King Kutter Free Floating User Manual

PO Box 1200 305 Commerce Drive Winfield, Alabama 35594

FREE FLOATING

REAR DISCHARGE

FINISHING MOWER

Part No 999994 www.kingkutter.com

TO THE PURCHASER

This manual contains valuable information about your new King Kutter Mower. It has been carefully prepared to give you helpful suggestions for operating, adjusting, servicing and ordering repair parts.

Keep this manual in a convenient place for quick and easy reference. Study it carefully. You have purchased a dependable and sturdy mower, but only by proper care and operation can you expect to receive the service and long life designed and built into it.

Sometime in the future your mower may need new parts to replace those that are worn or broken. If so, go to your dealer and provide him with the model and part number.

Customer Information

Name _______________________________________________

Purchased From ______________________________________

Date Purchased ______________________________________

Model No. ___________________________________________

Serial No. ___________________________________________

It is the purchaser and/or operator’s responsibility to….

z Read and understand the information contained in

this manual.

z Operate, lubricate, assemble and maintain the equip-

ment in accordance with all instructions and safety procedures in this manual.

z Inspect the equipment and replace or repair any parts

that are damaged or worn which under continued operation would cause damage, wear to other parts, or cause a safety hazard.

z Return the equipment or parts to the authorized King

Kutter dealer, from where it was purchased, for service or replacement of defective parts that are covered by warranty. (The King Kutter Factory may inspect equipment or parts before warranty claims are honored.)

z Payment of all costs incurred by the dealer for travel-

ing to or transporting the equipment for warranty inspection and or claims.

CONTENTS

ITEM PAGE

Safety ......................................................................... 6

Assembly Instructions ................................................8

Before Putting Into Service ...................................... 10

Safety Training ......................................................... 11

Transportation Safety ............................................... 15

Attaching To Tractor ................................................. 16

Sizing PTO ............................................................... 18

Operating Instructions.............................................. 19

Maintenance ............................................................. 21

5-6-7 FT. Belt Replacement ..................................... 22

4 FT. Belt Replacement ............................................ 24

Maintenance Safety ................................................. 26

Safety Decal's And Locations ................................... 27

Replacement Parts................................................... 34

PTO Shaft Parts ....................................................... 36

Spindle Unit Parts .................................................... 37

Gearbox Parts .......................................................... 38

PTO Shaft Cover Removal ....................................... 40

Warranty ................................................................... 43

SAFETY

READ AND FOLLOW THE INSTRUCTIONS IN THIS MANUAL AND ESPECIALLY IN THE SAFETY SECTION. FAILURE TO DO SO CAN RESULT IN SERIOUS INJURY OR DEATH.

TAKE NOTE! THIS SAFETY ALERT SYMBOL FOUND THROUGHOUT THIS MANUAL IS USED TO CALL YOUR ATTENTION TO INSTRUCTIONS INVOLVING YOUR PERSONAL SAFETY AND THE SAFETY OF OTHERS.

SIGNAL WORDS:

The signal words DANGER, WARNING and CAUTION are used with the

THIS SYMBOL MEANS

ATTENTION!

BECOME ALERT!

YOUR SAFTEY IS INVOLVED

safety messages in this manual and with each safety signs. They are defined as follows:

DANGER: Indicates an immediate hazardous situation that, if not avoided, could result in serious injury or death. This signal word is to be limited to the most extreme situations typically for machine components that, for functional purposes, cannot be guarded.

WARNING: Indicates a potentially hazardous situation that, if not avoided, could result in serious or death, and includes hazards that are exposed when guards are removed. It may also be used to alert against unsafe practices.

CAUTION: Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practice.

