Tiger COUGAR BOOM 7X30, JOHN DEERE 7X30, COUGAR BOOM Mounting And Operating Instructions

Download

Page 1

COUGAR BOOM

Current as of 01/17/2012

JOHN DEERE 7X30

P A RTS LISTING WITH MOUNTING AND OPERATING INSTRUCTIONS

Tiger Corporation

3301 N. Louise Ave.

Sioux Falls, SD 57107

1-800-843-6849

1-605-336-7900

www.tiger-mowers.com

Page 2

TO THE OWNER / OPERATOR / DEALER

All implements with moving parts are potentially hazardous. There is no substitute for a cautious, safe-minded operator who recognizes the potential hazards and follows reasonable safety practices. The manufacturer has designed this implement to be used with all its safety equipment properly attached to minimize the chance of accidents.

BEFORE YOU START!! Read the safety messages on the implement and shown in this manual. Observe the rules of safety and use common sense!

READ AND UNDERSTAND THIS MANUAL! Non–English speaking operators will need to GET THE MANUAL TRANSLATED as needed!

Warranty Information: Read and understand the complete Warranty S tatement found in this manual. Fill out the

Warranty Registration form in full and return it within 90 days. Make certain the Serial Number of the machine is

recorded on the Warranty Card, and form that you retain.

Page 3

FORWARD

This manual contains information about many features of the T iger mowing and roadside maintenance equipment. Some of these include: Safety precautions, Assembly instructions, Operations, Maintenance and Parts. This manual will also assist you in the proper break-in, daily care, andtroubleshooting of your new mower .

We recommend that you read carefully the entire manual before operating the unit. Also, time spent in becoming fully acquainted with its performance features, adjustments, and maintenance schedules will be repaid in a long and satisfactory life of the equipment.

T roubleshooting - Please, before you call, help us to help you!

Please look at the equipment to observe what is happening, then:

• Classify the problem

• Hydraulic, electrical or mechanical - Read the trouble shooting section

• Tractor or T ruck chassis - Contact vehicle dealer

• If unable to correct the problem yourself, contact your local Tiger Dealer after

gathering:

• Machine model _______________________

• Serial number ________________________

• Dealer name _________________________

• Detailed information about the problem including results of troubleshooting

Attention Owner / Operator / Dealer: It is your obligation to read, and understand, the warranty information section located at the back of this manual denoting that the purchaser understands the safety issues relating to this machine and has received and will read a copy of this manual.

If at any time, you have a service problem with your Tiger mower , Contact your local dealer for service and parts needed.

MANUF ACTURED BY: DISTRIBUTED BY : Tiger Corporation _____________________ 3301 N. Louise Ave. _____________________ Sioux Falls, SD 57107 1-_____-_____-________ 1-800-843-6849 1-_____-_____-________ 1-605-336-7900 www .tiger-mowers.com

Page 4

JD 7X30 COUGAR FORW ARD

Page 5

T ABLE OF CONTENTS

SAFETY_____________________________________________ 1-1

Safety Information__________________________________ 1-2 ASSEMBLY / MOUNTING SECTION_______________________2-1 OPERATION SECTION_________________________________ 3-1 MAINTENANCE SECTION______________________________ 4-1 PARTS SECTION_____________________________________ 5-1

Parts Ordering Guide_______________________________ 5-2

Parts Table of Contents_______________________________ 5-3

COMMON SABER SECTION______________________________ 6-1 WARRANTY INFORMA TION_____________________________ 7-1

This symbol means:

CAUTION – YOUR SAFETY IS AT RISK!

When you see this symbol, read and

follow the associated instructions carefully

or personal injury or damage may result.

Tiger is a registered trademark.

Page 6

Page 7

JD 7X30 COUGAR

SAFETY

SECTION

Safety Section 1-1

Page 8

SAFETY

A safe and careful operator is the best operator. Safety is of primary importance to the manufacturer and should be to the owner / operator. Most accidents can be avoided by being aware of your equipment, your surroundings, and observing certain precautions. The first section of this manual includes a list of Safety Messages that, if followed, will help protect the operator and bystanders from injury or death. Read and understand these Safety Messages before assembling, operating or servicing this mower. This equipment should only be operated by those persons who have read the Manual, who are responsible and trained, and who know how to do so safely and responsibly.

The Safety Alert Symbol combined with a Signal Word, as seen below, is used throughout this manual and on decals which are attached to the equipment. The Safety Alert Symbol means: “ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!” The symbol and signal word are intended to warn the owner / operator of impending hazards and the degree of possible injury when operating this equipment.

Practice all usual and customary safe working precautions and

above all -- remember safety is up to YOU! Only YOU can

prevent serious injury or death from unsafe practices.

This is the Safety Alert Symbol. When you see this symbol on your machine or in these instructions, be alert to the potential for personal injury .

The lowest level of Safety Message; warns of possible injury. Decals located on the equipment with this signal word are Black and Yellow.

Serious injury or possible death! Decals are Black and Orange.

Imminent death / critical injury . Decals are Red and White.

READ, UNDERSTAND , and FOLLOW the following Safety

Messages. Serious injury or death may occur unless care is taken to follow the warnings and instructions stated in the Safety Messages. Always use good common sense to avoid hazards. (SG-2)

JD 7X30 COUGAR Safety Section 1-2

Page 9

SAFETY

PELIGRO!

DANGER!

WARNING!

Si no lee Ingles, pida ayuda a alguien que si lo lea para que le traduzca las medidas de seguridad. (SG-3)

Never operate the Tractor or Implement until you have read and completely understand this Manual, the Tractor Operator’s Manual, and each of the Safety Messages found in the Manual or on the Tractor and Implement. Learn how to stop the tractor engine suddenly in an emergency. Never allow inexperienced or untrained personnel to operate the Tractor and Implement without supervision. Make sure the operator has fully read and understood the manuals prior to operation. (SG-4)

Always maintain the safety decals in good readable condition. If the decals are missing, damaged, or unreadable, obtain and install replacement decals immediately. (SG-5)

Make certain that the “Slow Moving Vehicle” (SMV) sign is installed in such a way as to be clearly visible and legible. When transporting the Equipment use the Tractor flashing warning lights and follow all local traffic regulations. (SG-6)

LEA EL

INSTRUCTIVO!

WARNING!

DANGER!

Operate this Equipment only with a Tractor equipped with an approved roll-over-protective system (ROPS). Always wear seat belts. Serious injury or even death could result from falling off the tractor--particularly during a turnover when the operator could be pinned under the ROPS. (SG-7)

Do not modify or alter this Implement. Do not permit anyone to modify or alter this Implement, any of its components or any Implement function. (SG-8)

BEFORE leaving the tractor seat, always engage the brake and/or set the tractor transmission in parking gear, disengage the PTO, stop the engine, remove the key, and wait for all moving parts to stop. Place the tractor shift lever into a low range or parking gear to prevent the tractor from rolling. Never dismount a Tractor that is moving or while the engine is running. Operate the Tractor controls from the tractor seat only.

(SG-9)

JD 7X30 COUGAR Safety Section 1-3

Page 10

SAFETY

DANGER!

WARNING!

DANGER!

Never allow children or other persons to ride on the Tractor or Implement. Falling off can result in serious injury or death.

(SG-10)

Never allow children to operate or ride on the Tractor or Implement.

(SG-11)

Do not mount the Tractor while the tractor is moving. Mount the Tractor only when the Tractor and all moving parts are completely stopped. (SG-

12)

Start tractor only when properly seated in the Tractor seat. Starting a tractor in gear can result in injury or death. Read the Tractor operators manual for proper starting instructions. (SG-13)

DANGER!

Never work under the Implement, the framework, or any lifted component unless the Implement is securely supported or blocked up to prevent sudden or inadvertent falling which could cause serious injury or even death. (SG-14)

DANGER! Do not operate this Equipment with hydraulic oil leaking. Oil is

expensive and its presence could present a hazard. Do not check for leaks with your hand! Use a piece of heavy paper or cardboard. Highpressure oil streams from breaks in the line could penetrate the skin and cause tissue damage including gangrene. If oil does penetrate the skin, have the injury treated immediately by a physician knowledgeable and skilled in this procedure. (SG-15)

JD 7X30 COUGAR Safety Section 1-4

Page 11

SAFETY

WARNING! The operator and all support personnel should wear hard hats,

safety shoes, safety glasses, and proper hearing protection at all times for protection from injury including injury from items thrown by the equipment. (SG-16)

CAUTION!

