Woods 7000, 7192, 7194, 7195, 7200, Operator`s manual

Woods 7000, 7192, 7194, 7195, 7200,  Operator`s manual
C360 Undermount Mower
mounting to
Cub Cadet Tractor Models
7000, 7192, 7194,
7195, 7200, 7205
Includes
Mounting Kit
1002875
MAN0137
MAN0137 (Rev. 8/13/2004)
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 Warranty Registration included in this manual. Both dealer and customer must sign the
registration which certifies that all Dealer Check List items have been completed. The dealer is to return the prepaid
postage portion to WOODS, give one copy to the customer, and retain one copy. Note: Warranty credit is subject to
this form being completed and returned.
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 the adjustment and operating procedures before attempting to operate. Replacement
manuals can be obtained from your dealer or, in the United States and Canada, by calling 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 IMPORTANT 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.
This Safety-Alert Symbol indicates a hazard and means
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
Indicates an imminently hazardous situation that, if not avoided, will
result in death or serious injury.
Indicates a potentially hazardous situation that, if not avoided,
could result in death or serious injury, and includes hazards that are
exposed when guards are removed.
Indicates a potentially hazardous situation that, if not avoided, may
result in minor or moderate injury.
Indicates that failure to observe can cause damage to equipment.
NOTE
ii
Indicates helpful information.
Introduction (2/9/01)
TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5
SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
OWNER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
DEALER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 - 28
ASSEMBLY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
PARTS INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
BOLT TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
BOLT SIZE CHART & ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . .53
PARTS WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
PRODUCT WARRANTY . . . . . . . . . . . . . . . . . . . . . . . INSIDE BACK COVER
MAN0137 (9/14/01))
Introduction 1
SPECIFICATIONS
Cutting Width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60”
Cutting Height Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1/2’ - 4”
Tractor Mid-PTO Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,000 RPM
Blade Speed (RPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,800
Blade Tip Speed (feet per minute) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15,200
Blade Spindles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Number of Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Universal Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0600
Caster Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Caster Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1/4” x 6-1/4”
Mower Frame Thickness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 GA Deck
GENERAL INFORMATION
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 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 but, 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.
2 Introduction
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.
Throughout this manual, references are made to right
and left direction. These are determined from the
operator’s position in the tractor seat. Blade rotation is
clockwise as viewed from the top of the mower.
MAN0137 (9/14/01)
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.
PREPARATION
„ Check that all hardware is properly installed.
Always tighten to torque chart specifications
unless instructed otherwise in this manual.
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.
„ Always wear relatively tight and belted clothing
to avoid entanglement in moving parts. Wear
sturdy, rough-soled work shoes and protective
equipment for eyes, hair, hands, hearing, and head.
It has been said “The best safety device is an
informed, careful operator.” We ask you to be that
kind of operator.
„ Make sure spring-activated locking pin or collar
slides freely and is seated firmly in tractor PTO
spline groove.
TRAINING
„ Safety instructions are important! Read all
attachment and power unit manuals; follow all
safety rules and safety decal information. (Replacement manuals are available from dealer or, in the
United States and Canada, call 1-800-319-6637.)
Failure to follow instructions or safety rules can
result in serious injury or death.
„ If you do not understand any part of this manual
and need assistance, see your dealer.
„ Know your controls and how to stop engine and
attachment quickly in an emergency.
„ 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.
„ Make sure attachment is properly secured,
adjusted, and in good operating condition.
„ 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 systems 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, tractor could tip over, causing personal
injury or death. The weight may be attained with a
loader, front wheel weights, ballast in tires or front
tractor weights. Weigh the tractor and equipment.
Do not estimate.
„ Keep hands and body away from pressurized
lines. Use paper or cardboard, not hands or other
body parts to check for leaks. Wear safety goggles.
Hydraulic fluid under pressure can easily penetrate
skin and will cause serious injury or death.
„ Inspect and clear area of stones, branches, or
other hard objects that might be thrown, causing
injury or damage.
„ Make sure that all operating and service personnel know that if hydraulic fluid penetrates skin, it
must be surgically removed as soon as possible by
a doctor familiar with this form of injury or gangrene, serious injury, or death will result. CONTACT A P HYS ICIA N IM ME DIATE LY IF FLU ID
ENTERS SKIN OR EYES. DO NOT DELAY.
„ You may not be able to stop the tractor safely if
the clutch or brake pedal mechanisms are improperly adjusted, allowing them to contact mower
components.
„ Never allow children or untrained persons to
operate equipment.
UM60/72 Mower Safety Rules (Rev. 7/22/2004)
OPERATION
„ When the mower lift stops are installed as
instructed in this manual, properly adjusted clutch
and brake pedal mechanisms will not contact
mower components. You should frequently check
that the tractor clutch and brake pedal mechanisms
are in adjustment.
Safety 3
SAFETY RULES
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
„ If the clutch or brake pedal mechanisms can
contact mower components, do not put mower into
service until properly adjusted.
„ Do not operate on steep slopes.
„ Do not put mower into service unless discharge
chute is installed and in good condition. Replace if
damaged.
„ Use extreme care and reduce ground speed on
slopes and rough terrain.
„ Keep bystanders away from equipment.
„ Do not stop, start, or change directions suddenly on slopes.
„ Watch for hidden hazards on the terrain during
operation.
„ 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
and blocking requirements or have work done by a
qualified dealer.
„ Stop power unit and equipment immediately
upon striking an obstruction. Turn off engine,
remove key, inspect, and repair any damage before
resuming operation.
„ Never direct discharge toward people, animals,
or property.
„ Before working underneath, read Operator's
Manual and Blocking Method section Disconnect
driveline, raise mower, install transport lock,
securely block up all corners, and check stability.
Secure blocking prevents equipment from dropping due to hydraulic leak down, hydraulic system
failures, or mechanical component failures.
„ Do not operate equipment while under the influence of alcohol or drugs.
„ Operate only in daylight or good artificial light.
„ 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.
„ 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 systems in “locked up” position at all times.
„ 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.
„ Operate tractor PTO at the RPM speed stated in
“Specifications” section.
„ Do not operate PTO during transport.
„ Do not operate auxiliary hydraulics during
transport.
„ Look down and to the rear and make sure area
is clear before operating in reverse.
4 Safety
„ 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.
TRANSPORTATION
„ Always comply with all state and local lighting
and marking requirements.
„ Never allow riders on power unit or attachment.
„ Do not operate PTO during transport.
„ Watch for hidden hazards on the terrain.
„ A minimum 20% of tractor and equipment
weight must be on the tractor front wheels when
attachments are in transport position. Without this
weight, tractor could tip over, causing personal
injury or death. The weight may be attained with a
loader, front wheel weights, ballast in tires or front
tractor weights. Weigh the tractor and equipment.
Do not estimate.
„ 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.
„ Do not operate or transport on steep slopes.
„ Do not operate or transport equipment while
under the influence of alcohol or drugs.
UM60/72 Mower Safety Rules (Rev. 7/22/2004)
SAFETY RULES
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
„ The maximum transport speed for towed and
semi-mounted machines is 20 mph (32 km/h).
Regardless of the maximum speed capability of the
towing tractor, do not exceed the implement’s maximum transport speed. Doing so could result in:
•
Loss of control of the implement and tractor
•
Reduced or no ability to stop during braking
•
•
Implement tire failure
Damage to the implement or its components.
„ Never tow this implement with a motor vehicle.
MAINTENANCE
„ 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.
„ Before working underneath, read Operator's
Manual and Blocking Method section Disconnect
driveline, raise mower, install transport lock,
securely block up all corners, 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.
„ Always wear relatively tight and belted clothing
to avoid entanglement in moving parts. Wear
sturdy, rough-soled work shoes and protective
equipment for eyes, hair, hands, hearing, and head.
„ 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
and blocking requirements or have work done by a
qualified dealer.
UM60/72 Mower Safety Rules (Rev. 7/22/2004)
„ Make sure attachment is properly secured,
adjusted, and in good operating condition.
„ Keep all persons away from operator control
area while performing adjustments, service, or
maintenance.
„ Make certain all movement of equipment components has stopped before approaching for service.
„ Frequently check blades. They should be sharp,
free of nicks and cracks, and securely fastened.
„ Use a new Nylok blade bolt and cup washers
when you replace the blade. Do not substitute any
bolt for the special blade bolt. It is self-locking,
meeting the non-loosening requirements for this
application.
„ 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.)
„ Make sure shields and guards are properly
installed and in good condition. Replace if damaged.
„ Do not disconnect hydraulic lines until machine
is securely blocked or placed in lowest position
and system pressure is released by operating
valve levers.
