Woods Equipment 7000, 7192, 7194, 7195, 7200 User Manual

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Page 1

C360 Undermount Mower

Cub Cadet Tractor Models 7000, 7192, 7194, 7195, 7200, 7205

Includes

Mounting Kit 1002875

mounting to

MAN0137

MAN0137 (Rev. 8/13/2004)

Page 2

TO THE DEALER:

Assembly and proper installation of this product is the responsibility of the WOODS dealer. Read manual instructions and safety rules. Make sure all items on the Dealer’s Pre-Delivery and Delivery Check Lists in the Operator’s Manual are completed before releasing equipment to the owner.

The dealer must complete the Warranty Registration included in this manual. Both dealer and customer must sign the registration which certifies that all Dealer Check List items have been completed. The dealer is to return the prepaid postage portion to WOODS, give one copy to the customer, and retain one copy. Note: Warranty credit is subject to

this form being completed and returned.

TO THE OWNER:

Read this manual before operating your WOODS equipment. The information presented will prepare you to do a better and safer job. Keep this manual handy for ready reference. Require all operators to read this manual carefully and become acquainted with all the adjustment and operating procedures before attempting to operate. Replacement manuals can be obtained from your dealer or, in the United States and Canada, by calling 1-800-319-6637.

The equipment you have purchased has been carefully engineered and manufactured to provide dependable and satisfactory use. Like all mechanical products, it will require cleaning and upkeep. Lubricate the unit as specified. Observe all safety information in this manual and safety decals on the equipment.

For service, your authorized WOODS dealer has trained mechanics, genuine WOODS service parts, and the necessary tools and equipment to handle all your needs.

Use only genuine WOODS service parts. Substitute parts will void the warranty and may not meet standards required for safe and satisfactory operation. Record the model number and serial number of your equipment in the spaces provided:

Model: _______________________________ Date of Purchase: _____________________

Serial Number: (see Safety Decal section for location) ____________________________________

Provide this information to your dealer to obtain correct repair parts. Throughout this manual, the term IMPORTANT is used to indicate that failure to observe can cause damage to

equipment. The terms CAUTION, WARNING and DANGER are used in conjunction with the Safety-Alert Symbol, (a triangle with an exclamation mark), to indicate the degree of hazard for items of personal safety.

This Safety-Alert Symbol indicates a hazard and means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.

Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury, and includes hazards that are exposed when guards are removed.

Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury.

Indicates that failure to observe can cause damage to equipment.

NOTE

Indicates helpful information.

Introduction (2/9/01)

Page 3

TABLE OF CONTENTS

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5

SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 7

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

OWNER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

DEALER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 - 28

ASSEMBLY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

PARTS INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

BOLT TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

BOLT SIZE CHART & ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . .53

PARTS WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

PRODUCT WARRANTY . . . . . . . . . . . . . . . . . . . . . . . INSIDE BACK COVER

MAN0137 (9/14/01))

Introduction 1

Page 4

SPECIFICATIONS

Cutting Width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60”

Cutting Height Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1/2’ - 4”

Tractor Mid-PTO Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,000 RPM

Blade Speed (RPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,800

Blade Tip Speed (feet per minute) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15,200

Blade Spindles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Number of Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Universal Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0600

Caster Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Caster Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1/4” x 6-1/4”

Mower Frame Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 GA Deck

GENERAL INFORMATION

The purpose of this manual is to assist you in operating and maintaining your mower. Read it carefully. It furnishes information and instructions that will help you achieve years of dependable performance. These instructions have been compiled from extensive field experience and engineering data. Some information may be general in nature due to unknown and varying operating conditions. However, through experience and these instructions, you should be able to develop procedures suitable to your particular situation.

The illustrations and data used in this manual were current at the time of printing but, due to possible inline production changes, your machine may vary slightly in detail. We reserve the right to redesign and change the machines as may be necessary without notification.

WARNING

■ Some illustrations in this manual show the

mower with safety shields removed to provide a better view. The mower should never be operated with any safety shielding removed.

Throughout this manual, references are made to right and left direction. These are determined from the operator’s position in the tractor seat. Blade rotation is clockwise as viewed from the top of the mower.

2 Introduction

MAN0137 (9/14/01)

Page 5

AFETY RULE

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Safety is a primary concern in the design and manufacture of our products. Unfortunately, our efforts to provide safe equipment can be wiped out by an operator’s single careless act.

In addition to the design and configuration of equipment, hazard control and accident prevention are dependent upon the awareness, concern, judgement, and proper training of personnel involved in the operation, transport, maintenance and storage of equipment.

It has been said “The best safety device is an informed, careful operator.” We ask you to be that kind of operator.

TRAINING

 Safety instructions are important! Read all attachment and power unit manuals; follow all safety rules and safety decal information. (Replacement manuals are available from dealer or, in the United States and Canada, call 1-800-319-6637.) Failure to follow instructions or safety rules can result in serious injury or death.

 If you do not understand any part of this manual and need assistance, see your dealer.

 Know your controls and how to stop engine and attachment quickly in an emergency.

 Operators must be instructed in and be capable of the safe operation of the equipment, its attachments, and all controls. Do not allow anyone to operate this equipment without proper instructions.

 Keep hands and body away from pressurized lines. Use paper or cardboard, not hands or other body parts to check for leaks. Wear safety goggles. Hydraulic fluid under pressure can easily penetrate skin and will cause serious injury or death.

 Make sure that all operating and service personnel know that if hydraulic fluid penetrates skin, it must be surgically removed as soon as possible by a doctor familiar with this form of injury or gangrene, serious injury, or death will result. CONTACT A PHYSICIAN IMMEDIATELY IF FLUID ENTERS SKIN OR EYES. DO NOT DELAY.

 Never allow children or untrained persons to operate equipment.

PREPARATION

 Check that all hardware is properly installed. Always tighten to torque chart specifications unless instructed otherwise in this manual.

 Always wear relatively tight and belted clothing to avoid entanglement in moving parts. Wear sturdy, rough-soled work shoes and protective equipment for eyes, hair, hands, hearing, and head.

 Make sure attachment is properly secured, adjusted, and in good operating condition.

 Make sure spring-activated locking pin or collar slides freely and is seated firmly in tractor PTO spline groove.

 Power unit must be equipped with ROPS or ROPS cab and seat belt. Keep seat belt securely fastened. Falling off power unit can result in death from being run over or crushed. Keep foldable ROPS systems in “locked up” position at all times.

 Remove accumulated debris from this equipment, power unit, and engine to avoid fire hazard.

 Make sure all safety decals are installed. Replace if damaged. (See Safety Decals section for location.)

 Make sure shields and guards are properly installed and in good condition. Replace if damaged.

 A minimum 20% of tractor and equipment weight must be on the tractor front wheels when attachments are in transport position. Without this weight, tractor could tip over, causing personal injury or death. The weight may be attained with a loader, front wheel weights, ballast in tires or front tractor weights. Weigh the tractor and equipment. Do not estimate.

 Inspect and clear area of stones, branches, or other hard objects that might be thrown, causing injury or damage.

OPERATION

 You may not be able to stop the tractor safely if the clutch or brake pedal mechanisms are improperly adjusted, allowing them to contact mower components.

 When the mower lift stops are installed as instructed in this manual, properly adjusted clutch and brake pedal mechanisms will not contact mower components. You should frequently check that the tractor clutch and brake pedal mechanisms are in adjustment.

UM60/72 Mower Safety Rules (Rev. 7/22/2004)

Safety 3

Page 6

AFETY RULE

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

 If the clutch or brake pedal mechanisms can contact mower components, do not put mower into service until properly adjusted.

 Do not put mower into service unless discharge chute is installed and in good condition. Replace if damaged.

 Keep bystanders away from equipment.

 Never go underneath equipment (lowered to the

ground or raised) unless it is properly blocked and secured. Never place any part of the body underneath equipment or between moveable parts even when the engine has been turned off. Hydraulic system leak down, hydraulic system failures, mechanical failures, or movement of control levers can cause equipment to drop or rotate unexpectedly and cause severe injury or death. Follow Operator's Manual instructions for working underneath and blocking requirements or have work done by a qualified dealer.

 Never direct discharge toward people, animals, or property.

 Do not operate equipment while under the influence of alcohol or drugs.

 Operate only in daylight or good artificial light.

 Keep hands, feet, hair, and clothing away from

equipment while engine is running. Stay clear of all moving parts.

 Always comply with all state and local lighting and marking requirements.

 Never allow riders on power unit or attachment.

 Power unit must be equipped with ROPS or

ROPS cab and seat belt. Keep seat belt securely fastened. Falling off power unit can result in death from being run over or crushed. Keep foldable ROPS systems in “locked up” position at all times.

 Always sit in power unit seat when operating controls or starting engine. Securely fasten seat belt, place transmission in neutral, engage brake, and ensure all other controls are disengaged before starting power unit engine.

 Operate tractor PTO at the RPM speed stated in “Specifications” section.

 Do not operate PTO during transport.

 Do not operate auxiliary hydraulics during

transport.

 Look down and to the rear and make sure area is clear before operating in reverse.

 Do not operate on steep slopes.

 Do not stop, start, or change directions sud-

denly on slopes.

 Use extreme care and reduce ground speed on slopes and rough terrain.

 Watch for hidden hazards on the terrain during operation.

 Stop power unit and equipment immediately upon striking an obstruction. Turn off engine, remove key, inspect, and repair any damage before resuming operation.