WARNING!

PROLONGED EXPOSURE TO LOUD NOISE MAY CAUSE PERMANENT HEARING LOSS! Tractors with or without an Implement at-

tached can often be noisy enough to cause permanent hearing loss. We recommend that you always wear hearing protection if the noise in the Operator’s position exceeds 80db. Noise over 85db over an extended period of time will cause severe hearing loss. Noise over 90db adjacent to the Operator over an extended period of time will cause permanent or 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. (SG-I7)

Transport only at safe speeds. Serious accidents and injuries can result from operating this equipment at unsafe speeds. Understand the T ractor and Implement and how it handles before transporting on streets and highways. Make sure the Tractor steering and brakes are in good condition and operate properly .

Before transporting the Tractor and Implement, determine

the safe transport speeds for you and the equipment.

Make

sure you abide by the following rules:

T est the tractor at a slow speed and increase the speed slowly. Apply the Brakes smoothly to determine the stopping characteristics of the Tractor and Implement. As you increase the speed of the Tractor the stopping distance increases. Determine the maximum safe transport speed for you and this Equipment.

Test the equipment at a slow speed in turns. Increase the speed

through the turn only after you determine that it is safe to operate at a higher speed. Use extreme care and reduce your speed when turning sharply to prevent the tractor and implement from turning over. Determine the maximum safe turning speed for you and this equipment before operating on roads or uneven ground.

Only transport the Tractor and Implement at the speeds that you

have determined are safe and which allow you to properly control the equipment.

Be aware of the operating conditions. Do not operate the Tractor with weak or faulty brakes. When operating down a hill or on wet or rain slick roads, the braking distance increases: use extreme care and reduce your speed. When operating in traffic always use the Tractor’s flashing warning lights and reduce your speed. Be aware of traffic around you and watch out for the other guy. (SG-19)

JD 7X30 COUGAR Safety Section 1-5

Page 12

SAFETY

WARNING! Never attempt to lubricate, adjust, or remove material from the

Implement while it is in motion or while tractor engine is running. Make sure the tractor engine is off before working on the Implement.

(SG-20)

WARNING!

DANGER!

Periodically inspect all moving parts for wear and replace when necessary with authorized service parts. Look for loose fasteners, worn or broken parts, and leaky or loose fittings. Make sure all pins are properly secured. Serious injury may occur from not maintaining this machine in good working order. (SG-21)

Always read carefully and comply fully with the manufacturers instructions when handling oil, solvents, cleansers, and any other chemical agent. (SG-22)

Never run the tractor engine in a closed building or without adequate ventilation. The exhaust fumes can be hazardous to your health.

(SG-23)

DANGER!

KEEP AWAY FROM ROTATING ELEMENTS to prevent entanglement and possible serious injury or death. (SG-24)

Never allow children to play on or around Tractor or Implement. Children can slip or fall off the Equipment and be injured or killed. Children can cause the Implement to shift or fall crushing themselves or others. (SG-25)

JD 7X30 COUGAR Safety Section 1-6

Page 13

SAFETY

DANGER!

DANGER! Operate the Tractor and/or Implement controls only while properly seated

WARNING!

NEVER use drugs or alcohol immediately before or while operating the

Tractor and Implement. Drugs and alcohol will affect an operator’s alertness and coordination and therefore affect the operator’s ability to operate the equipment safely. Before operating the Tractor or Implement, an operator on prescription or over-the-counter medication must consult a medical professional regarding any side effects of the medication that would hinder their ability to operate the Equipment safely. NEVER knowingly allow anyone to operate this equipment when their alertness or coordination is impaired. Serious injury or death to the operator or others could result if the operator is under the influence of drugs or alcohol. (SG-27)

in the Tractor seat with the seat belt securely fastened around you. Inadvertent movement of the Tractor or Implement may cause serious injury or death. (SG-29)

Mow only in conditions where you have clear visibility in daylight or with adequate artificial lighting. Never mow in darkness or foggy conditions where you cannot clearly see at least 100 yards in front and to the sides of the tractor and mower. Make sure that you can clearly see and identify passersby, steep slopes, ditches, drop-offs, overhead obstructions, power lines, debris and foreign objects. If you are unable to clearly see this type of items discontinue mowing. (SGM-1)

DANGER!

DANGER! All Safety Shields, Guards and Safety devices including

There are obvious and hidden potential hazards in the operation of this Mower. REMEMBER! This machine is often operated in heavy brush and in heavy weeds. The Blades of this Mower can throw objects if shields are not properly installed and maintained. Serious injury or even death may occur unless care is taken to insure the safety of the operator, bystanders, or passersby in the area. Do not operate this machine with anyone in the immediate area. Stop mowing if anyone is within 100 yards of mower. (SGM-2)

(but not limited to) - the Deflectors, Chain Guards, Steel Guards, Gearbox Shields, PTO integral shields , and Retractable Door Shields should be used and maintained in good working condition. All safety devices should be inspected carefully at least daily for missing or broken components. Missing, broken, or worn items must be replaced at once to reduce the possibility of injury or death from thrown objects, entanglement, or blade contact. (SGM-3)

JD 7X30 COUGAR Safety Section 1-7

Page 14

SAFETY

DANGER!

WARNING!

The rotating parts of this machine have been designed and tested for rugged use. However, the blades could fail upon impact with heavy, solid objects such as metal guard rails and concrete structures. 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.

(SGM-4)

Extreme care should be taken when operating near loose objects such as gravel, rocks, wire, and other debris. Inspect the area before mowing. Foreign objects should be removed from the site to prevent machine damage and/or bodily injury or even death. Any objects that cannot be removed must be clearly marked and carefully avoided by the operator. Stop mowing immediately if blades strike a foreign object. Repair all damage and make certain rotor or blade carrier is balanced before resuming mowing.

(SGM-5)

Many varied objects, such as wire, cable, rope, or chains, can become entangled in the operating parts of the mower head. These items could then swing outside the housing at greater velocities than the blades. Such a situation is extremely hazardous and could result in serious injury or even death. Inspect the cutting area for such objects before mowing. Remove any like object from the site. Never allow the cutting blades to contact such items. (SGM-6)

WARNING!

Mow at the speed that you can safely operate and control the tractor and mower. Safe mowing speed depends on terrain condition and grass type, density, and height of cut. Normal ground speed range is from 0 to 5 mph. Use slow mowing speeds when operating on or near steep slopes, ditches, drop-offs, overhead obstructions, power lines, or when debris and foreign objects are to be avoided. (SGM-7)

Avoid mowing in reverse direction when possible. Check to make sure there are no persons behind the mower and use extreme care when mowing in reverse. Mow only at a slow ground speed where you can safely operate and control the tractor and mower. Never mow an area that you have not inspected and removed debris or foreign material. (SGM-8)

Do not put hands or feet under mower decks. Blade Contact can result serious injury or even death. Stay away until all motion has stopped and the decks are securely blocked up. (SGM-9)

DANGER!

Replace bent or broken blade with new blades. NEVER ATTEMPT TO STRAIGHTEN OR WELD ON BLADES SINCE THIS WILL LIKELY CRACK OR OTHERWISE DAMAGE THE BLADE WITH SUBSEQUENT FAILURE AND POSSIBLE SERIOUS INJURY FROM THROWN BLADES. (SGM-10)

JD 7X30 COUGAR Safety Section 1-8

Page 15

WARNING!

SAFETY

Do not mow with two machines in the same area except with Cab tractors with the windows closed.

(SGM-11)

DANGER!

Rotary and Flail Mowers are capable under adverse conditions of throwing objects for great distances

(100 yards or more) and

causing serious injury or death. Follow safety messages carefully.

STOP MOWING IF PASSERSBY ARE WITHIN 100 YARDS UNLESS:

-Front and Rear Deflectors are installed and in good,

working condition;

-Mower Head is running close to and parallel to the ground

without exposed Blades;

-Passersby are outside the existing thrown-object zone;

-All areas have been thoroughly inspected and all foreign

material such as rocks, cans, glass, and general debris

has been removed.

NOTE:

Where there are grass and weeds high enough to hide debris that could be struck by the blades, the area should be: inspected and large debris removed, mowed at an intermediate height, inspected closely with any remaining debris being removed, and mowed again at desired final height.