„ Wear gloves when installing belt. Be careful to
prevent fingers from being caught between belt
and pulley.
STORAGE
„ Block equipment securely for storage.
„ Keep children and bystanders away from storage area.
Safety 5
SAFETY & INSTRUCTIONAL DECALS
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
Replace Immediately If Damaged!
WARNING
HIGH-PRESSURE HYDRAULIC OIL LEAKS CAN PENETRATE SKIN
RESULTING IN SERIOUS INJURY, GANGRENE OR DEATH.
n Check for leaks with cardboard; never use hand.
n Before loosening fittings: lower load, release pressure, and
be sure oil is cool.
19924-B
n Consult physician immediately if skin penetration occurs.
1 - PN 19924
WARNING
PTO speeds higher than 2000 RPM
can cause equipment failure and
personal injury.
OPERATE PTO AT
2000 RPM
15622-A
2 - PN 15622A
DC4000A
3 - PN 19007
6 Safety
MAN0137 (9/14/01)
SAFETY & INSTRUCTIONAL DECALS
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
Replace Immediately If Damaged!
WARNING
DANGER
TO AVOID SERIOUS
INJURY OR DEATH,
n Read Operator’s Manual (available
from dealer) and follow all safety
precautions.
ROTATING BLADES AND
THROWN OBJECTS
n Keep all shields in place and in good
condition.
n Operate mower from tractor seat only.
n Lower mower, stop engine and
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.
remove key before dismounting
tractor.
n Allow no children or untrained
persons to operate equipment.
FAILURE TO OPERATE SAFELY
CAN RESULT IN
INJURY OR DEATH.
18877--B
Keep bystanders away.
Keep discharge chute and guards in place and in good
condition.
BLADE CONTACT OR THROWN OBJECTS CAN
CAUSE SERIOUS INJURY OR DEATH.
4 -PN 18877B
18863-B
5 -PN 18863
DANGER
SHIELD MISSING
DO NOT OPERATE - PUT SHIELD ON
6 - PN 18869
18869
DANGER
SHIELD MISSING
DO NOT OPERATE
PUT SHIELD ON
18867--B
7 - PN 18867
8 - Serial Number Plate
MAN0137 (9/14/01)
Safety 7
OPERATION
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.
The operator is responsible for the safe operation of
this mower. The operator must be properly trained.
Operators should be familiar with the power unit,
mower, and all safety practices before starting operation. Read the safety rules and safety decals on and
page 7.
WARNING
„ Keep bystanders away from equipment.
„ Never allow riders on power unit or attachment.
„ Never allow children or untrained persons to
operate equipment.
„ Operate tractor PTO at the RPM speed stated
in “Specifications” section.
WARNING
„ Make sure spring-activated locking pin or collar slides freely and is seated firmly in tractor PTO
spline groove.
„ Before working underneath, read Operator's
Manual and Blocking Method section Disconnect
driveline, raise mower, install transport lock,
securely block up all corners, and check stability.
Secure blocking prevents equipment from dropping due to hydraulic leak down, hydraulic system failures, or mechanical component failures.
CAUTION
„ Know your controls and how to stop engine
and attachment quickly in an emergency.
„ 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.
„ Always wear relatively tight and belted clothing to avoid entanglement in moving parts. Wear
sturdy, rough-soled work shoes and protective
equipment for eyes, hair, hands, hearing, and
head.
„ Make sure attachment is properly secured,
adjusted, and in good operating condition.
„ Keep all persons away from operator control
area while performing adjustments, service, or
maintenance.
8 Operation
MAN0137 (9/14/01)
Operation Cont’d
Adjust Cutting Height
1. Mower cutting height is raised, lowered, and
maintained by adjusting caster and gauge wheels.
Refer to Figure 2 and accompanying chart for approximate cutting heights.
2. Raise mower with tractor hydraulics to adjust
gauge and caster wheels. It is important that all settings are the same.
DB2935
Approximate
Cutting Height
Position
1.50”
1
2.12”
2
2.75”
3
3.38”
4
4.0”
5
Figure 2 Cutting Height Adjustment
IMPORTANT
■
Avoid very low cutting heights. Striking the
ground with blades gives one of the most damaging shock loads a mower can encounter and, if
this occurs repeatedly, it will cause damage to
mower and drive.
Figure 1 Cutting Height Positions
Transport Lock Operation
There may be occasions when you would like to use
your tractor for tasks other than mowing but do not
want to remove the mower. For your convenience we
have provided a method to lock the mower up and
free the tractor auxiliary valve or 3-point arm for
implement use.
STORE
LOCK
1. To engage lock-up bar, raise mower to maximum
height, then lift lock-up handle and drop into outer
gate. This will lock mower in raised position.
1
2. To return to operating position, raise mower to
maximum height, then raise lock-up handle and move
to inner gate. Mower will now raise and lower freely.
2
CD4180
1. Front lift stop assembly
2. Lock-up bar
Figure 3 Transport Lock Installation
MAN0137 (9/14/01)
Operation 9
Operation Cont’d
Remove Mower from Tractor
NOTE: The lift mechanism maybe left on the tractor
when mower is removed.
1. Lift mower off of ground and remove adjustment
pins from gauge and caster wheel adjustment points.
2. Lower mower to ground, stop engine, and remove
key.
3. Remove driveshaft from tractor mid-PTO shaft.
6. Remove the pins and leave the linkage attached
to mower frame (flip lift bars down). Refer to Attach
Mower to Tractor, page 40 for locations.
7. Raise mower lift mechanism. Refer to Transport
Lock Operation, page 9 and lock the lift mechanism
up.
8. Place blocks between front tires and mower
frame.
4. Release pins from front mounting channel. There
are two pins connecting rockshaft lift to linkage
attached to the mower frame.
9. Back tractor front tires over mower frame.
5. Remove rear mower lift bars from rear rockshafts.
11. Refer to Attach Mower to Tractor, page 40 for
installing mower to tractor.
10. Place mower frame in storage.
Operation Safety
IMPORTANT
DANGER
„ Do not put mower into service unless discharge chute is installed and in good condition.
Replace if damaged.
Install Discharge Chute, page 36
CAUTION
„ Stop power unit and equipment immediately
upon striking an obstruction. Turn off engine,
remove key, inspect, and repair any damage
before resuming operation.
10 Operation
■
Power for operating mower is supplied by
tractor mid-PTO. Do not exceed tractor manufacturer's rated mid-PTO speed of 2000 rpm maximum. Know how to stop tractor and mower
quickly in case of an emergency.
■
Should mower become plugged, causing belt
to slip for over two seconds, maneuver equipment
into a previously cut area and allow mower to
clear accumulated material. Continue running at
least two minutes, allowing pulleys to cool. Stopping the mower with belt in contact with a very hot
pulley will bake and ruin belt.
■
Mower vibration tends to loosen bolts during
operation. All hardware should be checked regularly to maintain proper torque. It is a good practice to check mower before each operation to
ensure all bolts are secure.
MAN0137 (9/14/01)
Operation Cont’d
Operating Techniques
Operating Tips
1. Proper ground speed will depend upon the terrain, the height, type, and density of material to be
cut.
1. Extremely tall material should be cut twice. Set
mower at a higher cutting height for the first pass.
Then cut at desired height at 90 degrees to the first
pass.
2. Normally, ground speed will range from two to five
mph. Tall dense material should be cut at a low
speed; thin medium-height material can be cut at a
faster ground speed.
3. Always operate tractor mid-PTO at 2000 rpm.
This is necessary to maintain proper blade speed and
produce a clean cut.
4. 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 2000
rpm mid-PTO speed. The lower ground speed will
permit grass to at least partially rebound.
5. Under some conditions, grass will not rebound
enough to be cut evenly. In general, lower cutting
heights give a more even cut with less tendency to
leave 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.
6. When operating the mower, move the hydraulic
control valve to the float position. This will allow the
mower to follow ground contours.
2. Remember, sharp blades produce cleaner cuts
and require less power.
3. Analyze area to be cut to determine the best procedure. Consider height and type of grass and terrain
type: hilly, level, or rough.
4. Plan your mowing pattern to travel straight forward whenever possible. Mow with uncut grass to the
left. This will distribute the clippings over the cut area.
Discharging clippings over uncut grass will cause a
build-up and may prevent uniform cutting.
5. Use the inside edge of the right front caster wheel
as a cutting guide.
6. When transporting unit a long distance, pin all
four wheels in position 1 as shown in Figure 1, Cutting Height Positions, page 9. Raise mower and
engage lock-up.