If you have any questions not answered in this manual or require additional copies or the manual is damaged, please contact your dealer or King Kutter,

Inc. P.O. Box 1200 Winfield, AL 35594 (205) 487-3202 or www.kingkutter.com 6

EQUIPMENT SAFETY GUIDELINES

z Safety of the operator and by standards is one of the main concerns in designing and

developing a mower. However, every year accidents occur which could have been avoided

by a few seconds of thought and a more careful approach to handling equipment. You,

the operator, can avoid many accidents by observing the following precautions and insist

those working with you, or for you, follow them.

z In order to provide a better view, certain photographs or illustrations in this manual may

show an assembly with a safety shield removed. However, equipment should never be

operated in this condition. Keep all shields in place. If shield removal becomes neces-

sary for repairs, replace the shield prior to use.

z Replace any safety sign that is not readable or is missing. Location of such safety signs

is indicated in this manual.

z Never use alcoholic beverages or drugs that can hinder alertness or coordination while

operating this equipment. Consult your doctor about operating this machine while taking

prescription medications.

z Under no circumstances should children under the age of 18 be allowed to work

with this equipment. Do not allow persons to operate or assemble this unit until

they have read this manual and have developed a thorough understanding of

the safety precautions and of how it works. Review the safety instructions with all

users annually.

z This equipment is dangerous to children and persons unfamiliar with its operation. The

operator should be a responsible, properly trained and physically able person familiar

with farm machinery and trained in this equipment’s operations. If the elderly are assist-

ing with farm work, their physical limitations need to be recognized and accommodated.

z Use a tractor equipped with a Roll Over Protective System and seat belts. (ROPS)

z Never exceed the limits of a piece of machinery. If its ability to do a job, or to do so safely,

is in question- DON’T TRY IT.

z Do not modify the equipment in any way. Unauthorized modification could result in seri-

ous injury or death and may impair the function and life of the equipment.

z In addition to the design and the confirmation of this implement, including safety signs

and safety equipment, hazard control and accident prevention are dependent upon the

awareness, concern, prudence, and proper training of personnel involved in the opera-

tion, transport, maintenance, and storage of the machine. Refer also to safety messages

and operation instruction in each of the appropriate sections of the tractor and mower

manuals. Pay close attention to the safety signs affixed to the tractor and the finishing

mower.

FINISHING MOWER ASSEMBLY INSTRUCTIONS

STEP 1

With finishing mower still in crate, lay flat on a level surface. Remove the top & side sections of the crate, leaving the finishing mower resting on the bottom section. Set aside PTO shaft and tail wheel arm assemblies.

STEP 2

Insert tail wheel arms as shown in Figure A and tighten both the bolt & jam nut.

STEP 3

Remove swivel links and lift pins that are wired on the lift arm “A” frame. Set aside for step 5.

STEP 4

Remove the 4 bolts from the lift arm “A” frame.

Note: There are 2 different lengths of bolts.

STEP 5

Insert the swivel links in the center lift plate channel using the longer of the 2 bolts, on each side as shown in figure B.

STEP 6

Attach the other end of each swivel link to the outside lower hole on the lift arm “A” frame using the shorter bolts as shown in Figure B.

STEP 7

Attach the Category 1 lift pins as shown in Figure B.

STEP 8

Tighten all nuts and bolts.

Figure A

Figure B

BEFORE PUTTING FINISHING MOWER INTO SERVICE

IMPORTANT-INSTRUCTIONS PRIOR TO START UP)

( SHIPPED WITHOUT OIL IN GEAR BOX AND WITHOUT GREASE IN GREASE FITTINGS. UNIT MUST BE SERVICED BEFORE USING.

• Fill Gearbox using Multi-Purpose Gear Oil (I.E. S.A.E. 80w/90 or

S.A.E. 85w/140 Multi-purpose gear oil.)

• For all Grease Fittings use TYPE/grade II tube grease.

STEP 1 Place finishing mower so that the deck is secure and level. STEP 2 Remove 1/2” Pipe Plug (Located at top of gearbox) and 1/8” Pipe

Plug (located at lower 1/3 of gearbox.)

STEP 3 Fill gearbox using multi-purpose gear oil through top 1/2” fill hole

until gear oil is level with lower 1/8" hole.

STEP 4 Replace both the 1/2” pipe plug (located at top of gear box) and

1/8" pipe plug (located at lower 1/3 of gear box) and clean away any excess oil.