(SBM-1)

Use extreme caution when raising the Mower head. Stop the Blades from turning when the Mower Head is raised and passersby are within 100 yards. Raising the Mower head exposes the Cutting Blades which creates a potentially serious hazard and can cause serious injury by objects thrown from the Blades or by contact with the Blades.

(SBM-2)

DANGER!

Be particularly careful in transport. The Mower has raised the center

of gravity for the tractor and has increased the possibility of overturn. Turn

curves or go up slopes only at low speed and using a gradual turning angle. Slow down on rough or uneven surfaces. (SBM-3)

WARNING!

Never Leave the mower unattended while the head is in the raised position. The mower could fall causing serious injury to anyone who might inadvertently be under the mower.

WARNING!

The rotating parts of this machine continue to rotate even after the Tractor has been turned off. The operator should remain in his seat for 60 seconds after the brake has been set, the PTO disengaged, the tractor turned off, and all evidence of rotation has ceased. (SBM-5)

“Wait a minute...Save a life!”

(SBM-4)

JD 7X30 COUGAR Safety Section 1-9

Page 16

SAFETY

Relieve hydraulic pressure prior to doing any maintenance or repair work on the Implement. Place the Mower Head on the ground or securely supported on blocks or stands, disengage the PTO, and turn off the engine. Push and pull the control Levers or Joystick several times to relieve pressure prior to starting any maintenance or repair work.

(SBM-6)

DANGER!

Always keep a careful lookout and use extreme care when working around overhead obstructions. Never allow the Mower head or boom within 10 feet of any power line. When working close to overhead power lines consult your electric company for a safe code of operation.

(SBM-7)

When transporting Boom Mower on a truck or trailer, the height or width may exceed legal limits when the boom is in the transport position. Contact with side or overhead structures or power lines can cause property damage or serious injury or death. If necessary lower boom to reduce height and/or remove mowing head to reduce width to the legal limits. (SBM-8)

Never operate the Tractor and Mower Unit without an OPS (Operators Protective Structure) or Cab to prevent injury from objects thrown from ground or from overhead trimming. Stop mowing if workers or passersby are with in 100 yards. (SBM-9)

Each Rear Wheel must have a minimum of 1500 pound contact with the surface to prevent lateral instability and possible tip-over which could result in serious bodily injury or even death. Widen the wheel tread and add weights if needed. Refer to the mounting instructions or call Customer Service if you need assistance with Couterweight Procedure. (SBM-11)

DANGER!

Always disconnect the wire leads from the mower pump solenoid before performing service on the Tractor or Mower. Use caution when working on the Tractor or Mower. Tractor engine must be stopped before working on Mower or Tractor. The Mower Blades could inadvertently be turned on without warning and cause immediate dismemberment, injury or death. (SBM-12a)

DANGER!

The flail cutter shaft is designed for standard rotation (same rotation as the tractor wheels during forward travel). Never operate the cutter shaft in the reverse rotation. Operating this mower in reverse rotation may cause objects to be thrown out the front of the mower head.

JD 7X30 COUGAR Safety Section 1-10

Page 17

SAFETY

WARNING!

Engine Exhaust, some of its constituents, and certain components contain or emit chemicals known to the state of California to cause cancer and birth or other reproductive harm.

WARNING!

Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the state of California to cause cancer and birth or other reproductive harm. Wash hands after handling!

Tiger mowers use balanced and matched system components for blade carriers, blades, cutter-shafts, knives, knife hangers, rollers, drive-train components and bearings. These parts are made and tested to Tiger specifications. Non-genuine “will fit” parts do not consistently meet these specifications. The use of “will fit” parts may reduce mower performance, void mower warranties and present a safety hazard. Use genuine Tiger mower p arts for economy and safety.

SEE YOUR DEALER

In addition to the design and configuration 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 operation, 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 Equipment Manuals. Pay close attention to the Safety Signs affixed to the Tractor and Equipment. (SG-18)

JD 7X30 COUGAR Safety Section 1-11

Page 18

SAFETY

P ART NO. LOCA TION

002369

HYDRAULIC T ANK

00725746

INSIDE OF CAB

00769737

MOWER DECK

JD 7X30 COUGAR Safety Section 1-12

Page 19

SAFETY

P ART NO. LOCA TION

00758194

MOWER DECK

02962764

MAIN BOOM, SECONDARY BOOM, MAIN FRAME

02962765

MAIN FRAME

02965262

HYDRAULIC T ANK

JD 7X30 COUGAR Safety Section 1-13

Page 20

SAFETY

P ART NO. LOCA TION

02967668

MOWER DECK

02971123

HYDRAULIC T ANK

03200285

OUTSIDE OF CAB

22645

INSIDE OF CAB

22839

MOWER DECK

JD 7X30 COUGAR Safety Section 1-14

Page 21

SAFETY

P ART NO. LOCA TION

22840

INSIDE OF CAB

24028

MOWER DECK

25387

INSIDE OF CAB

10” x 5.5” 31522 MOWER DECK, MAIN BOOM

18.25” x 10” 31523 HYDRAULIC T ANK

13.5” x 7” 31513

JD 7X30 COUGAR Safety Section 1-15

Page 22

SAFETY

P ART NO. LOCA TION

27001

INSIDE OF CAB

31935

INSIDE OF CAB

JD 7X30 COUGAR Safety Section 1-16

32707

HYDRAULIC T ANK

42350

MOWER DECK

Page 23

SAFETY

P ART NO. LOCA TION

32708

HYDRAULIC T ANK

32709

INSIDE OF CAB

JD 7X30 COUGAR Safety Section 1-17

33224

MOWER DECK

33438

MAIN BOOM

Page 24

SAFETY

P ART NO. LOCA TION

06550012 INSIDE OF CAB

33743

INSIDE OF CAB

JD 7X30 COUGAR Safety Section 1-18

Page 25

SAFETY

P ART NO. LOCA TION

RED 42399 REFLECTIVE T APE

MOWER DECK

AMBER 4240006 REFLECTIVE T APE

MOWER DECK

6T3217

MOWER DECK

6T3219

INSIDE OF CAB

6T3220

FRONT PUMP MOUNT

JD 7X30 COUGAR Safety Section 1-19

Page 26

SAFETY

P ART NO. LOCA TION

6T3221

INSIDE OF CAB

6T3222

INSIDE OF CAB

6T3224

MOWER DECK

6T3225

INSIDE OF CAB

JD 7X30 COUGAR Safety Section 1-20

Page 27

SAFETY

P ART NO. LOCA TION

6T3230

INSIDE OF CAB

6T3231

INSIDE OF CAB

6T3233

HYDRAULIC T ANK

6T3234

INSIDE OF CAB

6T3236

MOWER DECK

JD 7X30 COUGAR Safety Section 1-21

Page 28

SAFETY

P ART NO. LOCA TION

6T3237

INSIDE OF CAB

06550008

INSIDE OF CAB

6T3243

INSIDE OF CAB

6T3249A

MOWER DECK

6T3261

MOWER DECK

JD 7X30 COUGAR Safety Section 1-22

Page 29

SAFETY

TB1011

MOWER DECK

34852

HYDRAULIC TANK

JD 7X30 COUGAR Safety Section 1-23

Page 30

SAFETY

ITEM PART NO. QTY. DESCRIPTION

50023 AVAIL MANUAL CANISTER COMPLETE

1 00776031 1 ROUND MANUAL CANISTER

33997 1 DECAL, SHEET, MANUAL CANISTER 2 * DECAL 3 * DECAL 4 * DECAL 5 * AVAIL SPECIFIC PRODUCT MANUAL 6 33753 1 E M I SAFETY MANUAL 7 34296 1 FRONT ADHESIVE PAD 8 34297 1 REAR ADHESIVE PAD 9 6T1823 4 ZIP TIE 14” LONG

NOTE:

The manual canister can be bolted, zip tied or adhered to a variety of surfaces. Locate a protected area within the view of the operator. Then select an installation method and attach the canister . CAUTION - AVOID DRILLING HOLES INTO UNKNOWN AREAS, wires and other parts may be located behind these areas. When adhering the canister to a surface, thoroughly clean that surface before installing the canister .