7. For a professional touch in large open areas, try
the mowing pattern in Figure 4. Make two or three
passes clockwise to discharge clippings away from
bordering objects. Then cut the lawn in half by mowing down the center. Turn counter-clockwise to the left
at the end of the area over grass previously mowed.
1
3
6
8
10
11
9
7
5
12
14
16
15
13
4
2
CD1276
Figure 4 Mowing Pattern
MAN0137 (9/14/01)
Operation 11
Operation Cont’d
Uneven Terrain
WARNING
„ Do not operate on steep slopes.
„ Do not stop, start, or change directions suddenly on slopes.
1. Pass diagonally through sharp dips and avoid
sharp drops to prevent "hanging up" the tractor and
mower. Practice will improve your skills in maneuvering rough terrain.
2. Take all possible precautions when leaving tractor
unattended: disengage mid-PTO, set parking brake,
stop engine, remove key, and lower mower to ground.
„ Use extreme care and reduce ground speed on
slopes and rough terrain.
„ Watch for hidden hazards on the terrain during
operation.
PRE-OPERATION CHECK LIST
(OWNER'S RESPONSIBILITY)
___ Review and follow all safety rules and safety
decal instructions on pages 3 through 7.
___ Check that all safety decals are installed and in
good condition. Replace if damaged.
___ Check to make sure all shields and guards are
properly installed and in good condition. Be sure
that either the discharge shield or complete vacuum attachment is installed.
___ Check that all hardware and cotter pins are
properly installed and secured.
___ Check that equipment is properly and securely
attached to power unit.
___ Inspect area and remove stones, branches or
other hard objects that might be thrown, causing
injury or damage.
___ Check to ensure blades are sharp, in good condition, and installed correctly. Replace if damaged.
___ Check all lubrication points and grease as
instructed in Lubrication Points, page 15.
___ Check cutting height and attitude adjustment.
___ Make sure tractor 3-point lift links do not interfere with hydraulic hoses or driveline throughout
full turning range.
___ Do not allow riders.
___ Make sure driveline spring-activated locking pin
or collar slides freely and is seated firmly in
power unit PTO spline groove and in gearbox
spline groove.
12 Operation
MAN0137 (9/14/01)
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
CAUTION
„ Always wear relatively tight and belted clothing to avoid entanglement in moving parts. Wear
sturdy, rough-soled work shoes and protective
equipment for eyes, hair, hands, hearing, and
head.
„ Before working underneath, read Operator's
Manual and Blocking Method section. Disconnect
driveline, raise mower, install transport lock,
securely block up all corners, 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.
Blocking Method
WARNING
„ Before working underneath, read Operator's
Manual and Blocking Method section Disconnect
driveline, raise mower, install transport lock,
securely block up all corners, and check stability.
Secure blocking prevents equipment from dropping due to hydraulic leak down, hydraulic system failures, or mechanical component failures.
1. 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.
2. Raise mower completely, set tractor brakes, turn
engine off, remove key, block tractor wheels front and
rear.
3. Install transport lock (see Transport Lock Operation, page 9).
DC2937
Figure 5 Block Location
NOTE: 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 blocks.
Test blocking stability before working under any portion of the mower.
4. Disconnect mower driveline from tractor PTO.
5. Install blocks securely under each corner of the
mower, Figure 5.
MAN0137 (9/14/01)
Owner Service 13
OWNER SERVICE Cont’d
Lubrication
1. Do not let excess grease collect on or around
parts, particularly when operating in sandy areas.
2. Figure 6 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.
3. Use SAE 90W gear lube in the 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.
5. Over-filling the gearbox will cause the excess
gear lube to blow out vent plug. The gear lube could
then ruin the belt.
6. 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.
7. In addition to the lubrication points shown (Figure
6), oil the six mower lift pivot points (See Oilite Bushing Location, page 21), at least once a year.
4. Check lube level every 50 hours by removing the
vent plug and inserting an object such as a wooden
pencil through the hole until it touches the bottom of
the gearbox. The oil level should show 1" on the pencil. You may also check the oil by using an Allen
wrench to remove the level plug in the front of the
gearbox.
Drive Shaft Lubrication
1. Lubricate the drive shaft slip joint every 8 operating hours. Failure to maintain proper lubrication could
result in damage to U-joints, gearbox and drive shaft.
2. Lower mower to ground and apply a bead of
grease all around the male half where it meets the
female half. Raise and lower mower several times to
distribute grease.
14 Owner Service
MAN0137 (9/14/01)
OWNER SERVICE Cont’d
DC2962A
REF
DESCRIPTION
FREQUENCY
1
Caster pivot
8 hrs.
2
Chaster wheel
8 hrs.
3
Blade Spindle
24 hrs.
4
Gearbox- Check level
(check for leaks daily)
50 hrs.
5
Drive shaft U-Joints
8 hrs.
6
Rear gauge wheels
8 hrs.
7
Drive shaft slip joint
8 hrs.
8
Spring Take-Up pivot arm
(30W Oil)
24 hrs.
9
Oil level plug
Figure 6 Lubrication Points
MAN0137 (9/14/01)
Owner Service 15
OWNER SERVICE Cont’d
BLADE SERVICING
Inspect blades for condition and proper installation
each time before operation. Replace any blade that is
bent, excessively nicked, worn or has any other damage. Small nicks can be ground out when sharpening.
Remove Blades
1. For right and left spindles, install spindle lock
wrench (5) through belt shield (3) and into holes in
spindle pulley as shown in Figure 7. Remove bolt (8)
that has RIGHT HAND THREADS. Remove cup
washers (7), washer (6), and blade (1).
4
5
3
2. On the center spindle use blade wrench handle
(4). The handle will rotate against gearbox stand
when blade bolt is removed.
3. Shoulder washer (2) will not normally come off
unless intentionally removed.
1.
2.
3.
4.
5.
6
7.
8.
Blade
Shoulder washer
Left blade shield
Spindle lock wrench handle
Spindle lock wrench
5/8 Standard flat washer
Cup washer
Blade bolt, special Nylok
(right hand thread)
2
1
6
7
8
Figure 7 Blade Assembly
16 Owner Service
MAN0137 (9/14/01)
OWNER SERVICE Cont’d
Install Blades
Refer to Figure 7.
CAUTION
„ Your dealer can supply genuine replacement
blades. Substitute blades may not meet original
equipment specifications and may be dangerous.
1. Install spindle lock wrench (5) through belt shield
(3) and into holes in spindle pulley as shown Figure 7.
2. Install shoulder washer (2) if removed, small end
up. Make sure blade cutting edge is positioned to lead
in a clockwise rotation, as viewed from top of mower.
■
3. Install two cup washers (7) on bolt (8). Install
washer (6) and blade (1) on bolt. Remember that bolt
(8) has right hand threads; install bolt and blade
assembly into spindle.
■
4. Torque bolt to 170 lbs.-ft. Remove spindle lock
wrench from pulley and shield.
IMPORTANT
We recommend you install a new Nylok blade
bolt when you replace the blade.
Do not substitute any bolt for the special
blade bolt. It is self-locking, meeting the non-loosening requirements for this application.
Sharpen Blades
IMPORTANT
■
When sharpening blades be sure to balance
them. Unbalanced blades will cause excessive
vibration which can damage blade spindle bearings. Vibration may also cause structural cracks
in mower components.
1. Remove blades.
Follow Original Pattern
CD3411
Maintain Corner
2. Always sharpen both ends at the same time to
maintain balance. Follow original sharpening pattern.
Do not sharpen blade to a razor edge. Leave from
1/32" to 1/16" blunt edge. Do not sharpen back side.
1-32"
Figure 8 Blade Sharpening
MAN0137 (9/14/01)
Owner Service 17
OWNER SERVICE Cont’d
Replace Belt
1. Loosen bolt holding belt guide A and swing it
away from pulley B.
WARNING
■
Use care when installing or removing belt
from spring-loaded idler at step 5. Springs store
energy when extended and, if released suddenly,
can cause personal injury.
One of the major causes of belt failure is improper
installation. Before installing a new belt, check pulley
shafts and bearings for wear. Check pulley grooves
for dirt. Make sure spindles turn freely and without
wobble.
If grooves require cleaning, moisten a cloth with a
non-flammable, 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.
2. Pass a loop of belt underneath front of gearbox
stand ahead of gearbox pulley C. Use care not to
over-bend belt as bending can cause internal damage.
3. Route belt over pulley D.
4. Route belt around gearbox pulley C and route a
loop underneath rear of gearbox stand.
5. Use a 1-1/4" open end wrench to rotate idler arm
E counter-clockwise enough to install belt around idler
pulley F.
