRIPTION 21 20897 1 Snap Ring SB 81 Int 22 57375 1 Cover, Top 23 24 * 6 Bolt, 8 mm x 14 mm 57076 25 1 Plug, 1/2 Breather Level * 1 Pin, Cotter 5 x 50 26 57478 1 Bearing Cup & Cone 27 20890 1 Ball Bearing * Standard Hardware, Obtain Locally MAN0845 (1/12/2011) RD990X DRIVE SHAFT ASSEMBLY REF PART QTY DESCRIPTION A 1029937 1 Drive Assembly Complete 1 40574 2 Yoke, 1-3/8-6SP (complete with lock collar) 2 110 2 Cross and bearing kit 3 40464 2 Spring Pin, 10 mm x 80 mm 4 40575 1 Inboard Youk (male drive tube) 5 40587 1 Inner Profile (cut to length) 6 40588 1 Outer Profile (cut to length) 7 40576 1 Inboard Yoke (female drive tube) 8 40776 1 Bearing Ring Kit (set of 2) 9 40778 1 Screw, Guard Retainer (Pkg of 10) 10 40779 2 Grease Zerk, Drive Line (Pkg of 10) 11 40767 1 Bearing, Guard Support 12 40589 2 Slide Lock Collar Repair Kit (without yoke) 13 1029938 1 Shield, Outer Half Non-Rotating (also includes items 8 & 9) 14 1029939 1 Shield, Inner Half Non-Rotating (also includes items 8, 9 & 11) MAN0845 (1/12/2011) Parts 39 RD900X BLADE & SPINDLE ASSEMBLY REF PART QTY DESCRIPTION 1 1032800 1 Blade Spindle, Complete 2 18359 1 Sleeve 1-3/8 x 1-3/4 x 5/8 3 2715 2 Seal 1.75 x 2.56 x .5 4 2717 2 Bearing Cone 5 1032806 1 Spindle Housing w/ Cups 6 2716 2 Bearing Cup 7 1032801 1 Spindle Shaft & Crossbar 8 1032815 2 Blade Lock 9 1032814 2 Blade Pin 10 13288 2 1/2 NC x 3/4 Nylock HHCS 11 29186 2 CW Standard Blade, 13" 12 1032794 1 Sheave, 5.75 PD, 2B 13 13557 1 Bushing, P1 1-3/8 Straight Bore 14 24549 1 5/16 x 5/16 x 1-3/4 Key 15 3689 * - 1 Standard Lock Washer 16 1386 - 1 NC Jam Nut 17 1972 * - 1/4-28 Tapered Grease Fitting HHCS Hex Head Cap Screw * Standard Hardware, Obtain Locally 40 Parts MAN0845 (1/12/2011) RD990X CHAIN SHIELDING ASSEMBLY REF PART QTY 1 1032821 2 Front Chain Shield Plate 2 1032832 1 Right Corner Chain Shield Plate 3 1032833 1 Left Corner Chain Shield Plate 4 1032822 1 Right Rear Chain Shield Plate 5 1032823 1 Left Rear Chain Shield Plate 6 4763 90 1/4 Chain - 3 Link 7 4765 100 1/4 Chain - 4 Link 8 1003646 2 Pin, 28 to 30 Chains 9 1007852 2 Pin, 7 to 9 Chains 10 1007854 2 Pin, 40 to 42 Chains 11 6697 * - 3/8 NC x 1 Carriage Bolt, GR5 12 14350 * - 3/8 NC Flange Lock Nut * MAN0845 (1/12/2011) DESCRIPTION Standard Hardware, Obtain Locally Parts 41 RD990X FRONT ROLLER ASSEMBLY (OPTIONAL) REF PART QTY DESCRIPTION A 1032828 1 Front Roller Kit - Complete 1 1032829 1 Roller Bracket 2 1006418 1 Roller, 4 x 7.38 3 1006420 1 Spacer, .75 x 7.27 4 35193 2 Bearing 5 38107 - 1/2 NC x 9 HHCS, GR5 6 3598 * - 1/2 SAE Flat Washer 7 11900 * - 1/2 NC Flange Lock Nut 8 20973 * - 3/8 NC x 1-1/4 Carriage Bolt, GR5 9 14350 * - 3/8 NC Flange Lock Nut * Standard Hardware, Obtain Locally QUICK HITCH KIT (OPTIONAL) REF PART QTY DESCRIPTION A 1032830 - Quick Hitch Kit 1 1032826 2 Offset Link 2 1002012 2 Sleeve, .94 x 1.44 x 2.75 (Cat 2 only) 3 1016517 2 Sleeve, .94 x 1.44 x 1.94 (Cat 1 only) 4 1002018 1 Sleeve, .81 x 1.25 x 2.12 10 13563 * - 1/2 NC x 6 HHCS GR5 5 29281 2 Sleeve, 7/8 x 1-1/8 x 19/32 HT 11 3699 * - 1/2 NC x 2 HHCS GR5 6 1257 * - 3/4 Flat Washer 12 1005401 2 Chain, 3/8 proof coil 38-link 7 29315 - 3/4 NC x 5-1/2 HHCS, GR5 8 1450 * - 3/4 NC Plated Hex Nut 9 854 * - 1/2 Flat Washer 42 Parts REF PART QTY HHCS DESCRIPTION Hex Head Cap Screw * Standard Hardware, Obtain Locally (Rev. 3/18/2011) MAN0845 (1/12/2011) BOLT TORQUE CHART Always tighten hardware to these values unless a different torque value or tightening procedure is listed for a specific application. Fasteners must always be replaced with the same grade as specified in the manual parts list. Always use the proper tool for tightening hardware: SAE for SAE hardware and Metric for metric hardware. Make sure fastener threads are clean and you start thread engagement properly. All torque values are given to specifications used on hardware defined by SAE J1701 MAR 99 & J1701M JUL 96. SAE SERIES TORQUE CHART A SAE Bolt Head Identification SAE Grade 2 (No Dashes) SAE Grade 8 (6 Radial Dashes) SAE Grade 5 (3 Radial Dashes) MARKING ON HEAD A SAE 2 