JD 7X30 COUGAR Safety Section 1-24

Page 31

SAFETY

FEDERAL LAWS AND REGULATIONS

This section is intended to explain in broad terms the concept and effect of federal laws and regulations concerning employer and employee equipment operators. This section is not intended as a legal interpretation of the law and should not be considered as such.

Employer-Employee Operator Regulations

U.S. Public Law 91-596 (The Williams-Steiger Occupational and Health Act of 1970) OSHA

This Act Seeks:

“...to assure so far as possible every working man and woman in the nation safe and healthful working conditions and to preserve our human resources...”

DUTIES

Sec. 5 (a) Each employer(1) shall furnish to each of his employees employment and a place of employment which are free from recognized hazards that are causing or are likely to cause death or serious physical harm to his employees; (2) shall comply with occupational safety and health standards promulgated under this Act. (b) Each employee shall comply with occupational safety and health standards and all rules, regulations and orders issued pursuant to this Act which are applicable to his own actions and conduct.

OSHA Regulations

OSHA regulations state in part: “At the time of initial assignment and at least annually thereafter , the employer shall instruct every employee in the safe operation and servicing of all equipment with which the employee is, or will be involved.”

Employer Responsibilities:

T o ensure employee safety during Tractor and Implement operation, it is the employer’s responsibility to:

1. Train the employee in the proper and safe operation of the T ractor and Implement.

2. Require that the employee read and fully understand the Tractor and Implement Operator’s manual.

3. Permit only qualified and properly trained employees to operate the Tractor and Implement.

4. Maintain the Tractor and Implement in a safe operational condition and maintain all shields and guards on the equipment.

5. Ensure the Tractor is equipped with a functional ROPS and seat belt and require that the employee operator securely fasten the safety belt and operate with the ROPS in the raised position at all times.

6. Forbid the employee operator to carry additional riders on the Tractor or Implement.

7. Provide the required tools to maintain the T ractor and Implement in a good safe working condition and provide the necessary support devices to secure the equipment safely while performing repairs and service.

Child Labor Under 16 Years of Age

Some regulations specify that no one under the age of 16 may operate power machinery. It is your responsibility to know what these regulations are in your own area or situation. (Refer to U.S. Dept. of Labor, Employment Standard Administration, W age & Home Division, Child Labor Bulletin #102.)

JD 7X30 COUGAR Safety Section 1-25

Page 32

SAFETY

JD 7X30 COUGAR Safety Section 1-26

Page 33

Page 34

Page 35

Page 36

Page 37

Page 38

Page 39

Page 40

Page 41

Page 42

Page 43

Page 44

Page 45

Page 46

Page 47

PLUMBING DECK ROTATION ON TRACTOR REMOTES

Hose 34358 to main boom shall be connected to quick disconnects and connected to ports A and B of tractor remote valve #1. This should provide Deck Rotation function such that moving remote valve lever “forward” will cause deck to rotate “counter-clockwise” and moving lever “aft” will cause deck to rotate “clockwise”. Note that the flow control for this tractor remote valve should be adjusted to rotate deck from the full “clockwise” position to the full “counter-clockwise” position in 15-20 seconds.

Page 48

Page 49

Page 50

Page 51

Page 52

Page 53

Page 54

Page 55

Page 56

Page 57

Page 58

Page 59

Page 60

Page 61

Page 62

Page 63

Page 64

Page 65

JD7X30 COUGAR

OPERATION

SECTION

Operation Section 3-1

Page 66

OPERATION

Safety is of primary importance to the owner / operator and to the manufacturer.

The first section of this manual includes a list of Safety Messages, that, if followed, will help protect the operator and bystanders from injury or death. Many of the messages will be repeated throughout the manual. The owner / operator / dealer should know these Safety Messages before assembly and be aware of the hazards of operating this mower during assembly, use, and maintenance.

The Safety Alert Symbol combined with a signal word, as seen below, is intended to warn the owner / operator of impending hazards and the degree of injury possible during operation.

The lowest level of Safety Message; Warns of possible minor injury. Decals located on the cutter with this Signal Word are Black and Yellow.

Serious injury or possible death! Decals are Black and Orange.

Imminent death / critical injury . Decals are Red and White.

WARNING!

Before any operation of tractor and mower, the user should read and understand the safety and operating instructions for both the tractor and the mower. The user should also be familiar with the location and functions of the units instruments and controls. Being familiar with the

machine and it’s controls will increase efficiency and reduce possibility of serious injury or damage to the unit. The operator should work slowly and carefully until he feels comfortable with the machine. Speed and skill will be att ained much easier if the necessary time is spent to familiarize yourself with the machine and its operations.

Since tractor makes and models vary, we recommend reading and following the

operators manual provided by the manufacturer pertaining to your particular unit.

WARNING!

JD 7X30 COUGAR Operation Section 3-2

Page 67

OPERATION

STARTING TRACTOR AND MOWER

Check the operators manual received from the tractor manufacturer, for

their recommendation and procedures pertaining to your particular make and model.

When rotating parts are in motion, serious injury may occur if caution is

not used or danger is not recognized. Never allow bystanders within 300

feet of the machine when mower is in operation.

Be sure the ball valves on the mower hydraulic tank are OPEN before

starting the tractor. Serious damage to the hydraulic system can occur if

the valves are not open.

Check to make sure mower switch is in the “OFF” position. The unit is

designed not to start if the switch is in the “on” position. If tractor starts

with switch on, turn off tractor and contact your local Tiger dealership for

assistance.

Start the tractor and allow the instrument s to stabilize. Without starting the mower, practice positioning the boom and deck. Remember, speed and skill will be attained easier if the necessary time is spent familiarizing yourself with the machine and its operations. When you feel comfortable at controlling the position of the mower , return the mower to the travel position, and transport the mower to the desired mowing location.

NOTE: Each mower head has a specific resting position for flatbed travel.

If mowing for the first time with a Tiger Boom Mower, we recommend choosing a ditch or area relatively flat with a minimum of sign posts, guard rails, etc. As always, you should inspect the area for other objects that can cause potential hazards and removing them before mowing.

The Mower Control switch turns the mower “ON” and “OFF. This switch is to be in

the “OFF” position to start the tractor. If the switch is “ON” and the tractor ignition switch is turned to “ON” the red “mower run” indicator light will come on. However, the tractor will not start with the Mower Control switch in the “ON” position. Upon starting tractor the “mower run” indicator light may flash briefly , and may flash briefly again when tractor is shut down.

If tractor starts with switch on, turn off tractor and contact your local Tiger dealership for assistance.

NOTE: The tractor ignition switch and the Master Switch must be “ON” ” to allow movement of the mower deck.

JD 7X30 COUGAR Operation Section 3-3

Page 68

OPERATION

CABLE CONTROLLED MOWERS

A control lever decal similar to the one shown below should be near the control valve to remind the operator of the lever functions.

The main control valve on the Tiger Rear Stow Boom has multiple sections with tapered spools, located near the right side of the steering wheel. The malfunction of a section of the valve does not necessitate the replacement of the entire “bank”, only the faulty section. Each section of the valve controls a certain position of the boom or deck. Seated in the operators seat, the controls from left to right are #1 - primary(main) boom, #2 – secondary boom, #3 – deck roll, #4 – boom (swivel)swing & knuckle boom, and #5 boom(safety) shield.

Lever #4 is set up to be used for both the swivel function and the knuckle function. When using the knuckle, stop any movement of the boom. Then push the button on the end of Lever #4. At this time the indicator light on the switch box will light up, telling you the knuckle funcion is activated. You will then be able to straighten the knuckle and move it backward.

To switch back to the swivel function, stop any movement to the boom. Push the button on the end of Lever #4. The indicator light will shut off, letting you know that the swivel is now active.

NOTE: The mower head can still move if the switch box has no power.

JD 7X30 COUGAR Operation Section 3-4

Page 69

OPERATION

LEVER #1

MAIN BOOM

LEVER #2

SECONDARY BOOM

LEVER #3

DECK ROLL

LEVER #4

BOOM SWIVEL

INDICATOR LIGHT OFF

LEVER #4

WITH BUTTON PRESSED

BOOM KNUCKLE

INDICATOR LIGHT ON

LEVER # 5

BOOM SHIELD

SWIVEL

KNUCKLE

JD 7X30 COUGAR Operation Section 3-5

Page 70

OPERATION

SWITCHBOX

The Safety Shield lever opens and closes the shield located on the front of the cutter head. When mowing at or near the ground, always have the shield in the closed position. When mowing in brush or in trees above ground level the shield may be opened for easier cutting. Read and follow the warnings on the decal shown below. Do not run the cutter head into material larger than 6” diameter.