6. Route belt around spindle pulley "G" and idler pulley H.
7. Grasp remaining belt loop with both hands and
pull the spring-loaded idler enough to route belt over
spindle pulley B. Make sure spring-loaded idler E pivots freely with belt installed.
8. Adjust belt guide A to provide 1/16 to 1/8" clearance from belt. Torque bolt to 85 lbs.-ft.
LA1
Figure 9 Replace Belt
18 Owner Service
MAN0137 (9/14/01)
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
CAUTION
„ Always wear relatively tight and belted clothing to avoid entanglement in moving parts. Wear
sturdy, rough-soled work shoes and protective
equipment for eyes, hair, hands, hearing, and
head.
WARNING
„ Before working underneath, read Operator's
Manual and Blocking Method section Disconnect
driveline, raise mower, install transport lock,
securely block up all corners, 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.
BLADE SPINDLE
Remove Blade Spindle
1. Remove blade from spindle. (See Remove
Blades, page 16.)
2. Remove belt shield.
3. Remove belt from pulleys.
5. Disassemble split taper bushing (located on top
of pulley) by removing the two bolts and inserting
them into the threaded holes in bushing flange.
Tighten bolts alternately to remove split taper bushing. Remove pulley.
6. Remove four bolts attaching spindle to mower
frame and remove spindle.
4. Remove bolt and flat washer from top of spindle
shaft.
Spindle Repair Tips
• As a reference point, the top of the spindle housing is the short portion.
• To minimize wear, bearing cups, cones and
sleeves are press-fit to the shaft and will require a
press or similar device for removal.
• When disassembling, support the housing casting
to prevent damage.
• Remove bearing cups by placing a punch in the
housing slots and driving cup out. Alternate punch
positions from side to side. Use care to prevent housing damage.
• Permatex®a sealant is used on the outer diameter
of the seals. Substitute seals may not meet original
equipment specifications and could cause leakage.
Disassemble Blade Spindle
3. Remove bearing cups from housing as described
in Spindle Repair Tips section.
Refer to Figure 10, page 20
4. Remove bearing cone (4) from shaft (8).
1. Support spindle in a press and push shaft (8)
down through housing (5).
2. Remove seals from housing.
a. Permatex is a registered trademark of the Permatex Corporation.
MAN0137 (9/14/01)
Dealer Service 19
DEALER SERVICE Cont’d
Assemble Blade Spindle
IMPORTANT
■
10. To prevent distortion to metal seal cage, carefully
press seal into housing. Seal should seat firmly and
squarely against machined shoulder in housing.
■
11. 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.
Bearing adjustment is set by pressing sleeve
against bearing cone until proper adjustment is
attained.
Improper positioning of seals can cause seal
failure.
1. Bearing cups and cones are designed to work
together. It is important to position them so the bearing cone taper mates with bearing cup taper.
2. Lubricate new cups (6) with a light oil. Place them
in spindle housing (5) so they will mate with cones (4).
Seat cups (6) against machined shoulder of housing
with a press or by placing a large drift on the flat lip
and driving them into housing.
12. Apply a thin coat of lubricant to top seal (2) and
install with spring facing up away from center of housing. Top seal should be flush with top of housing.
13. Lubricate spindle with a lithium grease of #2 consistency with a MOLY (molybdenum disulfide) additive. Vent bottom seal with a blunt edged tool such as
a letter opener while filling with grease. Rotate housing on spindle shaft, checking for free movement.
3. Place bottom bearing cone (4) onto spindle shaft
(8) with taper up. Seat on bottom shoulder of shaft
with a press.
2
3
4. Insert shaft and bearing cone assembly through
bottom of housing (5). Fill housing cavity with a lithium
grease of #2 consistency with a MOLY (molybdenum
disulfide) additive.
4
6
7
5. Place top bearing cone (4) on shaft (8) to mate
with top bearing cup. Install sleeve (3) on shaft and
press sleeve and bearing cone onto shaft until all
bearing free play is removed and there is a slight
drag. Check by spinning spindle. It should turn freely.
5
6
NOTE: Be careful not to over-tighten bearings. Proper
bearing adjustment is essential to good bearing life.
Should you over-tighten bearings, hold spindle housing and rap spindle shaft with a hammer and wood
block to loosen bearings. Readjust bearings until
proper setting is obtained.
4
8
6. Proper seal installation is important. An improperly installed seal will leak and could cause bearing
failure.
DB3403
2
7. Pull the rubber portion of seal back and locate
spring.
8. Apply a thin coat of lubricant to bottom seal (2)
and install with spring up toward center of housing.
9. Place bottom seal squarely onto housing. Select
a piece of pipe or tubing with an OD that will sit onto
outside edge of seal. A tube that is too small will bow
seal cage.
20 Dealer Service
Figure 10 Spindle Repair
1.
2.
3.
4.
5.
6.
7.
8.
Spindle Assembly
Seal
Sleeve
Bearing cone
Housing
Cup
Grease fitting
Shaft
MAN0137 (9/14/01)
DEALER SERVICE Cont’d
Install Blade Spindle
44
IMPORTANT
■
Pulley installation sequence is very important
for bearing life. Follow the sequence exactly.
1. Insert spindle through bottom of mower deck and
install three mounting bolts. Be sure to position
grease fittings toward lubrication access areas.
45
47
42
17
2. Install pulley (16) and split taper bushing (17) with
integral key on spindle shaft.
3. Install bolt (44) and flat washer (45) in top of spindle shaft. Torque this bolt to 12 lbs.-ft.
4. Install split taper bushing bolts (47) and lock
washers (42).
16
5. Alternately tighten and torque to 12 lbs.-ft.
DD3413A-1
Figure 11 Spindle Installation
Replace Oilite Bushings
1. Six pre-oiled bronze Oilite bushings are used in
the lift mechanism, two in front and four in rear (see
Figure 12). Oil these bushings once a year to extend
their life cycle.
Left Rear Rockshaft Mount
2. When replacement is required, use a new bushing to press the old bushing out. Make sure the new
bushings are pressed in flush.
Oilite Bushing
Left Front Lift Stop
Oilite Bushing
LA2
Figure 12 Oilite Bushing Location
MAN0137 (9/14/01)
Dealer Service 21
DEALER SERVICE Cont’d
UNIVERSAL JOINT REPAIR
1.
2.
3.
4.
5.
6.
2
Drive shaft yoke
Journal cross
Seal
Snap ring
Cup and bearings
Yoke
1
6
3
4
5
CD1402
Figure 13 U-Joint Exploded View
Disassemble U-Joint
1. Remove snap rings from inside of yokes in four
locations as shown in Figure 14.
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 15.
CD1386
CD1384
Figure 14
22 Dealer Service
Figure 15
MAN0137 (9/14/01)
DEALER SERVICE Cont’d
Disassemble U-Joint cont’d
3. Clamp cup in vise as shown in Figure 16 and tap
on yoke to completely remove cup from yoke. Repeat
steps two and three for opposite cup.
4. Place universal cross in vise as shown in Figure
17 and tap on yoke to remove cup. Repeat step three
for final removal. Drive remaining cup out with a drift
and hammer.
CD1388
CD1387
Figure 16
MAN0137 (9/14/01)
Figure 17
Dealer Service 23
DEALER SERVICE Cont’d
Assemble U-Joint
1. Place seals securely on bearing cups. Insert cup
into yoke from outside and press in with hand pressure as far as possible.
2. Insert journal cross into bearing cup with grease
fitting away from the shaft. Be careful not to disturb
needle bearings.
3. Insert another bearing cup directly across from
first cup and press in as far as possible with hand
pressure.
4. 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.
Tap yoke to aid in process.
5. Seat cups by placing a drift or socket (slightly
smaller than the cup) on cup and rapping with a hammer. See Figure 18.
6. Install snap ring and repeat on opposite cup.
7. Repeat steps 1 and 2 to install remaining cups in
remaining yoke.
CD1389
Figure 18
8. Move both yokes in all directions to check for free
movement. Should movement be restricted, rap on
yokes sharply with a hammer to relieve any tension.
Repeat until both yokes move in all directions without
restriction.
GEARBOX MAINTENANCE
Read this complete section before starting any repair.
Many steps are dependent on each other.
Gearbox bearings, gears, and shafts have an interference press fit. Gearbox repair is limited to seal, gasket, and vent plug replacement.
Always maintain correct gear lube level in gearbox.
Be sure proper vent plug is installed.
Troubleshooting is an important part of gearbox maintenance. Check for leakage and bad bearings.
Leakage is a very serious problem and must be corrected immediately or damage to gearbox and belt
will result. Remove gearbox from mower to repair
leakage problems.
24 Dealer Service
Leakage may be caused by a vent plug not venting.