 Before dismounting power unit or performing any service or maintenance, follow these steps: disengage power to equipment, lower the 3-point hitch and all raised components to the ground, operate valve levers to release any hydraulic pressure, set parking brake, stop engine, remove key, and unfasten seat belt.

 Before working underneath, read Operator's Manual and Blocking Method section Disconnect driveline, raise mower, install transport lock, securely block up all corners, and check stability. Secure blocking prevents equipment from dropping due to hydraulic leak down, hydraulic system failures, or mechanical component failures.

TRANSPORTATION

 Always comply with all state and local lighting and marking requirements.

 Never allow riders on power unit or attachment.

 Do not operate PTO during transport.

 Watch for hidden hazards on the terrain.

 A minimum 20% of tractor and equipment

weight must be on the tractor front wheels when attachments are in transport position. Without this weight, tractor could tip over, causing personal injury or death. The weight may be attained with a loader, front wheel weights, ballast in tires or front tractor weights. Weigh the tractor and equipment. Do not estimate.

 Do not operate or transport on steep slopes.

 Do not operate or transport equipment while

under the influence of alcohol or drugs.

4 Safety

UM60/72 Mower Safety Rules (Rev. 7/22/2004)

Page 7

SAFETY RULES

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

 The maximum transport speed for towed and semi-mounted machines is 20 mph (32 km/h). Regardless of the maximum speed capability of the towing tractor, do not exceed the implement’s maximum transport speed. Doing so could result in:

• Loss of control of the implement and tractor

• Reduced or no ability to stop during braking

• Implement tire failure

• Damage to the implement or its components.

 Never tow this implement with a motor vehicle.

MAINTENANCE

 Do not modify or alter or permit anyone else to modify or alter the equipment or any of its components in any way.

 Always wear relatively tight and belted clothing to avoid entanglement in moving parts. Wear sturdy, rough-soled work shoes and protective equipment for eyes, hair, hands, hearing, and head.

 Never go underneath equipment (lowered to the ground or raised) unless it is properly blocked and secured. Never place any part of the body underneath equipment or between moveable parts even when the engine has been turned off. Hydraulic system leak down, hydraulic system failures, mechanical failures, or movement of control levers can cause equipment to drop or rotate unexpectedly and cause severe injury or death. Follow Operator's Manual instructions for working underneath and blocking requirements or have work done by a qualified dealer.

 Make sure attachment is properly secured, adjusted, and in good operating condition.

 Keep all persons away from operator control area while performing adjustments, service, or maintenance.

 Make certain all movement of equipment components has stopped before approaching for service.

 Frequently check blades. They should be sharp, free of nicks and cracks, and securely fastened.

 Use a new Nylok blade bolt and cup washers when you replace the blade. Do not substitute any bolt for the special blade bolt. It is self-locking, meeting the non-loosening requirements for this application.

 Do not handle blades with bare hands. Careless or improper handling may result in serious injury.

 Your dealer can supply genuine replacement blades. Substitute blades may not meet original equipment specifications and may be dangerous.

 Tighten all bolts, nuts and screws to torque chart specifications. Check that all cotter pins are installed securely to ensure equipment is in a safe condition before putting unit into service.

 Make sure all safety decals are installed. Replace if damaged. (See Safety Decals section for location.)

 Make sure shields and guards are properly installed and in good condition. Replace if damaged.

 Do not disconnect hydraulic lines until machine is securely blocked or placed in lowest position and system pressure is released by operating valve levers.

 Wear gloves when installing belt. Be careful to prevent fingers from being caught between belt and pulley.

STORAGE

 Block equipment securely for storage.

 Keep children and bystanders away from stor-

age area.

UM60/72 Mower Safety Rules (Rev. 7/22/2004)

Safety 5

Page 8

SAFETY & INSTRUCTIONAL DECALS

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

HIGH-PRESSURE HYDRAULIC OIL LEAKS CAN PENETRATE SKIN

RESULTING IN SERIOUS INJURY, GANGRENE OR DEATH.

Check for leaks with cardboard; never use hand.

Before loosening fittings: lower load, release pressure, and be sure oil is cool.

19924-B

1 - PN 19924

Consult physician immediately if skin penetration occurs.

WARNING

PTO speeds higher than 2000 RPM can cause equipment failure and personal injury.

OPERATE PTO AT

2000 RPM

Replace Immediately If Damaged!

WARNING

15622-A

2 - PN 15622A

DC4000A

3 - PN 19007

6 Safety

MAN0137 (9/14/01)

Page 9

SAFETY & INSTRUCTIONAL DECALS

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Replace Immediately If Damaged!

WARNING

TO AVOID SERIOUS

INJURY OR DEATH,

Read Operator’s Manual (available from dealer) and follow all safety precautions.

Keep all shields in place and in good condition.

Operate mower from tractor seat only.

Lower mower, stop engine and remove key before dismounting tractor.

Allow no children or untrained persons to operate equipment.

FAILURE TO OPERATE SAFELY

CAN RESULT IN

INJURY OR DEATH.

4 -PN 18877B

DANGER

SHIELD MISSING

DO NOT OPERATE -- PUT SHIELD ON

6 - PN 18869

18877--B

18869

DANGER

ROTATING BLADES AND

THROWN OBJECTS

 Do not put hands or feet under or into mower when

engine is running.

 Before mowing, clear area of objects that may be

thrown by blade.

 Keep bystanders away.

 Keep discharge chute and guards in place and in good

condition.

BLADE CONTACT OR THROWN OBJECTS CAN

CAUSE SERIOUS INJURY OR DEATH.

5 -PN 18863

DANGER

SHIELD MISSING

DO NOT OPERATE

PUT SHIELD ON

18867--B

18863-B

MAN0137 (9/14/01)

7 - PN 18867

8 - Serial Number Plate

Safety 7

Page 10

OPERATION

Safety is a primary concern in the design and manufacture of our products. Unfortunately, our efforts to provide safe equipment can be wiped out by an operator’s single careless act.

It has been said “The best safety device is an informed, careful operator.” We ask you to be that kind of operator.

The operator is responsible for the safe operation of this mower. The operator must be properly trained. Operators should be familiar with the power unit, mower, and all safety practices before starting operation. Read the safety rules and safety decals on and page 7.

WARNING

 Keep bystanders away from equipment.

 Never allow riders on power unit or attach-

ment.

 Never allow children or untrained persons to operate equipment.

 Operate tractor PTO at the RPM speed stated in “Specifications” section.

WARNING

 Make sure spring-activated locking pin or collar slides freely and is seated firmly in tractor PTO spline groove.

CAUTION

 Know your controls and how to stop engine and attachment quickly in an emergency.

 Always wear relatively tight and belted clothing to avoid entanglement in moving parts. Wear sturdy, rough-soled work shoes and protective equipment for eyes, hair, hands, hearing, and head.

 Make sure attachment is properly secured, adjusted, and in good operating condition.

 Keep all persons away from operator control area while performing adjustments, service, or maintenance.

8 Operation

MAN0137 (9/14/01)

Page 11

Operation

Cont’d

Adjust Cutting Height

1. Mower cutting height is raised, lowered, and

maintained by adjusting caster and gauge wheels. Refer to Figure 2 and accompanying chart for approximate cutting heights.

2. Raise mower with tractor hydraulics to adjust gauge and caster wheels. It is important that all settings are the same.

DB2935

Approximate

Cutting Height

1.50” 1

2.12” 2

2.75” 3

3.38” 4

4.0” 5

Figure 1 Cutting Height Positions

Position

Transport Lock Operation

There may be occasions when you would like to use your tractor for tasks other than mowing but do not want to remove the mower. For your convenience we have provided a method to lock the mower up and free the tractor auxiliary valve or 3-point arm for implement use.

Figure 2 Cutting Height Adjustment

IMPORTANT

■ Avoid very low cutting heights. Striking the

ground with blades gives one of the most damaging shock loads a mower can encounter and, if this occurs repeatedly, it will cause damage to mower and drive.

STORE

LOCK

1. To engage lock-up bar, raise mower to maximum height, then lift lock-up handle and drop into outer gate. This will lock mower in raised position.

2. To return to operating position, raise mower to maximum height, then raise lock-up handle and move to inner gate. Mower will now raise and lower freely.

MAN0137 (9/14/01)

1. Front lift stop assembly

CD4180

Figure 3 Transport Lock Installation

2. Lock-up bar

Operation 9

Page 12

Operation

Cont’d

Remove Mower from Tractor

NOTE: The lift mechanism maybe left on the tractor

when mower is removed.

1. Lift mower off of ground and remove adjustment pins from gauge and caster wheel adjustment points.

2. Lower mower to ground, stop engine, and remove key.

3. Remove driveshaft from tractor mid-PTO shaft.

4. Release pins from front mounting channel. There

are two pins connecting rockshaft lift to linkage attached to the mower frame.

5. Remove rear mower lift bars from rear rockshafts.

Operation Safety

DANGER

 Do not put mower into service unless discharge chute is installed and in good condition. Replace if damaged.

Install Discharge Chute, page 36

CAUTION

 Stop power unit and equipment immediately upon striking an obstruction. Turn off engine, remove key, inspect, and repair any damage before resuming operation.

6. Remove the pins and leave the linkage attached

to mower frame (flip lift bars down). Refer to Attach Mower to Tractor, page 40 for locations.