SAE 5 SAE 8 Diameter (Inches) Wrench Size lbs-ft N-m lbs-ft N-m lbs-ft N-m 1/4" 5/16" 7/16" 1/2" 6 12 8 17 10 19 13 26 14 27 18 37 3/8" 7/16" 9/16" 5/8" 23 36 31 48 35 55 47 75 49 78 67 106 1/2" 9/16" 3/4" 13/16" 55 78 75 106 85 121 115 164 120 171 163 232 5/8" 3/4" 15/16" 1-1/8" 110 192 149 261 170 297 230 403 240 420 325 569 7/8" 1" 1-5/16" 1-1/2" 306 467 416 634 474 722 642 979 669 1020 907 1383 A METRIC SERIES TORQUE CHART A Metric Bolt Head Identification 8.8 Metric Grade 8.8 10.9 Metric Grade 10.9 Coarse Thread Fine Thread Marking on Head Marking on Head A Diameter & Thread Pitch (Millimeters) Wrench Size N-m lbs-ft N-m lbs-ft N-m lbs-ft N-m lbs-ft Diameter & Thread Pitch (Millimeters) 6 x 1.0 10 mm 8 6 11 8 8 6 11 8 6 x 1.0 8 x 1.25 10 x 1.5 13 mm 16 mm 20 39 15 29 27 54 20 40 21 41 16 30 29 57 22 42 8 x 1.0 10 x 1.25 12 x 1.75 14 x 2.0 18 mm 21 mm 68 109 50 80 94 151 70 111 75 118 55 87 103 163 76 120 12 x 1.25 14 x 1.5 16 x 2.0 18 x 2.5 24 mm 27 mm 169 234 125 172 234 323 173 239 181 263 133 194 250 363 184 268 16 x 1.5 18 x 1.5 20 x 2.5 22 x 2.5 30 mm 34 mm 330 451 244 332 457 623 337 460 367 495 270 365 507 684 374 505 20 x 1.5 22 x 1.5 24 x 3.0 30 x 3.0 36 mm 46 mm 571 1175 421 867 790 1626 583 1199 623 1258 459 928 861 1740 635 1283 24 x 2.0 30 x 2.0 Typical Washer Installations Bolt Metric 8.8 Lock Washer Metric 10.9 Metric 8.8 Metric 10.9 Flat Washer 8/9/00 Bolt Torque & Size Charts (Rev. 3/28/2007) Appendix 43 BOLT SIZE CHART NOTE: Chart shows bolt thread sizes and corresponding head (wrench) sizes for standard SAE and metric bolts. SAE Bolt Thread Sizes 5/16 3/8 1/2 IN MM 5/8 3/4 7/8 1 2 3 4 5 6 7 25 50 75 100 125 150 175 Metric Bolt Thread Sizes 8MM 10MM 12MM 14MM 16MM 18MM ABBREVIATIONS AG .............................................................. Agriculture ASABE ....................American Society of Agricultural & Biological Engineers (formerly ASAE) ASAE....... American Society of Agricultural Engineers ATF................................Automatic Transmission Fluid BSPP............................. British Standard Pipe Parallel BSPTM ................ British Standard Pipe Tapered Male CV .................................................... Constant Velocity CCW.............................................. Counter-Clockwise CW .............................................................. Clockwise F .......................................................................Female FT .............................................................. Full Thread GA ..................................................................... Gauge GR (5, etc.)........................................... Grade (5, etc.) HHCS ........................................ Hex Head Cap Screw HT ...........................................................Heat-Treated JIC ................. Joint Industry Council 37° Degree Flare LH................................................................. Left Hand LT ...........................................................................Left m ........................................................................ Meter mm ............................................................... Millimeter M .......................................................................... Male 44 Appendix MPa ........................................................ Mega Pascal N ...................................................................... Newton NC...................................................... National Coarse NF ........................................................... National Fine NPSM .................... National Pipe Straight Mechanical NPT...........................................National Pipe Tapered NPT SWF......... National Pipe Tapered Swivel Female ORBM ...........................................O-Ring Boss - Male P .......................................................................... Pitch PBY.......................................................Power-Beyond psi ......................................... Pounds per Square Inch PTO......................................................Power Take Off QD ................................................... Quick Disconnect RH.............................................................. Right Hand ROPS........................... Roll-Over Protective Structure RPM ........................................ Revolutions Per Minute RT ........................................................................Right SAE.......................... Society of Automotive Engineers UNC ..................................................... Unified Coarse UNF .......................................................... Unified Fine UNS ..................................................... Unified Special Bolt Torque & Size Charts (Rev. 3/28/2007) INDEX Assembly Chain Shielding 32 Dealer Set-Up Instructions 29 Initial Oil Fill 31 Optional Equipment Front Roller 32 Dealer Check Lists Delivery (Dealer’s Responsibility) 34 Pre-Delivery (Dealer’s Responsibility) 34 Dealer Service Blade Spindle Assembly 23 Disassembly 22 Installation 23 Removal 22 Service 22 Blocking Method 22 Gearbox Disassembly 26 Drive Sheave Installation 27 Horizontal Shaft Seal Replacement 25 Installation 27 Reassembly 26 Removal 25 Repair 24 Seal Installation 24 Seal Replacement 24 Vertical Shaft Seal Replacement 25 Universal Joint Assembly 28 Disassembly 27 Repair 27 General Abbreviations 44 Bolt Size Chart 44 Bolt Torque Chart 43 General Information 4 Introduction 2 Obtaining Replacement Manuals 2 Product Registration 2 Specifications 4 Table of Contents 3 Warranty Product 46 Replacement Parts 47 Operation Adjustment MAN0845 (1/12/2011) Cutting Height 11 Tractor Top Link 12 Attaching Mower to Tractor 10 Front Roller (Optional) 13 Levelling Mower 11 Mower Removal & Storage 14 Mowing Speed Recommended 10 Operating On Uneven Terrain 14 Technique 13 Tips 13 Pre-Operation Check List (Owners Responsibility) 14 Recommended Uses 10 Storage 14 Tractor Stability 10 Owner Service Belt Installation 17 Replacement 17 Routing 17 Service 17 Blade Assembly 18 Service 17 Sharpening 18 Blocking Method 15 Chain Shielding 18 Cleaning 18 Lubrication Driveshaft 15 Information 15 Lubrication Points & Chart 16 Parts Index to Parts Lists 35 Safety Blocking Method 15 Check Lists Delivery (Dealer’s Responsibility) 34 Pre-Delivery (Dealer’s Responsibility) 34 Pre-Operation (Owner’s Responsibility) 14 Safety & Instructional Decals 8, 9 Safety Rules 5, 6, 7 Safety Symbols Explained 2 Trouble Shooting Belt Conditions 20 Mowing Conditions 19 Index 45 WARRANTY All Models Except Mow’n MachineTM Zero-Turn Mowers Please Enter Information Below and Save for Future Reference. Date Purchased: ____________________________ From (Dealer): __________________________________________ Model Number: ____________________________ Serial Number: __________________________________________ Woods Equipment Company (“WOODS”) warrants this product to be free from defect in material and workmanship. Except as otherwise set forth below, the duration of this Warranty shall be for TWELVE (12) MONTHS COMMENCING ON THE DATE OF DELIVERY OF THE PRODUCT TO THE ORIGINAL PURCHASER. All current model loaders and backhoes are warranted for two (2) years from the date of delivery to the original purchaser. The warranty periods for specific parts or conditions are listed below: Part or Condition Warranted Model Number Duration (from date of delivery to the original purchaser) All units invoiced after 4/30/2012 BB48X, BB60X, BB72X, BB84X, BB600X, BB720X, BB840X, BB6000X, BB7200X, BB8400X, DS1260, DSO1260, DS1440, TS1680, BW15LH, BW126X, BW180X, BW126XHD, BW180XHD, BW1260X, BW1800X, Gearbox components Blade spindles Rust-through BW240X, BW240XHD, BW1620X, BW2400X 6 years PHD25, PHD35, PHD65, PHD95, DS96, DS120, RCC42, RD990X, PRD6000, PRD7200, PRD8400, S15CD, S20CD, S22CD, S25CD, S27CD, S30CD, TC/R74, TC/R68, TC/R60, TBW144, TBW180, TBW204, TSG50, S12ED, S15ED, S18ED, S20ED RDC54, RD60, RD72, TBW150C, TS/R60, TS/R52, TS/R44, HC48, HC54, HC60, HC72 3 years (1 year if