JD 7X30 COUGAR Operation Section 3-6

Page 71

OPERATION

MOWER OPERATION

When rotating parts are in motion, serious injury may occur if caution is not used or danger is not recognized. Never allow bystanders within 300 feet of the machine when in operation. Extreme care should be taken when operating near loose objects – such as gravel, rocks and debris. These conditions should be avoided.

The rotating parts in this machine have been designed and tested for rugged use. However, they could fail upon impact with heavy solid objects – such as steel guard rails, concrete abutments, etc., causing them to be thrown at a very high velocity . Never allow cutter head to contact such objects. Inspecting the cutting area for such objects and removing them prior to mowing can help eliminate these potential hazards.

Once on location, lower the mower deck slightly above the material to be cut, so the mower does not have to start under a load. With the tractor at an idle, engage mower. Bring tractor R.P.M. up to 1900 – 2200 R.P .M. and slowly lower deck to ground level.

A flail mower deck should be carried so that part of the deck weight is carried by the boom and part carried by the ground roller , when mowing on the ground. When the flail mower is carried this way, the ground roller follows the contour of the ground more easily during mowing operations.

The rotary mower deck should always be carried rather than dragged on the skid shoes when mowing on the ground. Dragging the rotary mower deck increases the side loads on the boom, decreases the horsepower available to the cutter head, and reduces the ability of the accumulator the carry part of the weight of the boom during mowing operations.

During mower operation, the hand throttle must be used to maintain engine speed at1900 – 2200 R.P .M. This prevent s radical changes in mower spindle speeds, reducing the possibility of cutter assembly damage.

The horizontal positioning action of the boom is designed to position the cutting head and provide a limited pressure relief when excessive pressure is applied to the boom. Do not force the cutting head into heavy branches or stumps. Damage to the unit may result.

When using the rotary cutting head for trimming trees and shrubs, let the mower saw into them. Do not lower the mower head down directly onto a tree or stump. The mower blades are designed to cut with the end, and misuse can cause damage to the blade and a hazardous situation for the operator.

Powering the boom down, forcing mower deck onto ground may damage mower deck and it’s attachment to the boom, creating a potentially hazardous situation.

JD 7X30 COUGAR Operation Section 3-7

Page 72

OPERATION

T o ensure a clean cut, engine speed should be maint ained at approximately 1900 – 2200 R.P.M. If the tractor slows to less than 1800 R.P.M., shift to the next lower gear. DO NOT ride the clutch, this will cause premature clutch failure. The engine should

not be operated at any time at more than 2400 R.P.M. on the tractor tachometer.

For cutting brush it is usually best to stop the tractor and swivel the boom and mower into foliage. The horizontal positioning action of the boom is designed to position the cutting head and provide a limited pressure relief when excessive pressure is applied to the boom.

DO NOT use excessive force when positioning cutting head into heavy branches or stumps. Damage to the unit may result. It is best to let the cutter head “eat away” slowly at heavy cutting jobs.

If foliage falls on top of mower deck causing tractor to become unstable, move the boom “Forward” and “Out” to relieve tipping of the tractor. Lower mower deck to ground and shut down unit. Af ter all motion stops, remove foliage from mower deck.

The mower will operate more efficiently in tougher conditions and with less power if the knives are kept sharp. If the mower begins to vibrate, stop the tractor, check for wire wrapped in the spindle or damaged knives. When replacing knives, replace all knives with new knives to ensure proper balance so the mower will not vibrate. Severe vibration will result, if knives with unequal wear are used.

Begin a pass at the top side of the trees and work down with each consecutive pass. When cutting trees and shrubs, use a lower speed to allow the knives time to cut as well as mulch the foliage.

If bystanders approach within 300 feet while mower is in operation turn mower switch “OFF” immediately! Af ter shutdown, never leave the tractor or allow bystanders to approach within 300 FEET of the unit until all motion stops completely.

If cutter shaft jams and stops, turn mower switch to “OFF”, and swivel boom “AFT”. Normally this action will clear the cutter head. If not, roll mower deck until adjacent to the secondary boom, then lower boom to rest mower deck on ground. Shut off the tractor, set p arking break, allow all motion to cease. At that point it is safe to leave the tractor and clear the cutter heads manually .

Begin each pass at the top side of the trees and work down with each consecutive pass. Use a low speed to allow the cutting blades time to mulch as well as cut the foliage. When the initial pass has been made, disengage the mower , and return boom to a safe travel position. Return to starting point and make next pass, etc..

After the first day of operation, all bolts should be checked and tightened securely. This should be done periodically to ensure the bolts do not become loose and cause damage to the tractor or mower, or injury to the operator.

JD 7X30 COUGAR Operation Section 3-8

Page 73

OPERATION

DANFOSS JOYSTICK CONTROLLED MOWERS

NOTE: DO NOT operate mower head while boom mower is in the boom rest, or in the stored position! Red “Mower Run” light indicates mower is “ON”.

The boom functions are controlled by an electronic joystick. The Joystick Master Switch enables the joystick control for controlling the boom motion functions. This switch is to be in the “OFF” position when starting the tractor and when boom is stowed for transporting the machine.

If the joystick control is not operating properly , turn the master switch to the “OFF” position. Install the manual valve handle onto valve and operate the functions individually to stow boom. After boom is stowed in rest, transport the unit to the maintenance facility and contact your T iger dealer for assistance.

DO NOT attempt to operate the valve manually for mowing operations!

Note: Pushing manual valve handles “out” or “away” from the tractor cab will bring the main boom “up”, secondary boom “out”, roll deck “out”, and swivel boom “aft”. Pulling manual handles toward cab will let main boom “down”, bring secondary boom “in”, roll deck “in”, and swivel boom “forward”.

MAIN CONTROL SWITCH BOX

JD 7X30 COUGAR Operation Section 3-9

Page 74

OPERATION

DANFOSS JOYSTICK CONTROL AND

SWITCH BOX

The diagrams below and on the following pages show the functions that are

performed through the use of the joystick controller.

JD 7X30 COUGAR Operation Section 3-10

Page 75

OPERATION

JOYSTICK FWD / BACK

MOVES MAIN BOOM

JOYSTICK LEFT / RIGHT

MOVES SECONDARY BOOM

LEFT JOYSTICK ROLLER

MOVES DECK ROLL

RIGHT JOYSTICK ROLLER

MOVES BOOM SWIVEL

RIGHT JOYSTICK ROLLER

WITH BUTTON PRESSED

MOVES BOOM KNUCKLE

SHIELD SWITCH

OPERATES SAFETY

SHIELD

JD 7X30 COUGAR Operation Section 3-11

SWIVEL

KNUCKLE

Page 76

OPERATION

The Safety Shield switch opens and closes the shield located on the front of the cutter head. When mowing at or near the ground, always have the shield in the closed position. When mowing in brush or in trees above ground level the shield may be opened for easier cutting. Read and follow the warnings on the decal shown below. Do not run the cutter head into material larger than 6” diameter.

The Heavy Duty Rotary mower was designed for cutting brush and foliage up to 6 inches in diameter or multiple branches that have a total cross section area equivalent to one 6 inch branch. Cutting multiple limbs at the same time may overload the mower causing it to slow down or stall completely. Regardless of the size of material being cut, the speed of the cutter head must be maintained. To ensure that the cutter head is running at maximum speed, run the tractor at full throttle during mowing operations. If the cutter head slows to the point that the knives are folding back, move the mower head away fron the foliage and allow the cutter head to regain full speed.

HEA VY DUTY ROT AR Y

JD 7X30 COUGAR Operation Section 3-12

Page 77

OPERATION

Operating the mower in a manner that allows the cutting knives to continually fold back will cause permanent damage to the knives, rotary disk, and spindle assembly.

The Heavy Duty Rotary cutter head is designed for clockwise rotation (clockwise as seen from the top or the currer head). Never operate the cutter head in the counterclockwise rotation. Operating this mower in counterclockwise rotation may cause objects to be thrown towards the tractor.