To check vent plug operation, remove plug and apply
low air pressure to opening in side of plug. Check to
make sure it is venting out of the top.
Operating gearbox with improper lube level may also
cause seals to leak. Also check for housing cracks. If
any of these conditions exist, correct them, clean area
where leakage was evident, return mower to service,
and check to make sure leakage has been stopped.
Bearing maladjustment or failure is indicated by noise
and excessive side and end play in gear shafts. If this
is indicated, replace the gearbox.
MAN0137 (9/14/01)
DEALER SERVICE Cont’d
Remove Gearbox
1. Disconnect drive shaft and remove key from keyway.
2. Remove belt and remove gear stand from mower.
3. Turn gear stand over. There are two set screws in
the split taper bushing; remove them. Insert one set
screw into the threaded bushing hole and tighten to
force bushing and pulley apart.
4. Remove gearbox from stand.
Repair Gearbox Leak
Permatex®a sealant is used on the outer diameter of
the seals. Substitute seals may not meet original
equipment specifications and could cause leakage.
1
8
5
3
4
1. Clean gearbox exterior to remove all foreign
material. When opening, use care to prevent foreign
material from entering gearbox.
6
2. To repair horizontal seal, vertical shaft, or leakage
between cover and gearbox, remove vent plug and
drain gear lube from box.
3. Remove leaking seal and replace (refer to Install
Seal, page 25). Use care to prevent rolling the seal lip
under.
4. Replace gasket between cover and gearbox.
DB3449A
2
7
Figure 19 Gearbox Repair
a. Permatex is a registered trademark of the Permatex Corporation.
Install Seal
Proper seal installation is important. An improperly
installed seal will leak and could result in bearing failure.
1. Clean areas in housing where seal outer diameter
seats. Inspect gear shafts. Pay specific attention to
areas where seals seat. Check for cracks, grooves,
nicks or bumps. Replace housing or shaft if damage
cannot be repaired by resurfacing with emery cloth.
2. Lubricate seal lip and carefully guide over shaft
using a blunt tool such as a letter opener. Be careful
not to roll seal lip under. Do not use a knife as it will
nick and ruin seal.
3. Place seal squarely on housing (spring-loaded lip
toward inside of gearbox). Select a seal driver, a
piece of pipe or tubing with an OD that will set on outside edge of seal but will clear housing. A driver that
is too small will bow seal cage and ruin seal.
4. Carefully press seal into housing, preventing distortion to metal seal cage. Seat vertical seal flush with
housing and horizontal seal against shoulder in housing.
Distortion to seal case or damage to seal lip will
cause seal to leak. Remove and replace seals damaged in installation.
5. Check for proper vent plug operation and fill gearbox with 8 oz. of SAE 90W gear lube.
MAN0137 (9/14/01)
Dealer Service 25
DEALER SERVICE Cont’d
Install Drive Pulley
1. Install drive pulley (19) with split taper bushing
(12) on gearbox vertical shaft. Make sure key (82)
and keyways are aligned.
20
2. Position center line of drive pulley (19) 15/16"
(plus or minus 1/32") above mounting surface of gearbox stand (20) as shown. This is a very critical
dimension and must be held.
3. Alternately tighten split taper bushing set screws
to 14 lbs.-ft. Check mounting distance to make sure it
is correct.
1-7/8"
19
82
12
15/16"
DB2938
Figure 20 Drive Pulley Dimensions
NOTES
26 Dealer Service
MAN0137 (9/14/01)
TROUBLE SHOOTING
TROUBLE SHOOTING
MOWING CONDITIONS
Problem
Grass cut higher in center of swath
than at edges
Grass cut lower in center of swath
than at edges
Streaking conditions in swath
Material discharges from mower
unevenly; bunches of material along
swath.
Erratic mower operation; mower
slows down without tractor engine
slowing
MAN0136 (9/28/01)
Possible
Solutions
Height of mower higher at front than
at rear
Check cutting height adjustment.
Refer to chart on page 9
Loose blades
Check clamping cup washers.
Replace if flat or not holding.
Height of mower lower at front than
at rear
Check cutting height adjustment.
Refer to chart on page 9.
Loose blades
Check clamping cup washers.
Replace if flat or not holding
Conditions too wet for mowing
Allow grass to dry before mowing.
Blades unable to cut grass pressed
down by path of tractor tires
Slow ground speed of tractor but
keep mid-PTO running at 2000 rpm.
Cutting lower will help. Under some
conditions it is impossible to pick up
and cut grass pressed down by tires.
Dull blades
Sharpen or replace blades.
Material too high and too much
material
Reduce ground speed but operate
tractor mid-PTO at 2000 rpm maximum, or make two passes over
material. Raise mower for the first
pass and lower to desired height for
the second and cut at 90 degrees to
first pass. Raise rear of mower high
enough to permit material 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 mid-PTO at 2000 rpm maximum. Cutting lower will help.
Rear of mower too low, trapping
material under mower
Adjust mower height. Refer to chart.
page 9
Clipping packed to underside of
mower
Remove clippings and clean underside of mower.
Belt slippage
See Trouble Shooting Belt Conditions, page 28.
Trouble Shooting 27
Trouble Shooting Cont’d.
TROUBLE SHOOTING
BELT CONDITIONS
Problems
Belt slippage
Possible
Solutions
Mower overloading; material too tall
or heavy
Reduce tractor ground speed but
operate mid-PTO at 2000 rpm. Cut
material twice, one high pass and
then mow at desired height. Cut a
partial swath.
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 for free travel in pulleys
and belt guides. Check under mower
and around blade spindle shafts for
wire, rags, or foreign material. Clean
material from under mower.
Belt or pulleys worn out
If belt rides in bottom of pulley
groove, either belt or pulley is worn
and must be replaced.
Frayed edges on belt cover
Belt misaligned
Re-align belt. Be sure belt does not
rub any other part while running.
Belt rollover
Damaged belt
Inspect all pulley grooves for rust,
paint, or weld spots and remove.
Foreign object in pulley grooves
Replace pulley.
Damaged belt
Rollover, high shock loads, or installation damage
Replace belt.*
Belt breakage
High shock loads
Avoid abusive mowing. Avoid hitting
the ground or obstructions.
Belt came off drive
Check pulleys for foreign material in
grooves. Avoid hitting solid objects
or ground.
* Check belt for damage by laying it flat on the floor. A belt that does not lay flat (has humps or twists, indicating
broken or stretched cords) it must be replaced.
28 Trouble Shooting
MAN0136 (9/28/01)
ASSEMBLY
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 mowing conditions.
Set up the mower as received from the factory with
these instructions. Complete check lists on page 42
when assembly is completed.
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 52.
WARNING
„ Keep all persons away from operator control
area while performing adjustments, service, or
maintenance.
CAUTION
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.
„ Always wear relatively tight and belted clothing to avoid entanglement in moving parts. Wear
sturdy, rough-soled work shoes and protective
equipment for eyes, hair, hands, hearing, and
head.
Adjust Wheel Stop Bolt
Mid-PTO Operation
IMPORTANT
■
On all four wheel drive mountings, the front
tractor wheel stop bolts must be set. Failure to
adjust may result in damage to tractor or mower.
Refer to the tractor owner's manual for mid-PTO operation.
1. The wheel stop bolts are located on the rear of
the front axle.
2. Loosen jam nut and adjust bolt in or out as necessary to obtain 18mm or 23/32" from axle casting to top
of bolt. Tighten jam nut.
Install Front Mounting Plate
1. Install right and left front mounting plates (1 & 3)
outside tractor frame (4), using two bolts (8) and
flange locknuts (7).
2. Install mounting plate brace bar (2) between
mounting plates with carriage bolts (6) and locknuts
(5).
1.
2.
3.
4.
5.
6.
7.
8.
Left front mounting plate
Mounting plate brace bar
Right front mounting plate
Tractor frame
3/8 Hex lock nut
3/8 x 1-1/4 Carriage bolt
5/8 Lock nut
5/8 x 1-1/2 Cap screw
MAN0137 (9/14/01)
Figure 21 Front Mounting Plate Installation
Assembly 29
Assembly Instructions Cont’d
Install Left Front Lift Stop
1. Attach left front lift stop (4) and spacer plate (2) to
tractor clutch housing mounting pad (5) with bolts (10
& 11). Bolt (10) is 5 mm shorter than bolt (11). Use the
shorter bolts in the top holes of spacer plate (2) and
bolts (11) in the center holes.
NOTE: Do not use spacer plate if tractor is equipped
with front loader. When front loader mounting bracket
(1) is installed, spacer plate (2) is not required. Do not
use hardware from loader bracket to install left front
lift stop (4); use the hardware supplied with mower.