used in rental or commercial applications) RD990X, PRD6000, PRD7200, PRD8400, TBW144, TBW180, TBW204 3 years BB600, BB720, BB840, BB6000, BB7200, BB8400, BW126X, BW180X, BW126XHD, BW180XHD, BW1260X, BW1800X, BW240, BW240HD, DS1260, DSO1260, DS1440, TS1680 10 years Under no circumstances will this Warranty apply in the event that the product, in the good faith opinion of WOODS, has been subjected to improper operation, improper maintenance, misuse, or an accident. This Warranty does not apply in the event that the product has been materially modified or repaired by someone other than WOODS, a WOODS authorized dealer or distributor, and/or a WOODS authorized service center. This Warranty does not cover normal wear or tear, or normal maintenance items. This Warranty also does not cover repairs made with parts other than those obtainable through WOODS. This Warranty is extended solely to the original purchaser of the product. Should the original purchaser sell or otherwise transfer this product to a third party, this Warranty does not transfer to the third party purchaser in any way. There are no third party beneficiaries of this Warranty. WOODS makes no warranty, express or implied, with respect to engines, batteries, tires or other parts or accessories not manufactured by WOODS. Warranties for these items, if any, are provided separately by their respective manufacturers. WOODS’ obligation under this Warranty is limited to, at WOODS’ option, the repair or replacement, free of charge, of the product if WOODS, in its sole discretion, deems it to be defective or in noncompliance with this Warranty. The product must be returned to WOODS with proof of purchase within thirty (30) days after such defect or noncompliance is discovered or should have been discovered, routed through the dealer and distributor from whom the purchase was made, transportation charges prepaid. WOODS shall complete such repair or replacement within a reasonable time after WOODS receives the product. THERE ARE NO OTHER REMEDIES UNDER THIS WARRANTY. THE REMEDY OF REPAIR OR REPLACEMENT IS THE SOLE AND EXCLUSIVE REMEDY UNDER THIS WARRANTY. THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE OF THIS WARRANTY. WOODS MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED, AND WOODS SPECIFICALLY DISCLAIMS ANY IMPLIED WARRANTY OF MERCHANTABILITY AND/OR ANY IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE. WOODS shall not be liable for any incidental or consequential losses, damages or expenses, arising directly or indirectly from the product, whether such claim is based upon breach of contract, breach of warranty, negligence, strict liability in tort or any other legal theory. Without limiting the generality of the foregoing, Woods specifically disclaims any damages relating to (i) lost profits, business, revenues or goodwill; (ii) loss of crops; (iii) loss because of delay in harvesting; (iv) any expense or loss incurred for labor, supplies, substitute machinery or rental; or (v) any other type of damage to property or economic loss. This Warranty is subject to any existing conditions of supply which may directly affect WOODS’ ability to obtain materials or manufacture replacement parts. No agent, representative, dealer, distributor, serviceperson, salesperson, or employee of any company, including without limitation, WOODS, its authorized dealers, distributors, and service centers, is authorized to alter, modify, or enlarge this Warranty. Answers to any questions regarding warranty service and locations may be obtained by contacting: Woods Equipment A Blount International Company 2606 South Illinois Route 2 Post Office Box 1000 Oregon, Illinois 61061 USA 800-319-6637 tel 800-399-6637 fax woodsequipment.com F-3079 (Rev. 5/10/2013) WARRANTY (Replacement Parts For All Models Except Mow’n MachineTM Zero-Turn Mowers and Woods BoundaryTM Utility Vehicles) Woods Equipment Company (“WOODS”) warrants this product to be free from defect in material and workmanship for a period of ninety (90) days from the date of delivery