7. Raise mower lift mechanism. Refer to Transport Lock Operation, page 9 and lock the lift mechanism up.

8. Place blocks between front tires and mower frame.

9. Back tractor front tires over mower frame.

10. Place mower frame in storage.

11. Refer to Attach Mower to Tractor, page 40 for

installing mower to tractor.

IMPORTANT

■ Power for operating mower is supplied by

tractor mid-PTO. Do not exceed tractor manufacturer's rated mid-PTO speed of 2000 rpm maximum. Know how to stop tractor and mower quickly in case of an emergency.

■ Should mower become plugged, causing belt

to slip for over two seconds, maneuver equipment into a previously cut area and allow mower to clear accumulated material. Continue running at least two minutes, allowing pulleys to cool. Stopping the mower with belt in contact with a very hot pulley will bake and ruin belt.

■ Mower vibration tends to loosen bolts during

operation. All hardware should be checked regularly to maintain proper torque. It is a good practice to check mower before each operation to ensure all bolts are secure.

10 Operation

MAN0137 (9/14/01)

Page 13

Operation

Cont’d

Operating Techniques Operating Tips

1. Proper ground speed will depend upon the ter-

rain, the height, type, and density of material to be cut.

2. Normally, ground speed will range from two to five mph. Tall dense material should be cut at a low speed; thin medium-height material can be cut at a faster ground speed.

3. Always operate tractor mid-PTO at 2000 rpm. This is necessary to maintain proper blade speed and produce a clean cut.

4. Under certain conditions, tractor tires may roll some grass down and prevent it from being cut at the same height as the surrounding area. When this occurs, reduce your ground speed, but maintain 2000 rpm mid-PTO speed. The lower ground speed will permit grass to at least partially rebound.

5. Under some conditions, grass will not rebound enough to be cut evenly. In general, lower cutting heights give a more even cut with less tendency to leave tire tracks. However, it is better to cut grass frequently rather than too short. Short grass deteriorates rapidly in hot weather and invites weed growth during growing seasons. Follow local recommendations for the suitable cutting height in your area.

6. When operating the mower, move the hydraulic control valve to the float position. This will allow the mower to follow ground contours.

1. Extremely tall material should be cut twice. Set mower at a higher cutting height for the first pass. Then cut at desired height at 90 degrees to the first pass.

2. Remember, sharp blades produce cleaner cuts and require less power.

3. Analyze area to be cut to determine the best procedure. Consider height and type of grass and terrain type: hilly, level, or rough.

4. Plan your mowing pattern to travel straight forward whenever possible. Mow with uncut grass to the left. This will distribute the clippings over the cut area. Discharging clippings over uncut grass will cause a build-up and may prevent uniform cutting.

5. Use the inside edge of the right front caster wheel as a cutting guide.

6. When transporting unit a long distance, pin all four wheels in position 1 as shown in Figure 1, Cutting Height Positions, page 9. Raise mower and engage lock-up.

7. For a professional touch in large open areas, try the mowing pattern in Figure 4. Make two or three passes clockwise to discharge clippings away from bordering objects. Then cut the lawn in half by mowing down the center. Turn counter-clockwise to the left at the end of the area over grass previously mowed.

MAN0137 (9/14/01)

CD1276

Figure 4 Mowing Pattern

Operation 11

Page 14

Operation

Uneven Terrain

Cont’d

WARNING

1. Pass diagonally through sharp dips and avoid sharp drops to prevent "hanging up" the tractor and mower. Practice will improve your skills in maneuvering rough terrain.

 Do not operate on steep slopes.

 Do not stop, start, or change directions sud-

denly on slopes.

 Use extreme care and reduce ground speed on slopes and rough terrain.

 Watch for hidden hazards on the terrain during operation.

PRE-OPERATION CHECK LIST

(OWNER'S RESPONSIBILITY)

___ Review and follow all safety rules and safety

decal instructions on pages 3 through 7.

___ Check that all safety decals are installed and in

good condition. Replace if damaged.

___ Check to make sure all shields and guards are

properly installed and in good condition. Be sure that either the discharge shield or complete vacuum attachment is installed.

2. Take all possible precautions when leaving tractor unattended: disengage mid-PTO, set parking brake, stop engine, remove key, and lower mower to ground.

___ Inspect area and remove stones, branches or

other hard objects that might be thrown, causing injury or damage.

___ Check to ensure blades are sharp, in good con-

dition, and installed correctly. Replace if damaged.

___ Check all lubrication points and grease as

instructed in Lubrication Points, page 15.

___ Check cutting height and attitude adjustment.

___ Check that all hardware and cotter pins are

properly installed and secured.

___ Check that equipment is properly and securely

attached to power unit.

___ Make sure driveline spring-activated locking pin

or collar slides freely and is seated firmly in power unit PTO spline groove and in gearbox spline groove.

___ Make sure tractor 3-point lift links do not inter-

fere with hydraulic hoses or driveline throughout full turning range.

___ Do not allow riders.

12 Operation

MAN0137 (9/14/01)

Page 15

OWNER SERVICE

The information in this section is written for operators who possess basic mechanical skills. If you need help, your dealer has trained service technicians available. For your protection, read and follow the safety information in this manual.

WARNING

 Before working underneath, read Operator's Manual and Blocking Method section. Disconnect driveline, raise mower, install transport lock, securely block up all corners, and check stability. Secure blocking prevents equipment from dropping due to hydraulic leak down, hydraulic system failures, or mechanical component failures.

 Keep all persons away from operator control area while performing adjustments, service, or maintenance.

CAUTION

 Always wear relatively tight and belted clothing to avoid entanglement in moving parts. Wear sturdy, rough-soled work shoes and protective equipment for eyes, hair, hands, hearing, and head.

Blocking Method

WARNING

1. Do not work underneath mower unless it is prop-

erly attached to the tractor and blocked securely. When properly attached, the unit will be anchored to minimize front-to-rear movement.

2. Raise mower completely, set tractor brakes, turn engine off, remove key, block tractor wheels front and rear.

3. Install transport lock (see Transport Lock Operation, page 9).

4. Disconnect mower driveline from tractor PTO.

DC2937

Figure 5 Block Location

NOTE: When blocking, you must consider overall sta-

bility of the unit. Just blocking under the unit will not ensure your safety. The working surface must be level and solid to support the loaded weight of the blocks. Test blocking stability before working under any portion of the mower.

5. Install blocks securely under each corner of the mower, Figure 5.

MAN0137 (9/14/01)

Owner Service 13

Page 16

OWNER SERVICE Cont’d

Lubrication

1. Do not let excess grease collect on or around

parts, particularly when operating in sandy areas.

2. Figure 6 shows the lubrication points. The accompanying chart gives the frequency of lubrication in operating hours, based on normal operating conditions. Severe or unusual conditions may require more frequent lubrication. Some reference numbers have more than one location; be sure you lubricate all locations.

3. Use SAE 90W gear lube in the gearbox. Check gearbox daily for evidence of leakage at both seals and the gasket between the housing and cover. If leakage is noted, repair immediately. There may be a small amount of lube emitted from the vent plug; this is not considered leakage.

4. Check lube level every 50 hours by removing the vent plug and inserting an object such as a wooden pencil through the hole until it touches the bottom of the gearbox. The oil level should show 1" on the pencil. You may also check the oil by using an Allen wrench to remove the level plug in the front of the gearbox.

5. Over-filling the gearbox will cause the excess gear lube to blow out vent plug. The gear lube could then ruin the belt.

6. Use a lithium grease of #2 consistency with a MOLY (molybdenum disulfide) additive for all locations. Be sure to clean fittings thoroughly before attaching grease gun. When applied according to the lubrication chart, one good pump of most guns is sufficient.

7. In addition to the lubrication points shown (Figure

6), oil the six mower lift pivot points (See Oilite Bushing Location, page 21), at least once a year.

Drive Shaft Lubrication

1. Lubricate the drive shaft slip joint every 8 operat-

ing hours. Failure to maintain proper lubrication could result in damage to U-joints, gearbox and drive shaft.

2. Lower mower to ground and apply a bead of grease all around the male half where it meets the female half. Raise and lower mower several times to distribute grease.

14 Owner Service

MAN0137 (9/14/01)

Page 17

OWNER SERVICE Cont’d

DC2962A

REF DESCRIPTION FREQUENCY

1 Caster pivot 8 hrs.

2 Chaster wheel 8 hrs.

3 Blade Spindle 24 hrs.

4 Gearbox- Check level

(check for leaks daily)

5 Drive shaft U-Joints 8 hrs.

6 Rear gauge wheels 8 hrs.

7 Drive shaft slip joint 8 hrs.

8 Spring Take-Up pivot arm

(30W Oil)

9 Oil level plug

50 hrs.

24 hrs.

MAN0137 (9/14/01)

Figure 6 Lubrication Points

Owner Service 15

Page 18

OWNER SERVICE Cont’d

BLADE SERVICING

Inspect blades for condition and proper installation each time before operation. Replace any blade that is bent, excessively nicked, worn or has any other damage. Small nicks can be ground out when sharpening.

Remove Blades

1. For right and left spindles, install spindle lock

wrench (5) through belt shield (3) and into holes in spindle pulley as shown in Figure 7. Remove bolt (8) that has RIGHT HAND THREADS. Remove cup washers (7), washer (6), and blade (1).

2. On the center spindle use blade wrench handle (4). The handle will rotate against gearbox stand when blade bolt is removed.

