King Kutter Rotary Mower User Manual
PO Box 1200
305 Commerce Drive
Winfield, Alabama 35594
ROTARY MOWER
OPERATION AND PARTS
MANUAL
Part No 999998 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. ___________________________________________
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It is the purchaser and/or operator’s responsibility to….
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z Read and understand the information contained in this
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manual.
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z Operate, lubricate, assemble and maintain the equip-
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ment in accordance with all instructions and safety procedures in this manual.
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z Inspect the equipment and replace or repair any parts
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that are damaged or worn which under continued operation would cause damage, wear to other parts, or cause
a safety hazard.
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z Return the equipment or parts to the authorized King
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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.)
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z Payment of all costs incurred by the dealer for traveling
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to or transporting the equipment for warranty inspection and or claims.
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CONTENTS
ITEM PAGE
Safety ......................................................................... 6
Assembly Instructions ................................................8
Before Putting Into Service ...................................... 11
Safety Training ......................................................... 12
Operational Safety ................................................... 14
Transportation Safety ............................................... 16
Attaching To Tractor ................................................. 17
Sizing PTO ............................................................... 19
Operating Instructions.............................................. 20
Maintenance ............................................................. 22
Maintenance Safety ................................................. 23
Safety Decal's And Locations................................... 24
PTO Shaft Parts ....................................................... 29
Replacement Parts................................................... 32
PTO Shaft Cover Removal......................................37
Gearbox Parts .......................................................... 40
Warranty ................................................................... 46
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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:
THIS SYMBOL MEANS
ATTENTION!
BECOME ALERT!
YOUR SAFTEY IS INVOLVED
The signal words DANGER, WARNING and CAUTION are used with the
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 injury 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 practices.
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
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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 equip-
ment. You, the operator, can avoid many accidents by observing the following precau-
tions 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.
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z Under no circumstances should children under the age of 18 be allowed to work
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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
assisting with farm work, their physical limitations need to be recognized and accom-
modated.
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
serious 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 mes-
sages 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
rotary mower.
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ROTARY MOWER ASSEMBLY INSTRUCTIONS
STEP 1
Place rotary mower on a flat, level surface. (See Figure A)
STEP 2
Remove the wired on PTO shaft, lift pins, and spacers. Loosen and remove the(4) bolts on the lift arm brackets, that secure the lift arm support
straps, lift arms, and lift arm braces from the shipping positions and set
aside. (See Figure B)
STEP 3
Install the right lift arm and lift arm support strap using (2) two short bolts
and (1) one lift pin. (See Figure C) Note: The lift arm support strap has
one hole punched larger than the other. The larger hole is to be used to
fasten with the lift pin. The lift arm & support straps should be fastened to
the outside of the lift arm bracket.
STEP 4
Loosen and remove the (2) nuts and washers for the A-frame tailwheel
section, leaving the bolts in place. (See Figure D)
STEP 5
Install both the right and left side lift arm braces by sliding them over the
(2) two A-frame tailwheel bolts that were loosened in step 4. Start the
nuts on the bolts, but at this time DO NOT TIGHTEN THEM. Allow the lift
arm braces to rotate forward and rest against the installed lift arm. (See
Figure E)
STEP 6
Install the long top mounting bolt by inserting it through the hole in the
left side lift arm brace, the lower of the (2) two holes in the left side lift
arm, the spacer, the lower of the (2) two holes in the top of the right side
lift arm (which should not be attached to the lift arm bracket at this time),
and finally through the right side lift arm brace. Install a washer and
start the nut on the bolt, but do not tighten it at this time. (See Figure
F,G & H) Note: You may have to move the assembly around to start the
nut & washer. If unable to get the nut and washer started a "C" clamp
may be necessary to compress the assembly to be able to start the nut
& washer. Install the swivel (U-Shaped piece) put mounting bolt through
upper hole in left lift arm, the spacer & swivel, (making sure the 1" block
on swivel is toward the front and rests against front side of the bottom
spacer), then through top hole of right lift arm, install a washer and start
the nut on the bolt, but do not tighten it at this time.
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STEP 7
Using the right side lift arm as a lever, pull to the outside of the lift arm
bracket and inset bolt through lift arm and lift arm bracket. (See Figure I) In-
stall washer and nut. Place the lift pin in the larger of the (2) holes on the lift arm
brace and loosley attach the lift arm. Finally insert bolt, nut and washer to lower
section of lift arm support strap to lift arm bracket. (See Figure J)
STEP 8
Tighten all nuts and bolts.
Figure A Figure B
Figure C Figure D
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Figure E Figure F
Figure G Figure H
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Figure I
BEFORE PUTTING ROTARY 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 rotary 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 Grease (with a grade II type tube grease)
The following zerks:
*Tail wheel wheel fork (See Figure M-1, page 23).
*Tail wheel fork (See Figure M-1, page 23).
*Both U-Joints on the PTO shaft (See Figure M-2, page 23).
STEP 6 Inspect all guards to insure they are in good working order. If not re-
place before using.
STEP 7 Check all bolts and nuts 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.
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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 operator.”
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 rotary 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 work-
ers. 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.
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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, mainte-
nance, 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: Hearing
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
condition.
STARTING AND STOPPING SAFETY
z Check the tractor master shield over the PTO stub shaft. Make sure it is in good
condition 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.
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OPERATIONAL SAFETY
z The use of this equipment is subject to certain hazards that cannot be pro-
tected 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 rotary
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 rotary mower.
z The rotary 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
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 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 en-
tangled 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 mow-
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ing. Remove any like objects from the site.
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