OPERA TING DECK ROTA TION

WITH TRACTOR REMOTES

Orient the Mower Deck in a horizontal position before rotating mower deck. Push

tractor remote valve lever forward to rotate deck counter - clockwise from stowed position to cutting position. Pull remote valve lever aft to rotate deck clockwise. Deck shall be rotated completely clockwise for stowing in the boom rest position.

UNSTOWING BOOM

To un-stow the boom from the boom rest, proceed as follows. Switch travel lock to “OFF”. Move main boom “UP” to lift the secondary boom off of the boom support. Swivel boom “FORWARD” perpendicular to tractor. The head and booms are now ready for full operation.

TRANSPORTING MOWER

Transporting under the units own power:

NOTE: ONLY when transporting under the units own power is it permissible to rest the head in any of the resting positions. When transporting on a trailer the head MUST be resting on the position designed for the head you are using.

When transporting between job sites, the following procedure should be followed: Shut off the power to the cutting head and allow all motion to come to a complete stop. Roll the mower deck “OUT” all the way until it is adjacent to the secondary boom. Extend the secondary boom “OUT” to clear the boom rest. Next, swivel the boom “AFT” and manuver the main boom until it rests on the boom rest. Switch over to the knuckle control and curl the knuckle “Back”. Slowly and carefully lower the secondary boom until it contacts the desired cradle. Lastly, place the “Travel Lock” switch on the main control switch box to the “ON” position. The unit is now ready for self transportation. (See picture of stowed boom on next page).

JD 7X30 COUGAR Operation Section 3-13

Page 78

OPERATION

JD 7X30 COUGAR Operation Section 3-14

Page 79

JD 7X30 COUGAR

MAINTENANCE

SECTION

Maintenance Section 4-1

Page 80

MAINTENANCE

Tiger Mowers are designed for high performance and rugged durability, yet with simplified maintenance. The purpose of this section of the manual is to help the operator in the regular servicing of the mower. Regular maintenance at the intervals mentioned will result in the maximum efficiency and long life of the T iger Mower.

When you purchase a T iger Mower you also acquire another valuable asset, Tiger’s parts organization. Our rapid and efficient service has guaranteed the customer satisfaction for many years. T iger parts keep up with the demands for efficiency , safety and endurance expected of the Tiger Mower.

MAINTENANCE PRECAUTIONS

· Be sure end of grease gun and zerks are clean before using. Debris injected into bearings, etc. with grease will cause immediate damage.

· DO NOT grease greaseless bearings. They can be identified by blackish/grey color. DO NOT use a power grease gun to lubricate bearings. These require very small and exact amounts of lubrication. Refer to the detailed maintenance section for specific lubrication instructions. DO NOT over-grease bearings.

· Polycarbonate windows should be washed with mild soap or detergent and luke warm water, using a sof t clean sponge or soft cloth. DO NOT use abrasive or alkaline cleaners or metal scrapers on Polycarbonate windows!

· Be alert to maintenance indicators such as the in-tank filter pressure gauge, hydraulic reservoir sight gauge, etc. T ake the required action to correct any problems immediately .

Release of energy from pressurized systems may cause inadvertent actuation of cylinders, or sudden release of compressed springs. Before disconnecting any hoses relieve pressure by shutting tractor off, setting cutter on ground and actuating lift valve handles.

DO NOT use hands to check for suspected leaks in hydraulic hoses! Hydraulic fluid escaping under pressure can have sufficient force to penetrate skin and cause serious injury . If fluid is injected into skin, it mustbe surgically removed within a few hours or gangrene may result. Use a small piece of wood or cardboard, not hands, to search for pin hose leaks. Be sure all pressure is relieved whenever disconnecting lines. Be sure all connections are tight and hoses and lines are not damaged before applying pressure.

BREAK IN PERIOD

In addition to following the break in instructions for your particular tractor , the in-tank hydraulic fluid filter should be replaced after the first 50 hours of service. Thereafter the filter should be replaced every 500 hours, or yearly, which ever comes first.

Re-torque wheel lugs after first five hours of operation and periodically thereafter. See torque specifications listed in the tractor’s service manual for your particular model.

Wheel lugs must always be re-torqued whenever a wheel is removed and reinstalled.

JD 7X30 COUGAR Maintenance Section 4-2

Page 81

MAINTENANCE

DANGER!

WARNING!

Do not modify or alter this Implement. Do not permit anyone to modify or alter this Implement, any of its components or any Implement function. (SG-8)

DANGER!

JD 7X30 COUGAR ROT Maintenance Section 4-3

Page 82

MAINTENANCE

REGULAR MAINTENANCE

The intervals at which regular servicing should be done are based on hours of operation. Use the tractors hour meter to determine when regular servicing is required.

This symbol indicates a point that needs to be greased at an interval noted in the section below. Refer to the Det ailed Maintenance section for further instructions on greasing. Copy and use the Daily Maintenance sheet located at the end of this section.

DAILY OR EVERY 8 HOURS

ITEM SERVICE COMMENTS

Drive Shaft Yoke, U-Joint Grease Grease as instructed in & Stub Shaft detailed maint. section Pump Drive Shaft Coupler Check and Lube Insure drive shaft end play

Crankshaft Adapter Check rubber grommets Replace grommets if

damaged or missing

Main & Secondary Lubricate Inject grease until it Cylinder Pivot Points appears at ends

Hydraulic Fittings Check for leaks Tighten when needed.

Do Not use hands to check for leaks, see maint. Precautions

Knives Check Inspect for missing or

damaged knives, change or sharpen as needed

Spindle mounting bolts Check 3/4” x 2” torque to 331 ft. (spindle to deck) lbs.

Knife mounting bolts Check 1-1/8” special bolt torque (knife to disk) to 1070 dry or 800 oiled ft.

lbs. Disk mounting blolts Check 5/8” x 1-3/4” bolt torque to (disk to spindle) 204 dry or 184 oiled ft. lbs. Belts Check / Adjust Check if broken, tighten

as required Main Frame and Check Retorque bolts to torque

Deck specifications in this section Hydraulic Fluid Level Check Add if required per

fluid recommendations Rear Flail Drive (if applicable) Lubricate Grease as instructed in

Bearing Flange and detailed maint. section Shaft Coupler

Cutter Shaft and Ground Roller Lubricate Grease as instructed in Deck and Bonnet linkages detailed maint. section

JD 7X30 COUGAR Maintenance Section 4-4

Page 83

MAINTENANCE

WEEKLY OR EVERY 50 HOURS

ITEM SERVICE COMMENTS

In T ank Hyd. Fluid Change Change after first 50 Filter hours only , then every (10 micron filter) 500 hours or yearly

In-Line High Pressure Change Change after first 50 Filter hours only , then every

(10 micron filter) 500 hours or yearly

MONTHLY OR EVERY 150 HOURS

Hydraulic Fluid Level Check Add as needed Hyd. Tank Breather Clean / Check / Replace Clean or replace

Element as required

Rear Tire Type Max P.S.I.

480/80R38 29

18.4-34 26

18.4-38 26

YEARLY OR EVERY 500 HOURS

Spindle Grease Change Hyd. T ank Fluid Change In T ank Hyd. Fluid Change

Filter

(10 micron filter)

In-Line High Pressure Change or Change when indicated Filter by restriction indicator.

(10 micron filter)

Hyd. T ank Breather Change

TROUBLESHOOTING

SYMPTOMS CAUSE REMEDY

Vibration 1 . Loose bolts 1. Check all bolts and tighten to

recommended torque specs.

2. Cutter assembly 2a. Check for damaged blades, disc. Unbalanced or cutter shaft. Replace if needed.

2b. Check for wire, rope, etc.

entangled in cutter assembly

Mower will not lift 1. Hyd. Fluid low 1. Check and refill Hyd Fluid

2. Leaks in line 2. Tighten or replace fittings and hoses

3. Faulty relief valve 3. Check pressure in line. Line

pressure in Control V alve should be at least 2500 P.S.I.

4. Kinked or blocked4. Clean or replace lines

5. Faulty cylinder 5. Inspect, repair or replace cylinder

JD 7X30 COUGAR ROT Maintenance Section 4-5

Page 84

MAINTENANCE

SYMPTOMS CAUSE REMEDY

Mower will not start 1. Blown fuse 1. Check fuse between mower switch or run and ignition / replace

2. Ball valves closed 2. Make sure valves are open

3. Low oil level 3. Check Hyd. tank and fill

4. Line leak 4. Check all fittings and lines, re-tighten or replace

5. Electronic 5a. Without the tractor running, turn

solenoid faulty the mower switch to on. A low

audible click should be heard if the solenoid is engaging the solenoid spool. If click is not heard, leave switch in on position and with a screwdriver or other steel object, touch the small nut on the end of the solenoid. If the metallic object is not attracted to the nut, check the fuse and wiring for an open circuit. If the object is attracted but no “click” is heard, replace the solenoid.