3. Shoulder washer (2) will not normally come off unless intentionally removed.

1. Blade

2. Shoulder washer

3. Left blade shield

4. Spindle lock wrench handle

5. Spindle lock wrench 6 5/8 Standard flat washer

7. Cup washer

8. Blade bolt, special Nylok (right hand thread)

Figure 7 Blade Assembly

16 Owner Service

MAN0137 (9/14/01)

Page 19

OWNER SERVICE Cont’d

Install Blades

CAUTION

Refer to Figure 7.

1. Install spindle lock wrench (5) through belt shield (3) and into holes in spindle pulley as shown Figure 7.

 Your dealer can supply genuine replacement blades. Substitute blades may not meet original equipment specifications and may be dangerous.

IMPORTANT

■ We recommend you install a new Nylok blade

bolt when you replace the blade.

■ Do not substitute any bolt for the special

blade bolt. It is self-locking, meeting the non-loosening requirements for this application.

Sharpen Blades

IMPORTANT

■ When sharpening blades be sure to balance

them. Unbalanced blades will cause excessive vibration which can damage blade spindle bearings. Vibration may also cause structural cracks in mower components.

1. Remove blades.

2. Always sharpen both ends at the same time to

maintain balance. Follow original sharpening pattern. Do not sharpen blade to a razor edge. Leave from 1/32" to 1/16" blunt edge. Do not sharpen back side.

2. Install shoulder washer (2) if removed, small end up. Make sure blade cutting edge is positioned to lead in a clockwise rotation, as viewed from top of mower.

3. Install two cup washers (7) on bolt (8). Install washer (6) and blade (1) on bolt. Remember that bolt (8) has right hand threads; install bolt and blade assembly into spindle.

4. Torque bolt to 170 lbs.-ft. Remove spindle lock wrench from pulley and shield.

Follow Original Pattern

CD3411

Maintain Corner

1-32"

MAN0137 (9/14/01)

Figure 8 Blade Sharpening

Owner Service 17

Page 20

OWNER SERVICE Cont’d

Replace Belt

WARNING

■ Use care when installing or removing belt

from spring-loaded idler at step 5. Springs store energy when extended and, if released suddenly, can cause personal injury.

One of the major causes of belt failure is improper installation. Before installing a new belt, check pulley shafts and bearings for wear. Check pulley grooves for dirt. Make sure spindles turn freely and without wobble.

If grooves require cleaning, moisten a cloth with a non-flammable, non-toxic degreasing agent or commercial detergent and water.

Avoid excessive force during installation. Do not use tools to pry belt into pulley groove. Do not roll belt over pulleys to install. This can cause hidden damage and premature belt failure.

1. Loosen bolt holding belt guide A and swing it away from pulley B.

2. Pass a loop of belt underneath front of gearbox stand ahead of gearbox pulley C. Use care not to over-bend belt as bending can cause internal damage.

3. Route belt over pulley D.

4. Route belt around gearbox pulley C and route a

loop underneath rear of gearbox stand.

5. Use a 1-1/4" open end wrench to rotate idler arm E counter-clockwise enough to install belt around idler pulley F.

6. Route belt around spindle pulley "G" and idler pulley H.

7. Grasp remaining belt loop with both hands and pull the spring-loaded idler enough to route belt over spindle pulley B. Make sure spring-loaded idler E pivots freely with belt installed.

8. Adjust belt guide A to provide 1/16 to 1/8" clearance from belt. Torque bolt to 85 lbs.-ft.

LA1

Figure 9 Replace Belt

18 Owner Service

MAN0137 (9/14/01)

Page 21

DEALER SERVICE

The information in this section is written for dealer service personnel. The repair described here requires special skills and tools. If your shop is not properly equipped or your mechanics are not properly trained in this type of repair, you may be time and money ahead to replace complete assemblies

CAUTION

 Always wear relatively tight and belted clothing to avoid entanglement in moving parts. Wear sturdy, rough-soled work shoes and protective equipment for eyes, hair, hands, hearing, and head.

BLADE SPINDLE

WARNING

 Keep all persons away from operator control area while performing adjustments, service, or maintenance.

Remove Blade Spindle

1. Remove blade from spindle. (See Remove

Blades, page 16.)

2. Remove belt shield.

3. Remove belt from pulleys.

4. Remove bolt and flat washer from top of spindle

shaft.

Spindle Repair Tips

• As a reference point, the top of the spindle housing is the short portion.

• To minimize wear, bearing cups, cones and sleeves are press-fit to the shaft and will require a press or similar device for removal.

• When disassembling, support the housing casting to prevent damage.

Disassemble Blade Spindle

Refer to Figure 10, page 20

1. Support spindle in a press and push shaft (8) down through housing (5).

5. Disassemble split taper bushing (located on top of pulley) by removing the two bolts and inserting them into the threaded holes in bushing flange. Tighten bolts alternately to remove split taper bushing. Remove pulley.

6. Remove four bolts attaching spindle to mower frame and remove spindle.

• Remove bearing cups by placing a punch in the housing slots and driving cup out. Alternate punch positions from side to side. Use care to prevent housing damage.

•Permatex of the seals. Substitute seals may not meet original equipment specifications and could cause leakage.

3. Remove bearing cups from housing as described in Spindle Repair Tips section.

4. Remove bearing cone (4) from shaft (8).

®a

sealant is used on the outer diameter

2. Remove seals from housing.

a. Permatex is a registered trademark of the Permatex Corporation.

MAN0137 (9/14/01)

Dealer Service 19

Page 22

DEALER SERVICE Cont’d

Assemble Blade Spindle

IMPORTANT

■ Bearing adjustment is set by pressing sleeve

against bearing cone until proper adjustment is attained.

■ Improper positioning of seals can cause seal

failure.

1. Bearing cups and cones are designed to work

together. It is important to position them so the bearing cone taper mates with bearing cup taper.

2. Lubricate new cups (6) with a light oil. Place them in spindle housing (5) so they will mate with cones (4). Seat cups (6) against machined shoulder of housing with a press or by placing a large drift on the flat lip and driving them into housing.

3. Place bottom bearing cone (4) onto spindle shaft (8) with taper up. Seat on bottom shoulder of shaft with a press.

4. Insert shaft and bearing cone assembly through bottom of housing (5). Fill housing cavity with a lithium grease of #2 consistency with a MOLY (molybdenum disulfide) additive.

5. Place top bearing cone (4) on shaft (8) to mate with top bearing cup. Install sleeve (3) on shaft and press sleeve and bearing cone onto shaft until all bearing free play is removed and there is a slight drag. Check by spinning spindle. It should turn freely.

10. To prevent distortion to metal seal cage, carefully press seal into housing. Seal should seat firmly and squarely against machined shoulder in housing.

11. Make sure seal lip did not roll under. Distortion to seal cage or damage to seal lip will cause seal to leak. Damaged seals must be replaced.

12. Apply a thin coat of lubricant to top seal (2) and install with spring facing up away from center of housing. Top seal should be flush with top of housing.

13. Lubricate spindle with a lithium grease of #2 consistency with a MOLY (molybdenum disulfide) additive. Vent bottom seal with a blunt edged tool such as a letter opener while filling with grease. Rotate housing on spindle shaft, checking for free movement.

NOTE: Be careful not to over-tighten bearings. Proper bearing adjustment is essential to good bearing life. Should you over-tighten bearings, hold spindle housing and rap spindle shaft with a hammer and wood block to loosen bearings. Readjust bearings until proper setting is obtained.

6. Proper seal installation is important. An improperly installed seal will leak and could cause bearing failure.

7. Pull the rubber portion of seal back and locate spring.

8. Apply a thin coat of lubricant to bottom seal (2) and install with spring up toward center of housing.

9. Place bottom seal squarely onto housing. Select a piece of pipe or tubing with an OD that will sit onto outside edge of seal. A tube that is too small will bow seal cage.

DB3403

Figure 10 Spindle Repair

1. Spindle Assembly

2. Seal

3. Sleeve

4. Bearing cone

5. Housing

6. Cup

7. Grease fitting

8. Shaft

20 Dealer Service

MAN0137 (9/14/01)

Page 23

DEALER SERVICE Cont’d

Install Blade Spindle

IMPORTANT

■ Pulley installation sequence is very important

for bearing life. Follow the sequence exactly.

1. Insert spindle through bottom of mower deck and

install three mounting bolts. Be sure to position grease fittings toward lubrication access areas.

2. Install pulley (16) and split taper bushing (17) with integral key on spindle shaft.

3. Install bolt (44) and flat washer (45) in top of spindle shaft. Torque this bolt to 12 lbs.-ft.

4. Install split taper bushing bolts (47) and lock washers (42).

5. Alternately tighten and torque to 12 lbs.-ft.

Replace Oilite Bushings

1. Six pre-oiled bronze Oilite bushings are used in

the lift mechanism, two in front and four in rear (see Figure 12). Oil these bushings once a year to extend their life cycle.

DD3413A-1

Figure 11 Spindle Installation

Left Rear Rockshaft Mount

2. When replacement is required, use a new bushing to press the old bushing out. Make sure the new bushings are pressed in flush.

Oilite Bushing

Figure 12 Oilite Bushing Location

Oilite Bushing

Left Front Lift Stop

LA2

MAN0137 (9/14/01)

Dealer Service 21

Page 24

DEALER SERVICE Cont’d

UNIVERSAL JOINT REPAIR

1. Drive shaft yoke

2. Journal cross

3. Seal

4. Snap ring

5. Cup and bearings

6. Yoke

Figure 13 U-Joint Exploded View

CD1402

Disassemble U-Joint

1. Remove snap rings from inside of yokes in four

locations as shown in Figure 14.