STEP 5 Fill spindle units (3) with grease until full. There are easy access

holes in top cover for greasing spindle units. (Figure C page 21)

STEP 6 Grease wheel axles (4), wheel forks (4), front roller axle (1), and

PTO shaft universal joints (2). (Figure C page 21)

STEP 7 Check air pressure in tires, maintain rated PSI listed on the tire at all

times.

STEP 8 Check all bolts, nuts and belt to insure they are tight and secure.

CAUTION:

DO NOT over fill gearbox. This could cause damage to oil seals and can

cause permanent damage to the gearbox. This issue will not be covered under warranty.

SAFETY TRAINING

z Safety is a primary concern in the design and manufacture of our product.

Unfortunately, our efforts to provide safe equipment can be wiped out by a single careless act of an operator or bystander.

z In addition to the design and configuration of equipment, hazard control

and accident prevention are dependent upon the awareness, concern, prudence and proper training of personnel involved in the operation, transport, maintenance and storage of this equipment.

z It has been said, “ The best safety device is an informed, careful opera-

tor.” We ask you to be that kind of operator. It is the operator’s responsibility to read and understand all safety and operating instructions in the manual and to follow them. Accidents can be avoided.

z Working with unfamiliar equipment can lead to careless injuries. Read

this manual, and the manual for your tractor, before assembly or operating, to acquaint yourself with the machines. If this machine is used by any person other than you, or is loaned or rented, it is the finishing mower owner’s responsibility to make certain that owner's manual be available to the operator prior to operating:

1- Reads and understands the operator’s manuals. 2- Is instructed in safe and proper use.

z Know your controls and how to stop tractor, engine, and the mower quickly

in an emergency. Read this manual and the one provided with your tractor.

z Train all new personnel and review instructions frequently with existing

workers. Be certain only a properly trained and physically able person will operate the machinery. A person who has not read and understood all operating and safety instructions is not qualified to operate the machine. An untrained operator exposes himself and bystanders to possible serious injury or death. If the elderly are assisting with farm work, their physical limitations need to be recognized and accommodated.

PREPARTION

z Never operate the tractor and mower until you have read and completely understand this

manual, the Tractor Operator’s Manual, and each of the safety messages found on the safety signs on the tractor and mower.

z Personal protection equipment including hardhat, safety glasses, safety shoes, and gloves

are recommended during assembly, installation, operation, adjustment, maintenance, repairing, removal, or moving the implement. Do not allow long hair, loose fitting clothing, or jewelry to be around equipment.

z PROLONGED EXPOSURE TO LOUD NOISE MAY CAUSE PERMANENT HEARING

LOSS! Tractors with or without mowers attached can often be noisy enough to cause permanent, partial hearing loss. We recommend that you wear hearing protection on a full-time basis if the noise in the operator’s position exceeds 80 db. Noise over 80 db on a long-term basis can cause severe hearing loss. Noise over 90 db adjacent to the operator over a long-term basis may cause permanent, total hearing loss. NOTE: Hear- ing loss from loud noise (from tractors, chain saws, radios, and other such sources close to the ear) is cumulative over a lifetime without hope of natural recovery.

z Operate the mower only with a tractor equipped with an approved Roll-Over-Protective

System (ROPS). Always wear your seat belt. Serious injury of even death could result from falling off the tractor — particularly during a turnover when the operator could be pinned under the ROPS or the tractor.

z Clear area to be cut of stones, branches or other debris that might be thrown, causing

injury or damage.

z Operate only in daylight or good artificial light. z Ensure mower is properly mounted, adjusted and in good operating condition. z Ensure that all safety shielding and safety signs are properly installed and in good condi-

tion.

STARTING AND STOPPING SAFETY

z Check the tractor master shield over the PTO stub shaft. Make sure it is in good condi-

tion and fastened securely to the tractor. Purchase a new shield if old shield is damaged or missing.

z All tractors that are not equipped with a “live” power takeoff (PTO) need to be equipped

with an over-running PTO clutch. These are available through most farm equipment stores. NOTE: The addition of an over-running PTO clutch may change the length of the PTO driveline required. Pay extra attention to the instructions on the PTO driveline Installation. Be sure that the driveline system guarding is adequate.

z Mower operating power is supplied from tractor PTO. Refer to your tractor manual for

PTO engagement and disengagement instructions. Know how to stop tractor and mower quickly in case of an emergency.

z When engaging PTO, the engine RPM should always be at idle speed. Once engaged

and ready to start cutting, raise PTO speed to 540 RPM and maintain throughout cutting operation.