5b. Remove the four bolts holding the

small block to the main block. Lift and remove small block being careful not to damage O-rings / filter. Clean filter and re-install.

5c. Remove large nut on side of large

valve block. Remove spring, and use needle nose vise grip to pull spool from block. Check block and spool for contaminates and scratches. Clean parts or replace if scratched.

Motor runs but 1. Belts 1. Inspect belts and pulleys. Replace will not cut. belts and repair as needed.

2. Tensioner 2. Adjust tensioner nut until flat washer washer is flush with top of guide.

Motor turns slowly 1. Contaminants 1. Remove large nut on side of large or not at all. restricting spool valve block. Remove spring, and use

movement in needle nose vise grip to pull spool valve body . from block. Check block and spool

for contaminates and scratches. Clean parts or replace if scratched.

2. Suction lines 2. Check for kinkes or obstruction in

obstructed suction hose.

3. Low oil level 3. Check Hyd. tank level and fill.

Pump will not work 1. Excessive wear 1. Disassemble and repair.

on internal parts

Motor will not work 1. Excessive wear 1. Disassemble and repair.

on internal parts

JD 7X30 COUGAR Maintenance Section 4-6

Page 85

MAINTENANCE

NOTE: If flow meter is available, check pressure and flow volume for all

suspected hydraulic problems.

If the solution to your problem cannot be found in this section, call the Technical Service representative at the number shown on the front cover of this manual.

JD 7X30 COUGAR ROT Maintenance Section 4-7

Page 86

MAINTENANCE

TORQUE SPECIFICATIONS

* These are intended to be general specifications. See tractor operators or service manual for exact specifications for your unit.

JD 7X30 COUGAR Maintenance Section 4-8

Page 87

MAINTENANCE

LUBRICATION RECOMMENDATIONS

Description Application General Specification Recomended

Mobil Lubricant

Tractor Hydraulics Reservoir JD-20C Mobilfluid 424

MF M1 135,M1 141 FNHM2C134D (FNH201)

Mower Hydraulics Reservoir

Cold T emperatures 0 F S tart-Up ISO 46 Anti-Wear - Low T emp Mobil DTE 15M Normal T emperatures 10 F S tart-Up JD-20C Mobilfluid 424

MF M1 135,M1 141

FNH M2C134D (FNH201) Normal T emperatures 15 F S tart-Up ISO 46 Anti-Wear Mobil DTE 25 High Operating T emp. Above 90 F ISO 100 Anti-W ear Mobil DTE 18M

Flail Rear Gearbox Grease P AO Synthetic Extreme Mobil SHC 75W-90

Pressure Gear Lube Mobil 1 Synthetic Gear

Cutter Shaft & Ground Grease Lithium-Complex Mobilgrease CM-S Roller Shaft (Flail) Gu n Extreme Pressure

NLGI 2 - ISO 320

Drive Shaft Coupler Grease Lithium-Complex Mobilgrease CM-S (Flail and Rotary) Gu n Extreme Pressure

NLGI2 - ISO 320

Drive Shaft Y oke, U-Joint & S tub Shaft Grease Lithium-Complex Mobilgrease CM-S Deck rotation linkages Gu n Extreme Pressure

NLGI 2 - ISO 320

Boom Swivel Grease Lithium-Complex Mobilgrease CM-S Boom Cylinder Pivots Gu n Extreme pressure

(Rotary & Flail Boom) NLGI2 - ISO 320

Deck Boom Pivot & Grease Lithium-Complex Mobilgrease CM-S Deck Stop Adjustment G un Extreme pressure

(Rotary & Flail) NLGI 2 - ISO 320

Deck Spindle (Rot ary) Grease Tiger S pindle Lubricant Mobilith SHC 220

Gu n part number 06540000

JD 7X30 COUGAR ROT Maintenance Section 4-9

03-01-05

Page 88

MAINTENANCE

RECOMMENDED FILLING INSTRUCTIONS

FOR HYDRAULIC RESERVIORS

When filling or checking the oil level, the unit should be parked on a level surface, shut “OFF”, and allowed sufficient time to cool to ambient temperature. Use caution when removing the pressurized breather. Do not place face over opening when removing the breather.

The reservior should be filled to the top of the lower sight glass on the side of the tank. Do not over-fill. The reservior has been over-filled when oil is visible in the upper sight glass. If tank has too much oil, the excess may be expelled through the pressurized breather.

DETAILED MAINTENANCE

REPLACEING IN-TANK HYDRAULIC FILTER:

Loosen the four bolts on the top cover of the filter housing. T urn cover counterclockwise until cover is free. Remove and replace filter. Replace top cover and cover bolts in opposite order as removed.

JD 7X30 COUGAR Maintenance Section 4-10

Page 89

MAINTENANCE

DETAILED MAINTENANCE

REPLACEING HIGH PRESSURE HYDRAULIC FILTER ELEMENT:

Assure system has been shut down and de-pressurized. Locate High Pressure Filter housing. Confirm that the element that is about to be installed matches the element p/n on the filter model tag. Example: V3.0510-06 (world line 100, HD049 model) Locate the bottom of the High Pressure Bowl, and use the appropriate spanner wrench –or- ratchet that matches the hex pattern. Using the spanner wrench -or- ratchet and turning in a counterclockwise rotation, (looking at the bottom of the bowl) remove the bowl from the head, The first couple rotations will seam tight as the o-ring passes the sealing flats, once the o-ring has cleared the sealing flats the bowl should spin freely. Taking care not to drop the bowl, finish removing the bowl from the head. WARNING: bowl will be full of oil! Pour the oil from the bowl into a container, this oil should be considered cont aminated due to the flow direction through the element is outside ~ in. Clean the inside of the bowl if “dirt” is present. Remove the old element from the filter head by pulling with a rotation motion. Dispose of the used element properly. Remove the new element from the packaging. Using your finger , dab and lubricate the o-ring in the top of the new element. Install the new element into and on the mounting boss with in the head; assure that the element is fully seated on the boss. Clean and inspect the o-ring that is affixed in the bowl, lubricate with oil. Using a clockwise rotation, screw the bowl back into the head, assuring that the bowl has not been cross threaded into the head. Continue “tighten” the bowl into the head, using the spanner wrench –orratchet, the rotation of the bowl will become tighter once the o-ring engages the sealing flats. Once the bowl has been fully inserted into the head, and the o-ring has reached the sealing flats, the bowl can no longer be “tightened” and bottoms out. Once the bowl has bottomed out, “back-off” the bowl by 1/6 turn, this assures that the o-ring is seated properly with in the sealing flats. Element change out and reassembly is now complete. Start the machine and inspect the filter area checking that there is no oil leaking from the filter assembly. This is first to be done at 50 hours of operation, then yearly(500 hours) or when indicated by restriction indicator .

JD 7X30 COUGAR ROT Maintenance Section 4-11

HEAD

BOWL

Page 90

MAINTENANCE

GREASING CUTTER SHAFT – FLAIL MOWERS

Locate grease zerks on each end of cutter shaft(s), these are located on the bearing cover. Normal conditions require one or two pump in each bearing, using Lithium-Complex Extreme Pressure grease conforming to NLGI2-ISO 320 specifications. This is to be done with a standard grease gun daily or at 8 hour

intervals. CAUTION: Over greasing may cause premature seal failure.

GREASING GROUND ROLLER SHAFT – FLAIL

Locate grease zerks on each end of roller tube at lower rear of head. Normal conditions require one or two pump in each bearing, using Lithium-Complex Extreme Pressure grease conforming to NLGI2-ISO 320 specifications. This is to be done with a standard grease gun daily or at 8 hour intervals.

CAUTION: Over greasing may cause premature seal failure.