2. With snap rings removed, support drive in vise, hold yoke in hand and tap on yoke to drive cup up out of yoke. See Figure 15.

CD1386

CD1384

Figure 14

22 Dealer Service

Figure 15

MAN0137 (9/14/01)

Page 25

DEALER SERVICE Cont’d

Disassemble U-Joint cont’d

3. Clamp cup in vise as shown in Figure 16 and tap

on yoke to completely remove cup from yoke. Repeat steps two and three for opposite cup.

4. Place universal cross in vise as shown in Figure 17 and tap on yoke to remove cup. Repeat step three for final removal. Drive remaining cup out with a drift and hammer.

CD1387

Figure 16

CD1388

Figure 17

MAN0137 (9/14/01)

Dealer Service 23

Page 26

DEALER SERVICE Cont’d

Assemble U-Joint

1. Place seals securely on bearing cups. Insert cup

into yoke from outside and press in with hand pressure as far as possible.

2. Insert journal cross into bearing cup with grease fitting away from the shaft. Be careful not to disturb needle bearings.

3. Insert another bearing cup directly across from first cup and press in as far as possible with hand pressure.

4. Trap cups in vise and apply pressure. Be sure journal cross is started into bearings and continue pressure with vise, squeezing in as far as possible. Tap yoke to aid in process.

5. Seat cups by placing a drift or socket (slightly smaller than the cup) on cup and rapping with a hammer. See Figure 18.

6. Install snap ring and repeat on opposite cup.

7. Repeat steps 1 and 2 to install remaining cups in

remaining yoke.

8. Move both yokes in all directions to check for free movement. Should movement be restricted, rap on yokes sharply with a hammer to relieve any tension. Repeat until both yokes move in all directions without restriction.

CD1389

Figure 18

GEARBOX MAINTENANCE

Read this complete section before starting any repair. Many steps are dependent on each other.

Gearbox bearings, gears, and shafts have an interference press fit. Gearbox repair is limited to seal, gasket, and vent plug replacement.

Always maintain correct gear lube level in gearbox. Be sure proper vent plug is installed.

Troubleshooting is an important part of gearbox maintenance. Check for leakage and bad bearings.

Leakage is a very serious problem and must be corrected immediately or damage to gearbox and belt will result. Remove gearbox from mower to repair leakage problems.

Leakage may be caused by a vent plug not venting. To check vent plug operation, remove plug and apply low air pressure to opening in side of plug. Check to make sure it is venting out of the top.

Operating gearbox with improper lube level may also cause seals to leak. Also check for housing cracks. If any of these conditions exist, correct them, clean area where leakage was evident, return mower to service, and check to make sure leakage has been stopped.

Bearing maladjustment or failure is indicated by noise and excessive side and end play in gear shafts. If this is indicated, replace the gearbox.

24 Dealer Service

MAN0137 (9/14/01)

Page 27

DEALER SERVICE Cont’d

Remove Gearbox

1. Disconnect drive shaft and remove key from key-

way.

2. Remove belt and remove gear stand from mower.

3. Turn gear stand over. There are two set screws in

the split taper bushing; remove them. Insert one set screw into the threaded bushing hole and tighten to force bushing and pulley apart.

4. Remove gearbox from stand.

Repair Gearbox Leak

Per matex®a sealant is used on the outer diameter of the seals. Substitute seals may not meet original equipment specifications and could cause leakage.

1. Clean gearbox exterior to remove all foreign material. When opening, use care to prevent foreign material from entering gearbox.

2. To repair horizontal seal, vertical shaft, or leakage between cover and gearbox, remove vent plug and drain gear lube from box.

3. Remove leaking seal and replace (refer to Install Seal, page 25). Use care to prevent rolling the seal lip under.

4. Replace gasket between cover and gearbox.

a. Permatex is a registered trademark of the Permatex Corporation.

Install Seal

Proper seal installation is important. An improperly installed seal will leak and could result in bearing failure.

1. Clean areas in housing where seal outer diameter seats. Inspect gear shafts. Pay specific attention to areas where seals seat. Check for cracks, grooves, nicks or bumps. Replace housing or shaft if damage cannot be repaired by resurfacing with emery cloth.

2. Lubricate seal lip and carefully guide over shaft using a blunt tool such as a letter opener. Be careful not to roll seal lip under. Do not use a knife as it will nick and ruin seal.

DB3449A

Figure 19 Gearbox Repair

3. Place seal squarely on housing (spring-loaded lip

toward inside of gearbox). Select a seal driver, a piece of pipe or tubing with an OD that will set on outside edge of seal but will clear housing. A driver that is too small will bow seal cage and ruin seal.

4. Carefully press seal into housing, preventing distortion to metal seal cage. Seat vertical seal flush with housing and horizontal seal against shoulder in housing.

Distortion to seal case or damage to seal lip will cause seal to leak. Remove and replace seals damaged in installation.

MAN0137 (9/14/01)

5. Check for proper vent plug operation and fill gearbox with 8 oz. of SAE 90W gear lube.

Dealer Service 25

Page 28

DEALER SERVICE Cont’d

Install Drive Pulley

1. Install drive pulley (19) with split taper bushing

(12) on gearbox vertical shaft. Make sure key (82) and keyways are aligned.

2. Position center line of drive pulley (19) 15/16" (plus or minus 1/32") above mounting surface of gearbox stand (20) as shown. This is a very critical

dimension and must be held.

3. Alternately tighten split taper bushing set screws

to 14 lbs.-ft. Check mounting distance to make sure it is correct.

NOTES

15/16"

Figure 20 Drive Pulley Dimensions

1-7/8"

DB2938

26 Dealer Service

MAN0137 (9/14/01)

Page 29

TROUBLE SHOOTING

MOWING CONDITIONS

Problem Possible Solutions

Grass cut higher in center of swath than at edges

Grass cut lower in center of swath than at edges

Streaking conditions in swath Conditions too wet for mowing Allow grass to dry before mowing.

Material discharges from mower unevenly; bunches of material along swath.

Height of mower higher at front than at rear

Loose blades Check clamping cup washers.

Height of mower lower at front than at rear

Loose blades Check clamping cup washers.

Blades unable to cut grass pressed down by path of tractor tires

Dull blades Sharpen or replace blades.

Material too high and too much material

Check cutting height adjustment. Refer to chart on page 9

Replace if flat or not holding.

Check cutting height adjustment. Refer to chart on page 9.

Replace if flat or not holding

Slow ground speed of tractor but keep mid-PTO running at 2000 rpm. Cutting lower will help. Under some conditions it is impossible to pick up and cut grass pressed down by tires.

Reduce ground speed but operate tractor mid-PTO at 2000 rpm maximum, or make two passes over material. Raise mower for the first pass and lower to desired height for the second and cut at 90 degrees to first pass. Raise rear of mower high enough to permit material discharge but not so high that conditions listed above occur.

Erratic mower operation; mower slows down without tractor engine slowing

MAN0136 (9/28/01)

Grass wet Allow grass to dry before mowing.

Slow ground speed of tractor but keep mid-PTO at 2000 rpm maximum. Cutting lower will help.

Rear of mower too low, trapping material under mower

Clipping packed to underside of mower

Belt slippage See Trouble Shooting Belt Condi-

Adjust mower height. Refer to chart. page 9

Remove clippings and clean underside of mower.

tions, page 28.

Trouble Shooting 27

Page 30

Trouble Shooting Cont’d.

Problems Possible Solutions

TROUBLE SHOOTING

BELT CONDITIONS

Belt slippage Mower overloading; material too tall

or heavy

Oil on belt from over-lubrication Be careful not to over-lubricate.

Belt hung up or rubbing Check belt for free travel in pulleys

Belt or pulleys worn out If belt rides in bottom of pulley

Frayed edges on belt cover Belt misaligned Re-align belt. Be sure belt does not

Belt rollover Damaged belt Inspect all pulley grooves for rust,

Reduce tractor ground speed but operate mid-PTO at 2000 rpm. Cut material twice, one high pass and then mow at desired height. Cut a partial swath.

Clean lubricant from belt and pulleys with clean rag. Replace oil-soaked belt.

and belt guides. Check under mower and around blade spindle shafts for wire, rags, or foreign material. Clean material from under mower.

groove, either belt or pulley is worn and must be replaced.

rub any other part while running.

paint, or weld spots and remove.

Foreign object in pulley grooves Replace pulley.

Damaged belt Rollover, high shock loads, or instal-

lation damage

Belt breakage High shock loads Avoid abusive mowing. Avoid hitting

Belt came off drive Check pulleys for foreign material in

* Check belt for damage by laying it flat on the floor. A belt that does not lay flat (has humps or twists, indicating broken or stretched cords) it must be replaced.

Replace belt.*

the ground or obstructions.

grooves. Avoid hitting solid objects or ground.

28 Trouble Shooting

MAN0136 (9/28/01)

Page 31

ASSEMBLY

DEALER SET-UP INSTRUCTIONS

Assembly of this mower is the responsibility of the Woods dealer. If should be delivered to the owner completely assembled, lubricated, and adjusted for normal mowing conditions.

WARNING

Set up the mower as received from the factory with these instructions. Complete check lists on page 42 when assembly is completed.

The mower is shipped partially assembled. Assembly will be easier if components are aligned and loosely assembled before tightening hardware. Recommended torque values for hardware are located on page 52.