of the product to the original purchaser with the exception of V-belts, which will be free of defect in material and workmanship for a period of 12 months. Under no circumstances will this Warranty apply in the event that the product, in the good faith opinion of WOODS, has been subjected to improper operation, improper maintenance, misuse, or an accident. This Warranty does not cover normal wear or tear, or normal maintenance items. This Warranty is extended solely to the original purchaser of the product. Should the original purchaser sell or otherwise transfer this product to a third party, this Warranty does not transfer to the third party purchaser in any way. There are no third party beneficiaries of this Warranty. WOODS’ obligation under this Warranty is limited to, at WOODS’ option, the repair or replacement, free of charge, of the product if WOODS, in its sole discretion, deems it to be defective or in noncompliance with this Warranty. The product must be returned to WOODS with proof of purchase within thirty (30) days after such defect or noncompliance is discovered or should have been discovered, routed through the dealer and distributor from whom the purchase was made, transportation charges prepaid. WOODS shall complete such repair or replacement within a reasonable time after WOODS receives the product. THERE ARE NO OTHER REMEDIES UNDER THIS WARRANTY. THE REMEDY OF REPAIR OR REPLACEMENT IS THE SOLE AND EXCLUSIVE REMEDY UNDER THIS WARRANTY. THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE OF THIS WARRANTY. WOODS MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED, AND WOODS SPECIFICALLY DISCLAIMS ANY IMPLIED WARRANTY OF MERCHANTABILITY AND/OR ANY IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE. WOODS shall not be liable for any incidental or consequential losses, damages or expenses, arising directly or indirectly from the product, whether such claim is based upon breach of contract, breach of warranty, negligence, strict liability in tort or any other legal theory. Without limiting the generality of the foregoing, Woods specifically disclaims any damages relating to (i) lost profits, business, revenues or goodwill; (ii) loss of crops; (iii) loss because of delay in harvesting; (iv) any expense or loss incurred for labor, supplies, substitute machinery or rental; or (v) any other type of damage to property or economic loss. This Warranty is subject to any existing conditions of supply which may directly affect WOODS’ ability to obtain materials or manufacture replacement parts. No agent, representative, dealer, distributor, service person, salesperson, or employee of any company, including without limitation, WOODS, its authorized dealers, distributors, and service centers, is authorized to alter, modify, or enlarge this Warranty. Answers to any questions regarding warranty service and locations may be obtained by contacting: Woods Equipment A Blount International Company 2606 South Illinois Route 2 Post Office Box 1000 Oregon, Illinois 61061 800-319-6637 tel 800-399-6637 fax woodsequipment.com ©2013 Woods Equipment Company. All rights reserved. Woods® and the Woods logo are trademarks of Woods Equipment Company. All other trademarks, trade names, or service marks not owned by Woods Equipment Company that appear in this manual are the property of their respective companies or mark holders. Specifications subject to change without notice. F-8494 (Rev. 2/5/2013) MAN0845 Woods Equipment Company 2606 South Illinois Route 2 Post Office Box 1000 Oregon, Illinois 61061 815-732-2141 tel 815-732-7580 fax www.WoodsEquipment.com © 2011 Woods Equipment Company. All rights reserved. WOODS, the Woods logo, and "Tested. Proven. Unbeatable." are trademarks of Woods Equipment Company. All other trademarks, trade names, or service marks not owned by Woods Equipment Company that appear in this manual are the property of their respective companies or mark holders. Specifications subject to change without notice.
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