JD 7X30 COUGAR Maintenance Section 4-12

Page 91

MAINTENANCE

GREASING PUMP DRIVE SHAFT COUPLER

With engine stopped, ensure drive shaft alignment by grasping coupler and sliding back and forth. Coupler should slide freely with approximately 1/8” of end play . If coupler does not slide freely, inspect for loose pump mount bolts, or damaged or loose crank shaft adapter. Inject Lithium-Complex Extreme Pressure grease conforming to NLGI2-ISO 320 specifications into coupler until grease begins to protrude from ends. Grease daily or every 8 hours. Do not over grease.

DRIVE SHAFT YOKE, U-JOINT & STUB SHAFT

With engine stopped, inject Lithium-Complex extreme pressure grease conforming to NLGI2-ISO 320 specifications into universal joints and slip yoke untill grease appears at the seal. Grease them daily or every 8 hours .

JD 7X30 COUGAR ROT Maintenance Section 4-13

Page 92

MAINTENANCE

VISUAL MAP OF GREASE POINTS

Please read the specific instructions for each area.

JD 7X30 COUGAR Maintenance Section 4-14

Page 93

MAINTENANCE

GREASELESS BEARINGS ON THE BOOM

The pivot points on the boom have greaseless bearings. Check the guide on the

last page for greasing points.

NOTE: The new greaseless bearing is blackish/gray in color and should not be greased.

GREASING BOOM CYLINDERS

Locate the zerk on the butt end tang and on rod end tang of the main and secondary boom cylinder. Inject Lithium-Complex Extreme Pressure grease conforming to NLGI2-ISO 320 specifications until grease begins to protrude from ends. This procedure is to be performed daily or at 8 hour intervals.

GREASING SPINDLE

Locate grease fitting on inside of deck housing. Inject Tiger Spindle Lubricant, part number 06540000 into spindle housing. Fill with lubricant until lubricant weeps out of top spindle seal. Lubricate spindle at end of day while mower is still warm.

GREASING DECK ROTATION LINKAGE

Locate grease zerks on linkages. Inject Lithium-Complex Extreme Pressure grease conforming to NLGI2-ISO 320 specifications.. Fill with lubricant until lubricant weeps out of pin locations. Lubricate daily.

JD 7X30 COUGAR ROT Maintenance Section 4-15

Page 94

MAINTENANCE

ADJUSTING / CHECKING BELT TENSION

To adjust belt tension or replace belts on flail cutter head, remove four bolts that secure belt cover and remove cover. The hex nuts shown below can be adjusted to increase / decrease the belt tension as needed. (NOTE: Location of adjustment nuts may vary on flail cutter heads.) Be sure to replace the belt cover BEFORE

operating mower!

DECK STOP ADJUSTMENT

Loosen locking nut. Turn adjustment bolt in, and run deck cylinder out to full extension. Adjust bolt out until the head just touches the boom, and tighten lock nut.

NOTE: Bolt should not hit boom before cylinder reaches full travel.

JD 7X30 COUGAR Maintenance Section 4-16

Page 95

MAINTENANCE

TIGHTENING KNIFE BOLTS AND DISK BOLTS:

After every 8 hours of operation or daily , the Knife Bolt s and Disk Bolt s should be tightened as follows:

Knife mounting bolts (3ea.) torque to 1070 dry or 800 oiled ft. lbs.(Recomended oiled) Disk mounting bolts (6ea. ) torque to 204 dry or 184 oiled ft. lbs.(Recomended oiled)

TIGHTENING SPINDLE BOLTS

The spindle mounting bolts should be checked and retorqued daily or every 10 hours of service. Torque the (6) bolts shown below to 331 ft. lbs.

JD 7X30 COUGAR ROT Maintenance Section 4-17

Page 96

MAINTENANCE

BALL VALVES

The ball valve at the hydraulic reservoir may need to be closed during certain maintenance or repair procedures. THE BALL VALVES MUST BE OPEN (handle

parallel with valve) WHEN TRACTOR IS RE-STARTED OR PUMP IS COUPLED TO MOTOR OR P.T.O. ! Failure to do so will result in component failure!

JD 7X30 COUGAR Maintenance Section 4-18

Page 97

MAINTENANCE

INSPECTION OF ROTARY KNIFE

Failure to follow the following warnings and instructions may result in serious injury or damage to the equipment or property!

1 – DO NOT weld on the knives or bolts. Damaged or worn knives must be replaced.

2 – Knives must be replaced in sets. Knives with unequal wear may cause

serious vibration and resulting structural damage to the mower.

3 – The self-locking nuts for the knife mounting bolts must NOT be reused. If the self-locking nut is removed from the knife mounting bolt, the nut must be replaced with a new self-locking nut.

4 – Inspect the condition and tightness of the knife mounting bolts and disk mounting bolts daily .

ROTARY KNIFE REPLACEMENT

1 – Be sure you have a complete matching set of new knives for replacement. 2 – Remove knives and inspect holes for damage. Also watch for cracks in the disk

around the holes. 3 – Install bolt through knife and disk from bottom side of disk. Install new self-locking

nuts and torque them to 1070 dry or 800 oiled ft. lbs. It is recommended that they are oiled.

4 – The knives should swing freely to absorb shocks from impact when striking objects.

WHEN CUTTING HEAVY BRUSH, KNIFE BOLTS SHOULD BE INSPECTED HOURLY AND RETORQUED TO 1070 DRY OR 800 OILED FT. LBS.

JD 7X30 COUGAR ROT Maintenance Section 4-19

Page 98

MAINTENANCE

HEAVY DUTY SPINDLE ASSEMBLY

INSTALLA TION AND BEARING ADJUSTMENT

WARNING! A press MUST be used to install bearing cups, bearing cones, and

seals. DO NOT use a hammer to install races, bearings, or seals. The parts of assembly may be damaged.

NOTE: The grease zerk and gussets are located on the top side of the spindle housing. Be sure the spindle is assembled correctly.

Be sure to wear eye protection and other protective equipment as needed when working on spindle assembly .

THE SPINDLE ASSEMBLY

See the diagram below for identification of spindle parts, while servicing.

JD 7X30 COUGAR Maintenance Section 4-20

Page 99

MAINTENANCE

BEARING INSTALLATION

1 – Press upper bearing cup into the spindle housing. 2 – Turn the spindle housing over and press in the lower bearing cup. 3 – Place the lower bearing cone in the bearing cup. Next press the seal into the

spindle housing. The inner lip of the seal must be DOWN, towards the bearing, so lubricant is sealed inside the housing.

4 – Install the spindle in the housing. Lightly tap the end of the spindle with a soft faced hammer to seat the spindle against the bearing inner race.

5 – T urn the spindle housing over (up position) and fill with Tiger Spindle Lubricant (part number 06540000) to the top edge of the upper bearing cup.

6 – Support the bottom of the spindle and press the upper bearing cone and bearing adjustment sleeve onto the spindle.

NOTE: The spindle housing must turn freely when seating the bearing cone and sleeve.

7 – Press the two upper seals into the spindle housing. The inner lip of the seals must be UP, away from the bearing, so excess lubricant can escape.

8 – Install the bearing adjustment nut (thin nut) so there is 1/16” clearance between the nut and the sleeve. Install the jam washer , placing the tab into the key-way. Install the bearing lock nut (thin nut) and hand tighten against jam washer and adjustment nut. See the following section for bearing adjustment.

JD 7X30 COUGAR ROT Maintenance Section 4-21

Page 100

MAINTENANCE

BEARING ADJUSTMENT

1 – Clamp the bottom end of the spindle securely in a vise so the spindle housing turns freely .

2 – Position a magnetic base dial indicator on the outer diameter of the spindle housing. Locate the end of the dial indicator against the flat end of the spindle shaft. The dial indicator will now measure accurately bearing end play .

3 – Tighten the bearing adjustment nut until there is .012 inch movement when the spindle housing is pried upward away from the vise jaws.

4 – When there is .012 inch free play between the spindle and housing, install the bearing lock nut (thick nut). Hold the adjusting nut securely and tighten the lock nut to 300 ft. lbs. of torque.

5 – Af ter the lock nut is tightened, there must be .001 inch to .003 inch of free play when lightly prying up on the spindle housing.

If the end play is correct, .001 inch to .003 inch, bend tabs up on jam washer to prevent the lock nut from loosening.

If the end play in NOT correct, loosen the lock nut and turn the adjustment nut as required and re-tighten the lock nut. Repeat first part of step 5.

JD 7X30 COUGAR Maintenance Section 4-22