Select a suitable working area. Open parts boxes and lay out parts and hardware to make location easy. Refer to illustrations, accompanying text, parts lists, and exploded view drawings.

Adjust Wheel Stop Bolt

IMPORTANT

■ On all four wheel drive mountings, the front

tractor wheel stop bolts must be set. Failure to adjust may result in damage to tractor or mower.

1. The wheel stop bolts are located on the rear of

the front axle.

 Keep all persons away from operator control area while performing adjustments, service, or maintenance.

CAUTION

 Always wear relatively tight and belted clothing to avoid entanglement in moving parts. Wear sturdy, rough-soled work shoes and protective equipment for eyes, hair, hands, hearing, and head.

Mid-PTO Operation

Refer to the tractor owner's manual for mid-PTO operation.

2. Loosen jam nut and adjust bolt in or out as necessary to obtain 18mm or 23/32" from axle casting to top of bolt. Tighten jam nut.

Install Front Mounting Plate

1. Install right and left front mounting plates (1 & 3)

outside tractor frame (4), using two bolts (8) and flange locknuts (7).

2. Install mounting plate brace bar (2) between mounting plates with carriage bolts (6) and locknuts (5).

1. Left front mounting plate

2. Mounting plate brace bar

3. Right front mounting plate

4. Tractor frame

5. 3/8 Hex lock nut

6. 3/8 x 1-1/4 Carriage bolt

7. 5/8 Lock nut

8. 5/8 x 1-1/2 Cap screw

MAN0137 (9/14/01)

Figure 21 Front Mounting Plate Installation

Assembly 29

Page 32

Assembly Instructions

Cont’d

Install Left Front Lift Stop

1. Attach left front lift stop (4) and spacer plate (2) to

tractor clutch housing mounting pad (5) with bolts (10 & 11). Bolt (10) is 5 mm shorter than bolt (11). Use the shorter bolts in the top holes of spacer plate (2) and bolts (11) in the center holes.

NOTE: Do not use spacer plate if tractor is equipped with front loader. When front loader mounting bracket (1) is installed, spacer plate (2) is not required. Do not use hardware from loader bracket to install left front lift stop (4); use the hardware supplied with mower.

2. Place a hardened flat washer (12) on bolts (10 &

11) and insert through spacer plate and into tractor clutch housing mounting pad (5).

3. Place flat washers (7) on bolts (9) and insert through bottom holes. Secure bolts (9) with locknuts (8).

4. Hand tighten all hardware.

5. Insert rockshaft (3), clevis forward as shown,

through lift stop (4). Place washer (13) over rockshaft and secure with spirol pin (6).

1. Loader mounting bracket

2. Spacer plate

3. Front rock shaft assembly

4. Left front lift stop

5. Tractor clutch housing mounting pad

6. 1/4 x 2 Spirol pin

7. 1/2 Flat washer

8. 1/2 Flange lock nut

9. 1/2 x 1-3/4 Cap screw

10. 14mm x 35mm Cap screw

11. 14mm x 40mm Cap screw

12. 9/16 Hardened flat washer

13. 1” Flat washer

Figure 22 Left Front Lift Stop Installation

30 Assembly

MAN0137 (9/14/01)

Page 33

Assembly Instructions

Cont’d

Install Right Front Lift Stop

1. Slide right front lift stop (4) over rockshaft (3).

2. Place spacer plate (2) over front lift stop and

secure both to tractor clutch housing mounting pad (5) with bolts (7 & 8) and hardened flat washers (9).

NOTE: If loader mounting bracket (1) is installed, do not use spacer plate. Attach lift stop directly to loader mounting bracket.

3. Bolt (7) is 5 mm shorter than bolt (8). Use the shorter bolts (7) in the top holes of spacer plate (2) and bolts (8) in the center holes.

4. Place a hardened flat washer (9) on bolts (7 & 8) and insert through spacer plate and into tractor clutch housing mounting pad (5).

5. Place washers (12) on bolts (11) and through bottom holes. Secure bolts (9) with locknuts (13).

6. Hand tighten all hardware.

7. Position both lift stops and rockshaft so rockshaft

rotates freely, then tighten the 14 mm bolts to 95 lbs.ft. and the 1/2" hardware to 85 lbs.-ft. on both front lift stops.

8. Place washer (10) over rockshaft and secure with spirol pin (6).

1. Loader mounting bracket (if installed)

2. Spacer plate

3. Front rockshaft assembly

4. Right front lift stop

5. Tractor clutch housing mounting pad

6. 1/4 x 2" Spirol pin

7. 14 mm x 35 mm Bolt

8. 14 mm x 40 mm Bolt

9. 9/16" Hardened flat washer

10. 1" Flat washer

11. 1/2 x 1-3/4" Bolt

12. 1/2" Flat washer

13. 1/2" Flanged locknut

Figure 23 Right Front Lift Stop Installation

MAN0137 (9/14/01)

Assembly 31

Page 34

Assembly Instructions

Install Right Rear Rockshaft

Cont’d

1. Jack up rear of tractor, block securely, and remove right rear tire.

2. Apply Loctite (9).

3. Install right rear rockshaft mounting bracket (3) to tractor transmission (2), using bolts (9). Secure to tractor axle mounting pad (1), using bolts (10) and hardened flat washers (11).

4. Hand tighten hardware.

5. Place right rear rockshaft assembly (4) into

mounting bracket (3) and insert rockshaft bar (6).

6. Align holes of rockshaft bar (6) and right rear rockshaft assembly (4). Secure with bolts (7) and locknuts (8).

7. Do not tighten hardware at this time.

8. Re install the right rear tire.

®a

242 to both 12 mm x 25 mm bolts

1. Tractor rear axle mounting pad

2. Tractor transmission

3. Right rear rockshaft mounting bracket

4. Right rear rockshaft assembly

6. Rockshaft bar

7. 3/8 x 1-3/4 Bolt

8. 3/8" Hex locknut

9. 12 mm x 25 mm Bolt

10. 14 mm x 30 mm Bolt

11. 9/16" Hardened flat washer

DB3416A

Figure 24 Right Rear Rockshaft Installation

a. Loctite is a registered trademark of the Loctite Corporation.

32 Assembly

MAN0137 (9/14/01)

Page 35

Assembly Instructions

Install Left Rear Rockshaft

Cont’d

1. Jack up rear of tractor, block securely, and remove left rear tire.

2. Apply Loctite (9).

3. Install left rear rockshaft mounting bracket (3) to tractor transmission (2), using bolts (9). Secure to tractor axle mounting pad (1), using bolts (10) and hardened flat washers (11).

4. Hand tighten hardware.

5. Place left rear rockshaft assembly (4) into mount-

ing bracket (3) and insert rockshaft bar (6).

6. Align holes of rockshaft bar (6) and left rear rockshaft assembly (4). Secure with bolts (7) and locknuts (8).

1. Tractor rear axle mounting pad

2. Tractor transmission

3. Left rear rockshaft mounting bracket

4. Left rear rockshaft assembly

5. 1 x 10.31" Crankshaft bar

6. 1 x 8.90" Rockshaft bar

7. 3/8 x 1-3/4 Bolt

8. 3/8" Hex locknut

9. 12 mm x 25 mm Bolt

10. 14 mm x 30 mm Bolt

11. 9/16" Hardened flat washer

®a

242 to both 12 mm x 25 mm bolts

7. Pass crankshaft bar (5) through rockshaft assembly (4) and right rockshaft assembly. Align holes of crankshaft bar holes in both right and left rockshaft assemblies. Secure with bolts (7) and locknuts (8).

8. Position left rear rockshaft mounting bracket (3) so that both right and left rockshaft assemblies rotate freely. It may be necessary to loosen the right side mounting and reposition.

9. After making adjustments, torque all 12 mm bolts (9) to 75 lb.-ft., 14 mm bolts (10) to 85 lb.-ft., and 3/8 bolts (7) to 35 lbs.-ft.

10. Reinstall the left rear tire.

Figure 25 Left Rear Rockshaft Installation

a. Loctite is a registered trademark of the Loctite Corporation.

MAN0137 (9/14/01)

Assembly 33

Page 36

Assembly Instructions

Cont’d

Install Transport Lock-Up

1. Slide lock-up bar (2) into left front lift stop (1).

1. Attach lock-up bar extension (3) using 1-1/4" hex

bolts (10) and 3/8" locknut (9).

2. Thread 1/2" jam nut (8) and clevis yoke (5) onto lock-up bar to obtain the 32" dimension shown in Figure 27. Hand tighten jam nut (8) against clevis yoke (5).

3. Secure clevis yoke (5) to rear rockshaft assembly (4) with clevis pin (6). Flat washers (11) must be installed as shown in Figure 26.

4. Secure clevis pin (6) with cotter pin (7). Do not spread cotter pin at this time.

5. Install handle grip (12) on lock-up bar (2)

1. Front lift stop

2. Lock-up bar

3. Lock-up bar extension

4. Rear rockshaft assembly

5. Clevis yoke

6. 1/2 x 1-3/4" Clevis pin

7. 3/16" x 1 Cotter pin

8. 1/2" Jam nut

9. 3/8" Locknut

10. 3/8 x 1-1/4" Bolt

11. 1/2" Flat washer

12. Handle grip

Figure 26 Transport Lock-Up Installation

32"

Figure 27 Lock-Up Bar Length

CD4178

CD4201B

34 Assembly

MAN0137 (9/14/01)

Page 37

Assembly Instructions

Cont’d

Assemble Mechanical Lift Pull Rod

1. Thread jam nut (17) onto pull rod (7) until it bot-

toms out.