OPERATIONAL SAFETY

z The use of this equipment is subject to certain hazards that cannot be

protected against by the mechanical means or product design. All operators of this equipment must read and understand this entire manual, paying particular attention to safety and operating instructions, prior to using. If there is something in this manual you do not understand, ask your supervisor, or your dealer, to explain it to you.

z Most accidents occur because of neglect or carelessness. Keep all help-

ers and bystanders at least several hundred feet from an operating finishing mower. Only properly trained people should operate this machine.

z When machine is operated in populated areas where thrown objects could

injure persons or property, operation must be stopped when anyone

comes within several hundred feet.

z The majority of the accidents involve entanglement on the driveline, injury

of bystanders by the objects thrown by the rotating blades, and operators being knocked off the tractor by low hanging limbs and then being run over by the mower. Accidents are most likely to occur with machines that are loaned or rented to someone who has not read the owner’s manual and is not familiar with a finishing mower.

z The finishing mower is designed for use only on tractors with 540-RPM

power take off.

z Install and secure all guards and shields before starting or operating.

The discharge chute, bands, flaps, driveline guards and tractor, shields should be used and maintained in good working condition. They should be inspected carefully, at least daily, for missing or broken cable, chain links, shields, or guards. (Worn items must be replaced at once to reduce possibility of injury)

z Disengage power takeoff (PTO) and place transmission in neutral before

attempting to start engine.

z Many varied objects, such as wire, cable, rope, or chains, can become

entangled in the operating parts of the mower. These items could then swing outside the housing at greater velocities than the blades. Such a situation is extremely hazardous. Inspect the cutting area for such objects before mowing. Remove any like objects from the site.

OPERATIONAL SAFETY continued...

z Never allow the cutting blade to contact such items. Cut material higher

at first, allowing finishing mower to clear hidden objects. Never assume an area is clear. Always Check!

z Always stop the tractor, disengage PTO, set brake, shut off the tractor

engine, remove the ignition key, lower implement to the ground and allow cutter blades to come to a complete stop before dismounting tractor. Never leave equipment unattended with the tractor running.

z Never place hands or feet under mower with tractor engine running or

before you are sure all motion has stopped. Stay clear of all moving parts.

z Do not reach or place any part of your body under equipment until it is

blocked securely.

z Do not allow riders on the finishing mower or tractor at anytime. There is

no safe place for any riders.

z Do not operate unless all personnel, livestock, and pets are several hun-

dred feet away to prevent injury by thrown objects. Never direct discharge chute toward anyone.

z Never operate tractor and finishing mower under trees with low hanging

limbs. Operators can be knocked off the tractor and then run over by the rotating blades.

z The rotating parts of this machine have been designed and tested for

rugged use. However, they could fail upon impact with heavy, solid objects such as steel guardrails and concrete abutment. Such impact could cause the broken objects to be thrown outward at very high velocities. To reduce the possibility of property damage, serious injury, or even death, never allow the cutting blades to contact such obstacles.

z Stop mower and tractor immediately upon striking an obstruction. Turn

engine off, remove key, inspect and repair any damage before resuming operation.

z Stay alert for uneven terrain, holes, rocks, and roots and other hidden

hazards. Keep away from drop-offs and hazards that could cause roll over. Use extreme care and maintain minimum ground speed when transporting or operating on hillsides, over rough ground and when operating close to ditches or fences. Be careful and slow down when turning sharp corners and changing direction on slopes. Do not start or stop suddenly on slopes. Avoid operation on steep slopes. In extremely uneven terrain, rear wheels weights, front tractor weight, and/or tire ballast should be used to improve stability.

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