2. Place a hardened flat washer (12) on bolts (10 &
11) and insert through spacer plate and into tractor
clutch housing mounting pad (5).
3. Place flat washers (7) on bolts (9) and insert
through bottom holes. Secure bolts (9) with locknuts
(8).
4. Hand tighten all hardware.
5. Insert rockshaft (3), clevis forward as shown,
through lift stop (4). Place washer (13) over rockshaft
and secure with spirol pin (6).
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Loader mounting bracket
Spacer plate
Front rock shaft assembly
Left front lift stop
Tractor clutch housing mounting pad
1/4 x 2 Spirol pin
1/2 Flat washer
1/2 Flange lock nut
1/2 x 1-3/4 Cap screw
14mm x 35mm Cap screw
14mm x 40mm Cap screw
9/16 Hardened flat washer
1” Flat washer
30 Assembly
Figure 22 Left Front Lift Stop Installation
MAN0137 (9/14/01)
Assembly Instructions Cont’d
Install Right Front Lift Stop
1. Slide right front lift stop (4) over rockshaft (3).
2. Place spacer plate (2) over front lift stop and
secure both to tractor clutch housing mounting pad
(5) with bolts (7 & 8) and hardened flat washers (9).
NOTE: If loader mounting bracket (1) is installed, do
not use spacer plate. Attach lift stop directly to loader
mounting bracket.
3. Bolt (7) is 5 mm shorter than bolt (8). Use the
shorter bolts (7) in the top holes of spacer plate (2)
and bolts (8) in the center holes.
4. Place a hardened flat washer (9) on bolts (7 & 8)
and insert through spacer plate and into tractor clutch
housing mounting pad (5).
5. Place washers (12) on bolts (11) and through bottom holes. Secure bolts (9) with locknuts (13).
6. Hand tighten all hardware.
7. Position both lift stops and rockshaft so rockshaft
rotates freely, then tighten the 14 mm bolts to 95 lbs.ft. and the 1/2" hardware to 85 lbs.-ft. on both front lift
stops.
8. Place washer (10) over rockshaft and secure with
spirol pin (6).
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Loader mounting bracket (if installed)
Spacer plate
Front rockshaft assembly
Right front lift stop
Tractor clutch housing mounting pad
1/4 x 2" Spirol pin
14 mm x 35 mm Bolt
14 mm x 40 mm Bolt
9/16" Hardened flat washer
1" Flat washer
1/2 x 1-3/4" Bolt
1/2" Flat washer
1/2" Flanged locknut
MAN0137 (9/14/01)
Figure 23 Right Front Lift Stop Installation
Assembly 31
Assembly Instructions Cont’d
Install Right Rear Rockshaft
1. Jack up rear of tractor, block securely, and
remove right rear tire.
2. Apply Loctite®a 242 to both 12 mm x 25 mm bolts
(9).
3. Install right rear rockshaft mounting bracket (3) to
tractor transmission (2), using bolts (9). Secure to
tractor axle mounting pad (1), using bolts (10) and
hardened flat washers (11).
4. Hand tighten hardware.
5. Place right rear rockshaft assembly (4) into
mounting bracket (3) and insert rockshaft bar (6).
1.
2.
3.
4.
6.
7.
8.
9.
10.
11.
Tractor rear axle mounting pad
Tractor transmission
Right rear rockshaft mounting bracket
Right rear rockshaft assembly
Rockshaft bar
3/8 x 1-3/4 Bolt
3/8" Hex locknut
12 mm x 25 mm Bolt
14 mm x 30 mm Bolt
9/16" Hardened flat washer
6. Align holes of rockshaft bar (6) and right rear
rockshaft assembly (4). Secure with bolts (7) and
locknuts (8).
7. Do not tighten hardware at this time.
8. Re install the right rear tire.
2
9
1
3
6
4
11
8
10
DB3416A
7
Figure 24 Right Rear Rockshaft Installation
a. Loctite is a registered trademark of the Loctite Corporation.
32 Assembly
MAN0137 (9/14/01)
Assembly Instructions Cont’d
Install Left Rear Rockshaft
1. Jack up rear of tractor, block securely, and
remove left rear tire.
2. Apply Loctite®a 242 to both 12 mm x 25 mm bolts
(9).
3. Install left rear rockshaft mounting bracket (3) to
tractor transmission (2), using bolts (9). Secure to
tractor axle mounting pad (1), using bolts (10) and
hardened flat washers (11).
4. Hand tighten hardware.
5. Place left rear rockshaft assembly (4) into mounting bracket (3) and insert rockshaft bar (6).
7. Pass crankshaft bar (5) through rockshaft assembly (4) and right rockshaft assembly. Align holes of
crankshaft bar holes in both right and left rockshaft
assemblies. Secure with bolts (7) and locknuts (8).
8. Position left rear rockshaft mounting bracket (3)
so that both right and left rockshaft assemblies rotate
freely. It may be necessary to loosen the right side
mounting and reposition.
9. After making adjustments, torque all 12 mm bolts
(9) to 75 lb.-ft., 14 mm bolts (10) to 85 lb.-ft., and 3/8
bolts (7) to 35 lbs.-ft.
10. Reinstall the left rear tire.
6. Align holes of rockshaft bar (6) and left rear rockshaft assembly (4). Secure with bolts (7) and locknuts
(8).
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Tractor rear axle mounting pad
Tractor transmission
Left rear rockshaft mounting bracket
Left rear rockshaft assembly
1 x 10.31" Crankshaft bar
1 x 8.90" Rockshaft bar
3/8 x 1-3/4 Bolt
3/8" Hex locknut
12 mm x 25 mm Bolt
14 mm x 30 mm Bolt
9/16" Hardened flat washer
Figure 25 Left Rear Rockshaft Installation
a. Loctite is a registered trademark of the Loctite Corporation.
MAN0137 (9/14/01)
Assembly 33
Assembly Instructions Cont’d
Install Transport Lock-Up
1. Slide lock-up bar (2) into left front lift stop (1).
1. Attach lock-up bar extension (3) using 1-1/4" hex
bolts (10) and 3/8" locknut (9).
2. Thread 1/2" jam nut (8) and clevis yoke (5) onto
lock-up bar to obtain the 32" dimension shown in Figure 27. Hand tighten jam nut (8) against clevis yoke
(5).
1
12
4
11
3
9
3. Secure clevis yoke (5) to rear rockshaft assembly
(4) with clevis pin (6). Flat washers (11) must be
installed as shown in Figure 26.
4. Secure clevis pin (6) with cotter pin (7). Do not
spread cotter pin at this time.
8
5
10
7
6
CD4178
2
5. Install handle grip (12) on lock-up bar (2)
Figure 26 Transport Lock-Up Installation
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Front lift stop
Lock-up bar
Lock-up bar extension
Rear rockshaft assembly
Clevis yoke
1/2 x 1-3/4" Clevis pin
3/16" x 1 Cotter pin
1/2" Jam nut
3/8" Locknut
3/8 x 1-1/4" Bolt
1/2" Flat washer
Handle grip
34 Assembly
32"
CD4201B
Figure 27 Lock-Up Bar Length
MAN0137 (9/14/01)
Assembly Instructions Cont’d
Assemble Mechanical Lift Pull Rod
1. Thread jam nut (17) onto pull rod (7) until it bottoms out.
NOTE: For tractor models 7000, 7200, and 7205, use
pull rod (7A) with bend up to clear hydraulic line.
2. Thread clevis yoke (8) onto pull rod (7) to obtain a
33-1/4" dimension from center to center between the
clevis and rod holes as shown. Hand tighten jam nut
(17) against clevis yoke (8).
3. Attach pull rod assembly (17) to lug (21) on left
rear rockshaft (6) and secure with washer (15) and
cotter pin (16).
4. Connect clevis yoke (8) to front rockshaft (1) with
clevis pin (12) and secure with cotter pin (16). Do not
spread pin at this time.
5. Remove left lower 3-point arm (9) from lift mounting plate (4).
1.
2.
3.
4.
5.
6.
7.
7A.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
19.
20.
21.
6. Remove the three axle housing bolts (19) and
replace lift mounting plate (4) with the lift mounting
plate supplied with mower lift kit.
7. Reinstall the three 12mm bolts and torque to 75
lbs.-ft.
8. Slide rear lift arm assembly (5) over lower 3-point
arm (9) and slide both onto pin of lift mounting plate
(4). Secure with Klik pin (10).
9. Thread clevis yoke (8) onto rear pull rod (3) to
obtain 16.5" length.