NOTE: For tractor models 7000, 7200, and 7205, use pull rod (7A) with bend up to clear hydraulic line.

2. Thread clevis yoke (8) onto pull rod (7) to obtain a 33-1/4" dimension from center to center between the clevis and rod holes as shown. Hand tighten jam nut (17) against clevis yoke (8).

3. Attach pull rod assembly (17) to lug (21) on left rear rockshaft (6) and secure with washer (15) and cotter pin (16).

4. Connect clevis yoke (8) to front rockshaft (1) with clevis pin (12) and secure with cotter pin (16). Do not spread pin at this time.

5. Remove left lower 3-point arm (9) from lift mounting plate (4).

6. Remove the three axle housing bolts (19) and replace lift mounting plate (4) with the lift mounting plate supplied with mower lift kit.

7. Reinstall the three 12mm bolts and torque to 75 lbs.-ft.

8. Slide rear lift arm assembly (5) over lower 3-point arm (9) and slide both onto pin of lift mounting plate (4). Secure with Klik pin (10).

9. Thread clevis yoke (8) onto rear pull rod (3) to obtain 16.5" length.

10. Connect rear pull rod (3) to rear rockshaft (6) using clevis pin (14) and secure with washer (13) and cotter pin (16).

11. Connect clevis yoke (8) to rear lift arm assembly (5) with clevis pin (11) and cotter pin (16).

1. Front rockshaft assembly

2. Left front lift stop

3. Rear pull rod

4. Lift mounting plate assembly

5. Rear lift arm assembly

6. Left rear rockshaft assembly

7. Pull rod (7192, 7194, 7195) or

7A. Pull rod (bent) (7000,7200,7205)

8. Adjustable clevis yoke

9. 3-Point arm

10. Klik pin

11. 1/2 x 2-3/4" Clevis pin

12. 1/2 x 1-3/4" Clevis pin

13. 5/8" Flat washer

14. 5/8 x 1.65" Clevis pin

15. 1/2" Flat washer

16. 3/16 x 1-1/2" Cotter pin

17. 1/2" Jam nut

19. 12mm Bolt

20. ROPS

21. Lug

DC4203B

MAN0137 (9/14/01)

Figure 28 Mechanical Lift Pull Rod Assembly

Assembly 35

Page 38

Assembly Instructions

Cont’d

PREPARE MOWER

Install Discharge Chute

1. Position discharge chute (2) over stud (5) on

mower frame (1).

2. Install carriage bolts (3) (attached to discharge chute assembly) and secure with nuts (4).

3. Install knob (6) on stud (5).

1. Mower frame

2. Discharge chute

3. 3/8 x 1-1/4" Carriage bolt

4. 3/8" Nut

5. 3/8" Stud

6. 3/8" Knob

Install Mounting Channel & Lift Bar

NOTE: 7000, 7200 and 7205 tractors use alternate

front channel (1A).

1. Insert sleeve (5) into front mounting channel (1). Place washer (6) on bolt (7) and insert through sleeve (5) and front lift bracket (2).

2. Slide second sleeve (5) over bolt (7) and install front mower lift bar (3). Secure with flanged locknut (4).

3. Repeat this procedure for opposite side of front mounting channel.

LA3

Figure 29 Discharge Chute Installation

1. 7192, 7194, & 7195 Front mount channel

1A. 7000, 7200, & 7205 Front mount channel

2 Front lift bracket

3. Front mower lift bar, 6.5"

4. 1/2" Flanged locknut

5. 1/2 x 3/4 x 1/2" Sleeve

6. 1/2" Flat washer

7. 1/2 x 2" Bolt

36 Assembly

DB3406A

Figure 30 Front Channel Installation

MAN0137 (9/14/01)

Page 39

Assembly Instructions

Cont’d

Install Rear Lift Bars

1. Thread jam nut (3) onto upper rear lift bar (1) until

it bottoms out.

2. Thread upper rear lift bar into lower rear lift bar (2) to obtain the 8-1/4" dimension shown.

3. Hand tighten jam nut against lower rear lift bar.

4. Place washer (6) and sleeve (5) over bolt (7) and

insert through lower rear lift bar (2) and rear lift bracket (8). Secure with flanged locknut (4).

5. Repeat procedure for opposite side.

1. Upper rear lift bar

2. Lower rear lift bar

3. 1/2" Jam nut

4. 1/2" Flanged locknut

5. 1/2 x 3/4 x 1/2" Sleeve

6. 1/2" Flat washer

7. 1/2 x 1-1/2" Bolt

8. Rear lift bracket

Install Front Caster Wheel

1. Insert sleeve (68) through wheel (6).

2. Place washer (63) on bolt (70) and insert through

yoke (31) and sleeve in wheel.

3. Tighten flanged locknut (65) until yoke (31) contacts both ends of sleeve (68).

4. Check that wheel turns freely. Loosen and retighten if necessary.

5. Repeat procedure for opposite front caster wheel.

6. Caster wheel

31. Wheel yoke

63. 1/2" Flat washer

65. 1/2" Flanged locknut

68. 1/2 x 3/4 x 3-3/8" Sleeve

70. 1/2 x 5" Bolt

Figure 31 Rear Lift Bar Installation

Figure 32 Front caste Wheel Installation

MAN0137 (9/14/01)

Assembly 37

Page 40

Assembly Instructions

Cont’d

Install Rear Gauge Wheel

1. Assemble gauge wheel with grease fitting facing

outward for lubrication access.

1. Insert sleeve (68) through wheel (6).

2. Place washer (63) on bolt (69) and insert through

sleeve in wheel and rear gauge wheel arm (7).

3. Secure with flanged locknut (65).

4. Repeat for opposite side.

6. Gauge wheel

7. Rear gauge wheel arm

63. 1/2" Flat washer

65. 1/2" Flanged locknut

68. 1/2 x 3/4 x 3-3/8" Sleeve

69. 1/2 x 4-1/2" Bolt

Install Mid-PTO Driveshaft

IMPORTANT

■ Stake end of keyway to secure key.

1. Insert key (3) into gearbox (2) input shaft.

2. Install driveshaft (1) onto gearbox shaft and

secure with spirol pin (4).

21. Driveshaft assembly

22. Gearbox

46. 1/4 x 1/4 x 7/8" Key

60. 3/8 x 1-1/2" Spirol pin

Figure 33 Rear Gauge Wheel Installation

Figure 34 Driveshaft Installation

38 Assembly

MAN0137 (9/14/01)

Page 41

Assembly Instructions

Cont’d

Install Gearbox Vent Plug

1. Remove and discard solid plug from top of gear-

box cover.

2. Remove level plug (2) when filling and checking oil level.

3. Fill gearbox with SAE 90W oil until it reaches level hole in front of gearbox.

4. Reinstall level plug.

5. Install plastic vent plug (3) from bag of parts.

DB2947A

1. Gearbox

2. Level plug

3. Vent plug

Install Rear Lift Stop

1. Attach rear lift stop (1) to gearbox stand (3) with

two bolts (4) and locknuts (5) as shown.

NOTE: Rear lift stops (1 & 2) are the same part, mounted differently for gear and hydro tractors.

1. Rear lift stop (Hydro)

2. Rear lift stop (Gear)

3. Gearbox stand

4. 3/8 x 1" Bolt

5. 3/8" Locknut

Figure 35 Vent Plug Installation

MAN0137 (9/14/01)

Figure 36 Rear Lift Stop Installation

Assembly 39

Page 42

Assembly Instructions

Cont’d

Attach Mower to Tractor

Refer to Figure 37.

WARNING

 Keep all persons away from operator control area while performing adjustments, service, or maintenance.

 Make sure spring-activated locking pin or collar slides freely and is seated firmly in tractor PTO spline groove.

1. Be sure belt shields are installed on mower.

2. Remove lynch pins from front caster arms.

3. Remove clevis pin from rear gauge wheel handle.

Make sure rear mower lift bars (8) are down as far as possible.

4. Make sure that driveshaft (9) is between lift bars (8).

5. Drive tractor up to mower frame. Position boards between front tractor tires and mower to serve as a transition ramp, and drive tractor over frame.

6. Attach front mounting channel (4) to front mounting plates (3) with spring-loaded front channel pin (2).

7. Attach front mounting plate cover (1) to front mounting plates (3) with bolts (15) and washers (14).

8. Place front lift bars (6) in clevis portion of front rockshaft (7). Attach with clevis pins (17) and klik pins (13).

9. Place rear mower lift bars (8) over stud on rear rockshaft (10 & 11) and secure with washer (16) and Klik pin (13).

10. Attach driveshaft (9) to mid-PTO shaft (12).

1. Front mounting plate cover

2. Spring-loaded front channel pin

3. Front mounting plate assembly

4. Front mounting channel

5. Mower frame 6 Front mower lift bar

7. Front rockshaft assembly

8. Rear mower lift bar

9. Driveshaft assembly

10. Right rear rockshaft assembly

11. Left rear rockshaft assembly

12. Tractor mid-PTO

13. 3/16 x 1" Klik pin

14. 5/16" Flat washer

15. 5/16 x 3/4" Bolt

16. 1/2" Flat washer

17. 1/2 x 1-3/4" Clevis pin

40 Assembly

DB4200A

Figure 37 Attach Mower to Tractor

MAN0137 (9/14/01)

Page 43

Assembly Instructions

Cont’d

Adjust Mower with Mechanical Lift

1. Remove clevis pin connecting rear pull rod (10) to

the rear lift arm assembly (12).