10. Connect rear pull rod (3) to rear rockshaft (6)
using clevis pin (14) and secure with washer (13) and
cotter pin (16).
11. Connect clevis yoke (8) to rear lift arm assembly
(5) with clevis pin (11) and cotter pin (16).
Front rockshaft assembly
Left front lift stop
Rear pull rod
Lift mounting plate assembly
Rear lift arm assembly
Left rear rockshaft assembly
Pull rod (7192, 7194, 7195)
or
Pull rod (bent) (7000,7200,7205)
Adjustable clevis yoke
3-Point arm
Klik pin
1/2 x 2-3/4" Clevis pin
1/2 x 1-3/4" Clevis pin
5/8" Flat washer
5/8 x 1.65" Clevis pin
1/2" Flat washer
3/16 x 1-1/2" Cotter pin
1/2" Jam nut
12mm Bolt
ROPS
Lug
DC4203B
Figure 28 Mechanical Lift Pull Rod Assembly
MAN0137 (9/14/01)
Assembly 35
Assembly Instructions Cont’d
PREPARE MOWER
Install Discharge Chute
1. Position discharge chute (2) over stud (5) on
mower frame (1).
5
2. Install carriage bolts (3) (attached to discharge
chute assembly) and secure with nuts (4).
6
3. Install knob (6) on stud (5).
1.
2.
3.
4.
5.
6.
Mower frame
Discharge chute
3/8 x 1-1/4" Carriage bolt
3/8" Nut
3/8" Stud
3/8" Knob
4
1
3
LA3
2
Figure 29 Discharge Chute Installation
Install Mounting Channel & Lift Bar
NOTE: 7000, 7200 and 7205 tractors use alternate
front channel (1A).
1. Insert sleeve (5) into front mounting channel (1).
Place washer (6) on bolt (7) and insert through sleeve
(5) and front lift bracket (2).
3
2. Slide second sleeve (5) over bolt (7) and install
front mower lift bar (3). Secure with flanged locknut
(4).
3. Repeat this procedure for opposite side of front
mounting channel.
5
6
7
4
1
2
5
1.
1A.
2
3.
4.
5.
6.
7.
7192, 7194, & 7195 Front mount channel
7000, 7200, & 7205 Front mount channel
Front lift bracket
Front mower lift bar, 6.5"
1/2" Flanged locknut
1/2 x 3/4 x 1/2" Sleeve
1/2" Flat washer
1/2 x 2" Bolt
36 Assembly
DB3406A
1A
Figure 30 Front Channel Installation
MAN0137 (9/14/01)
Assembly Instructions Cont’d
Install Rear Lift Bars
1. Thread jam nut (3) onto upper rear lift bar (1) until
it bottoms out.
2. Thread upper rear lift bar into lower rear lift bar (2)
to obtain the 8-1/4" dimension shown.
3. Hand tighten jam nut against lower rear lift bar.
4. Place washer (6) and sleeve (5) over bolt (7) and
insert through lower rear lift bar (2) and rear lift
bracket (8). Secure with flanged locknut (4).
5. Repeat procedure for opposite side.
1.
2.
3.
4.
5.
6.
7.
8.
Upper rear lift bar
Lower rear lift bar
1/2" Jam nut
1/2" Flanged locknut
1/2 x 3/4 x 1/2" Sleeve
1/2" Flat washer
1/2 x 1-1/2" Bolt
Rear lift bracket
Figure 31 Rear Lift Bar Installation
Install Front Caster Wheel
1. Insert sleeve (68) through wheel (6).
2. Place washer (63) on bolt (70) and insert through
yoke (31) and sleeve in wheel.
3. Tighten flanged locknut (65) until yoke (31) contacts both ends of sleeve (68).
4. Check that wheel turns freely. Loosen and
retighten if necessary.
5. Repeat procedure for opposite front caster wheel.
6.
31.
63.
65.
68.
70.
Caster wheel
Wheel yoke
1/2" Flat washer
1/2" Flanged locknut
1/2 x 3/4 x 3-3/8" Sleeve
1/2 x 5" Bolt
MAN0137 (9/14/01)
Figure 32 Front caste Wheel Installation
Assembly 37
Assembly Instructions Cont’d
Install Rear Gauge Wheel
1. Assemble gauge wheel with grease fitting facing
outward for lubrication access.
1. Insert sleeve (68) through wheel (6).
2. Place washer (63) on bolt (69) and insert through
sleeve in wheel and rear gauge wheel arm (7).
3. Secure with flanged locknut (65).
4. Repeat for opposite side.
6.
7.
63.
65.
68.
69.
Gauge wheel
Rear gauge wheel arm
1/2" Flat washer
1/2" Flanged locknut
1/2 x 3/4 x 3-3/8" Sleeve
1/2 x 4-1/2" Bolt
Figure 33 Rear Gauge Wheel Installation
Install Mid-PTO Driveshaft
IMPORTANT
■
Stake end of keyway to secure key.
1. Insert key (3) into gearbox (2) input shaft.
2. Install driveshaft (1) onto gearbox shaft and
secure with spirol pin (4).
21.
22.
46.
60.
Driveshaft assembly
Gearbox
1/4 x 1/4 x 7/8" Key
3/8 x 1-1/2" Spirol pin
Figure 34 Driveshaft Installation
38 Assembly
MAN0137 (9/14/01)
Assembly Instructions Cont’d
Install Gearbox Vent Plug
1. Remove and discard solid plug from top of gearbox cover.
1
3
2. Remove level plug (2) when filling and checking
oil level.
3. Fill gearbox with SAE 90W oil until it reaches
level hole in front of gearbox.
4. Reinstall level plug.
5. Install plastic vent plug (3) from bag of parts.
DB2947A
2
Figure 35 Vent Plug Installation
1.
2.
3.
Gearbox
Level plug
Vent plug
Install Rear Lift Stop
1. Attach rear lift stop (1) to gearbox stand (3) with
two bolts (4) and locknuts (5) as shown.
NOTE: Rear lift stops (1 & 2) are the same part,
mounted differently for gear and hydro tractors.
1.
2.
3.
4.
5.
Rear lift stop (Hydro)
Rear lift stop (Gear)
Gearbox stand
3/8 x 1" Bolt
3/8" Locknut
Figure 36 Rear Lift Stop Installation
MAN0137 (9/14/01)
Assembly 39
Assembly Instructions Cont’d
Attach Mower to Tractor
8. Place front lift bars (6) in clevis portion of front
rockshaft (7). Attach with clevis pins (17) and klik pins
(13).
Refer to Figure 37.
9. Place rear mower lift bars (8) over stud on rear
rockshaft (10 & 11) and secure with washer (16) and
Klik pin (13).
WARNING
„ Keep all persons away from operator control
area while performing adjustments, service, or
maintenance.
„ Make sure spring-activated locking pin or collar slides freely and is seated firmly in tractor PTO
spline groove.
1. Be sure belt shields are installed on mower.
2. Remove lynch pins from front caster arms.
3. Remove clevis pin from rear gauge wheel handle.
Make sure rear mower lift bars (8) are down as far as
possible.
4. Make sure that driveshaft (9) is between lift bars
(8).
5. Drive tractor up to mower frame. Position boards
between front tractor tires and mower to serve as a
transition ramp, and drive tractor over frame.
6. Attach front mounting channel (4) to front mounting plates (3) with spring-loaded front channel pin (2).
10. Attach driveshaft (9) to mid-PTO shaft (12).
1.
2.
3.
4.
5.
6
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Front mounting plate cover
Spring-loaded front channel pin
Front mounting plate assembly
Front mounting channel
Mower frame
Front mower lift bar
Front rockshaft assembly
Rear mower lift bar
Driveshaft assembly
Right rear rockshaft assembly
Left rear rockshaft assembly
Tractor mid-PTO
3/16 x 1" Klik pin
5/16" Flat washer
5/16 x 3/4" Bolt
1/2" Flat washer
1/2 x 1-3/4" Clevis pin
7. Attach front mounting plate cover (1) to front
mounting plates (3) with bolts (15) and washers (14).
DB4200A
Figure 37 Attach Mower to Tractor
40 Assembly
MAN0137 (9/14/01)
Assembly Instructions Cont’d
Adjust Mower with Mechanical Lift
1. Remove clevis pin connecting rear pull rod (10) to
the rear lift arm assembly (12).
2. Raise tractor lower 3-point lift arms (3) to their
highest position.
3. Remove clevis pin that connects clevis yoke (9) to
front rockshaft (1).
4. Block mower frame (2) up against front lift stop
(4) and so rear lift stop (13) contacts tractor transmission.
5. With tractor lower 3-point arms (3) in their highest
position, rotate rear rockshaft (8) up and adjust rear
pull rod (10) until clevis pin connecting rear pull rod
(10) to rear lift arm assembly (12) just slips in. Install
clevis pin and secure with cotter pin.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
6. Rotate front rockshaft assembly (1) up and adjust
clevis yoke (9) on pull rod (5) until clevis pin just slips
in. Install clevis pin and secure with cotter pin.
7. Remove block from mower frame. The deck will
drop slightly. Readjust clevis (9) and rear pull rod (10)
so mower just contacts lift stops when 3-point arms
are at maximum lift height.
8. With tractor 3-point arms at their maximum lift
height, adjust lock-up bar (11) and clevis (9) so slot on
lock-up bar will just drop into lock position. Spread
cotter pin on clevis pin that connects clevis yoke (9) to
rear rockshaft (8).
Front rockshaft assembly
Mower frame
3-Point lift arm
Front lift stop
Pull rod
Upper rear lift link
Lower rear lift link
Rear rockshaft assembly
Adjustable clevis yoke
Rear pull rod
Lock-up bar
Rear lift arm assembly
Rear lift stop
Figure 38 Mechanical Lift Adjustment
MAN0137 (9/14/01)
Assembly 41
Assembly Instructions Cont’d
PRE-DELIVERY CHECK LIST
(DEALER’S RESPONSIBILITY)
DELIVERY CHECK LIST
(DEALER’S RESPONSIBILITY)
Inspect the equipment thoroughly after assembly to
make sure it is set up properly before delivering it to
the customer. The following check list is a reminder of
points to inspect. Check off each item as it is found
satisfactory, corrections are made, or services are
performed.
___ Show customer how to make adjustments and
select proper PTO speed.
___ Check all bolts to be sure they are properly
torqued.
___ 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.
___ Check that all cotter pins and safety pins are
properly installed. Replace if damaged.
___ Check and grease all lubrication points as identified in “Service, lubrication information
___ Check the level of gearbox fluids before delivery. Service, if required, as specified in the “Service, lubrication information.”
___ Check that blades have been properly installed.
___ Check mower attitude and belt alignment.
___ Instruct customer how to lubricate and explain
importance of lubrication.
___ Point out all guards and shields. Explain their
importance and the safety hazards that exist
when not kept in place and in good condition.
___ 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 that when equipment is
transported on a road or highway, a Slow Moving Vehicle (SMV) sign should be used to provide adequate warning to operators of other
vehicles.
42 Assembly
MAN0137 (9/14/01)
PARTS
CONTACT YOUR WOODS DEALER TO ORDER PARTS
To locate your nearest dealer:
„
Check the Dealer Locator at www.WoodsEquipment.com, or
„
In the United States and Canada, phone 1-800-319-6637
„
Outside the United States, phone 1-815-732-9509 plus the
appropriate international dialing code for the USA
To order correct parts, provide this information to your dealer:
„
Model Number: ____________________________
„
Serial Number: ____________________________
Parts
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 & J1701M JUL96.
SAE Bolt Head
Identification
SAE SERIES
TORQUE
CHART
A
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”
7/16”
6
8
10
13
14
18
5/16”
3/8”
1/2”
9/16”
12
23
17
31
19
35
26
47
27
49
37
67
7/16”
1/2”
5/8”
3/4”
36
55
48
75
55
85
75
115
78
120
106
163
9/16”
5/8”
13/16”
15/16”
78
110
106
149
121
170
164
230
171
240
232
325
3/4”
7/8”
1-1/8”
1-15/16”
192
306
261
416
297
474
403
642
420
669
569
907
1”
1-1/2”
467
634
722
979
1020
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
8 x 1.25
10 mm
13 mm
8
20
6
15
11
27
8
20
8
21
6
16
11
29
8
22
6 x 1.0
8 x 1.0
10 x 1.5
12 x 1.75
16 mm
18 mm
39
68
29
50
54
94
40
70
41
75
30
55
57
103
42
76
10 x 1.25
12 x 1.25
14 x 2.0
16 x 2.0
21 mm
24 mm
109
169
80
125
151
234
111
173
118
181
87
133
163
250
120
184
14 x 1.5
16 x 1.5
18 x 2.5
20 x 2.5
27 mm
30 mm
234
330
172
244
323
457
239
337
263
367
194
270
363
507
268
374
18 x 1.5
20 x 1.5
22 x 2.5
24 x 3.0
34 mm
36 mm
451
571
332
421
623
790
460
583
495
623
365
459
684
861
505
635
22 x 1.5
24 x 2.0
30 x 3.0
46 mm
1175
867
1626
1199
1258
928
1740
1283
30 x 2.0
Metric 8.8
Typical Washer Installations
Lockwasher
Metric 10.9
Metric 8.8
Metric 10.9
Flat Washer
Bolt
Nut
52 Appendix
8/9/00
Bolt Torque & Size Charts (Rev. 9/5/00)
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
5/8
3/4
7/8
IN
1
2
3
4
5
6
7
MM
25
50
75
100
125
150
175
Metric Bolt Thread Sizes
8MM
10MM
12MM
14MM
16MM
18MM
ABBREVIATIONS
AG............................................................. Agriculture
NC ....................................................National Coarse
ATF .............................. Automatic Transmission Fluid
NF ......................................................... National Fine
BSPP ........................... British Standard Pipe Parallel
NPSM ...................National Pipe Straight Mechanical
BSPTM .............. British Standard Pipe Tapered Male
NPT ........................................ National Pipe Tapered
CV................................................... Constant Velocity
NPT SWF........ National Pipe Tapered Swivel Female
CCW ............................................ Counter-Clockwise
ORBM ......................................... O-Ring Boss - Male
CW............................................................. Clockwise
P .........................................................................Pitch
F .....................................................................Female
PBY .....................................................Power Beyond
GA ...................................................................Gauge
psi ........................................ Pounds per Square Inch
GR (5, etc.) ......................................... Grade (5, etc.)
PTO ................................................... Power Take Off
HHCS ...................................... Hex Head Cap Screw
QD ..................................................Quick Disconnect
HT .......................................................... Heat Treated
RH ............................................................Right Hand
JIC ...............Joint Industry Council 37° Degree Flare
ROPS.......................... Roll Over Protective Structure
LH ............................................................... Left Hand
RPM.......................................Revolutions Per Minute
LT ..........................................................................Left
RT ...................................................................... Right
m....................................................................... Meter
SAE ........................Society of Automotive Engineers
mm.............................................................. Millimeter
UNC ....................................................Unified Coarse
M.........................................................................Male
UNF ........................................................ Unified Fine
MPa ....................................................... Mega Pascal
UNS ....................................................Unified Special
N .................................................................... Newton
Bolt Torque & Size Charts (Rev. 9/5/00)
Appendix 53
WARRANTY
(Replacement Parts For All Models Except Mow’n Machines)
WEC Company, d/b/a 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
Company
2606 South Illinois Route 2
Post Office Box 1000
Oregon, Illinois 61061
815-732-2141 tel
815-732-7580 fax
www.WoodsEquipment.com
F-8494 (Rev. 7/15/2004)
WARRANTY
(All Models Except Mow’n Machines)
Please Enter Information Below and Save for Future Reference.
Date Purchased: __________________________
From (Dealer): ________________________________________
Model Number: __________________________
Serial Number:________________________________________
WEC Company, d/b/a 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.
The warranty periods for certain gearboxes are listed below:
Model No.
Part Warranted
PHD25, PHD35, PHD65, PHD95, 1260, 2120, 2162, 3180, 3240, BB600,
BB720, BB840, BB6000, BB7200, BB8400, BW180, RM550-2, RM660-2,
Gearbox
RM990-3, RD6000-2, RD7200-2, RD8400-2, 7144RD-2, 9180RD-2, 9204RD-2
components
Gearbox
BB48, BB60, BB72, BB84, RCC42
components
BW180
Gearbox
components
Duration
5 years from the date of delivery
the original purchaser.
3 years from the date of delivery
the original purchaser.
1 year from the date of delivery
the original purchaser if used
rental or commercial applications.
to
to
to
in
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
Company
2606 South Illinois Route 2
Post Office Box 1000
Oregon, Illinois 61061
815-732-2141 tel
815-732-7580 fax
www.WoodsEquipment.com
F-3079 (Rev. 7/15/2004)
PART NUMBER
MAN0137
Woods Equipment
Company
2606 Illinois Route 2 South
Post Office Box 1000
Oregon, Illinois 61061
815-732-2141 tel
815-732-7580 fax
© 2001 Woods Equipment Company. All rights reserved.
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