2. Raise tractor lower 3-point lift arms (3) to their highest position.

3. Remove clevis pin that connects clevis yoke (9) to front rockshaft (1).

4. Block mower frame (2) up against front lift stop (4) and so rear lift stop (13) contacts tractor transmission.

5. With tractor lower 3-point arms (3) in their highest position, rotate rear rockshaft (8) up and adjust rear pull rod (10) until clevis pin connecting rear pull rod (10) to rear lift arm assembly (12) just slips in. Install clevis pin and secure with cotter pin.

1. Front rockshaft assembly

2. Mower frame

3. 3-Point lift arm

4. Front lift stop

5. Pull rod

6. Upper rear lift link

7. Lower rear lift link

8. Rear rockshaft assembly

9. Adjustable clevis yoke

10. Rear pull rod

11. Lock-up bar

12. Rear lift arm assembly

13. Rear lift stop

6. Rotate front rockshaft assembly (1) up and adjust clevis yoke (9) on pull rod (5) until clevis pin just slips in. Install clevis pin and secure with cotter pin.

7. Remove block from mower frame. The deck will drop slightly. Readjust clevis (9) and rear pull rod (10) so mower just contacts lift stops when 3-point arms are at maximum lift height.

8. With tractor 3-point arms at their maximum lift height, adjust lock-up bar (11) and clevis (9) so slot on lock-up bar will just drop into lock position. Spread cotter pin on clevis pin that connects clevis yoke (9) to rear rockshaft (8).

MAN0137 (9/14/01)

Figure 38 Mechanical Lift Adjustment

Assembly 41

Page 44

Assembly Instructions

Cont’d

PRE-DELIVERY CHECK LIST DELIVERY CHECK LIST

(DEALER’S RESPONSIBILITY)

Inspect the equipment thoroughly after assembly to make sure it is set up properly before delivering it to the customer. The following check list is a reminder of points to inspect. Check off each item as it is found satisfactory, corrections are made, or services are performed.

___ Check all bolts to be sure they are properly

torqued.

___ Check that all cotter pins and safety pins are

properly installed. Replace if damaged.

___ Check and grease all lubrication points as iden-

tified in “Service, lubrication information

___ Check the level of gearbox fluids before deliv-

ery. Service, if required, as specified in the “Service, lubrication information.”

___ Check that blades have been properly installed.

(DEALER’S RESPONSIBILITY)

___ Show customer how to make adjustments and

select proper PTO speed.

___ Check mower attitude and belt alignment.

___ Instruct customer how to lubricate and explain

importance of lubrication.

___ Point out the safety decals. Explain their mean-

ing and the need to keep them in place and in good condition. Emphasize the increased safety hazards when instructions are not followed.

___ Point out all guards and shields. Explain their

importance and the safety hazards that exist when not kept in place and in good condition.

___ Present Operator's Manual and request that

customer and all operators read it before operating equipment. Point out the manual safety rules, explain their meanings and emphasize the increased safety hazards that exist when safety rules are not followed.

___ Explain to customer that when equipment is

transported on a road or highway, a Slow Moving Vehicle (SMV) sign should be used to provide adequate warning to operators of other vehicles.

42 Assembly

MAN0137 (9/14/01)

Page 45

PARTS

CONTACT YOUR WOODS DEALER TO ORDER PARTS

To locate your nearest dealer:

 Check the Dealer Locator at www.WoodsEquipment.com, or

 In the United States and Canada, phone 1-800-319-6637

 Outside the United States, phone 1-815-732-9509 plus the

appropriate international dialing code for the USA

To order correct parts, provide this information to your dealer:

 Model Number: ____________________________

 Serial Number: ____________________________

Parts

Page 46

BOLT TORQUE CHART

(

)

(

)

Always tighten hardware to these values unless a different torque value or tightening procedure is listed for a specific application. Fasteners must always be replaced with the same grade as specified in the manual parts list. Always use the proper tool for tightening hardware: SAE for SAE hardware and Metric for metric hardware. Make sure fastener threads are clean and you start thread engagement properly. All torque values are given to specifications used on hardware defined by SAE J1701 & J1701M JUL96.

SAE SERIES

Diameter

(Inches)

1/4” 7/16” 6 8 10 13 14 18

5/16”1/2”121719262737

3/8” 9/16” 23 31 35 47 49 67

7/16”5/8”3648557578106

1/2” 3/4” 55 75 85 115 120 163

9/16” 13/16” 78 106 121 164 171 232

5/8” 15/16” 110 149 170 230 240 325

3/4” 1-1/8” 192 261 297 403 420 569

7/8” 1-15/16” 306 416 474 642 669 907

1” 1-1/2” 467 634 722 979 1020 1383

TORQUE CHART

Wrench

Size

SAE Grade 2

(No Dashes)

SAE 2 SAE 5 SAE 8

Lbs.-Ft. N-m Lbs.-Ft. N-m Lbs.-Ft. N-m

METRIC SERIES

TORQUE CHART

Diameter &

Thread Pitch

(Millimeters)

6 x 1.0 10 mm 8 6 11 8 8 6 11 8 6 x 1.0

8 x 1.25 13 mm 20 15 27 20 21 16 29 22 8 x 1.0

10 x 1.5 16 mm 39 29 54 40 41 30 57 42 10 x 1.25

12 x 1.75 18 mm 68 50 94 70 75 55 103 76 12 x 1.25

14 x 2.0 21 mm 109 80 151 111 118 87 163 120 14 x 1.5

16 x 2.0 24 mm 169 125 234 173 181 133 250 184 16 x 1.5

18 x 2.5 27 mm 234 172 323 239 263 194 363 268 18 x 1.5

20 x 2.5 30 mm 330 244 457 337 367 270 507 374 20 x 1.5

22 x 2.5 34 mm 451 332 623 460 495 365 684 505 22 x 1.5

24 x 3.0 36 mm 571 421 790 583 623 459 861 635 24 x 2.0

30 x 3.0 46 mm 1175 867 1626 1199 1258 928 1740 1283 30 x 2.0

Wrench

Size

N-m Lbs.-Ft. N-m Lbs.-Ft. N-m Lbs.-Ft. N-m Lbs.-Ft.

COARSE THREAD FINE THREAD

MARKING ON HEAD MARKING ON HEAD

Metric 8.8 Metric 10.9 Metric 8.8 Metric 10.9

SAE Bolt Head

Identification

8.8

Metric

Grade 8.8

SAE Grade 5

3 Radial Dashes

MARKING ON HEAD

Metric Bolt Head

Identification

SAE Grade 8

6 Radial Dashes

10.9

Metric

Grade 10.9

Diameter &

Thread Pitch

(Millimeters)

Typical Washer Installations

Lockwasher

Bolt

52 Appendix

Nut

Flat Washer

8/9/00

Bolt Torque & Size Charts (Rev. 9/5/00)

Page 47

BOLT SIZE CHART

NOTE: Chart shows bolt thread sizes and corresponding head (wrench) sizes for standard SAE and metric bolts.

SAE Bolt Thread Sizes

5/16 3/8 1/2 5/8 3/4 7/8

IN 1 2 3 4 5 6 7

MM 25 50 75 100 125 150 175

Metric Bolt Thread Sizes

8MM 18MM14MM12MM10MM 16MM

ABBREVIATIONS

AG............................................................. Agriculture

ATF .............................. Automatic Transmission Fluid

BSPP ........................... British Standard Pipe Parallel

BSPTM ..............British Standard Pipe Tapered Male

CV................................................... Constant Velocity

CCW ............................................ Counter-Clockwise

CW............................................................. Clockwise

F .....................................................................Female

GA ................................................................... Gauge

GR (5, etc.) ......................................... Grade (5, etc.)

HHCS ...................................... Hex Head Cap Screw

HT.......................................................... Heat Treated

JIC ...............Joint Industry Council 37° Degree Flare

LH ............................................................... Left Hand

LT ..........................................................................Left

m....................................................................... Meter

mm.............................................................. Millimeter

M.........................................................................Male

MPa ....................................................... Mega Pascal

N .................................................................... Newton

NC ....................................................National Coarse

NF......................................................... National Fine

NPSM ...................National Pipe Straight Mechanical

NPT ........................................ National Pipe Tapered

NPT SWF........ National Pipe Tapered Swivel Female

ORBM ......................................... O-Ring Boss - Male

P .........................................................................Pitch

PBY .....................................................Power Beyond

psi ........................................Pounds per Square Inch

PTO ................................................... Power Take Off

QD ..................................................Quick Disconnect

RH ............................................................Right Hand

ROPS.......................... Roll Over Protective Structure

RPM....................................... Revolutions Per Minute

RT...................................................................... Right

SAE ........................ Society of Automotive Engineers

UNC .................................................... Unified Coarse

UNF ........................................................ Unified Fine

UNS ....................................................Unified Special

Bolt Torque & Size Charts (Rev. 9/5/00)

Appendix 53

Page 48

WARRANTY

(Replacement Parts For All Models Except Mow’n Machines)

WEC Company, d/b/a Woods Equipment Company (“WOODS”), warrants this product to be free from defect in material and workmanship for a period of ninety (90) days from the date of delivery of the product to the original purchaser with the exception of V-belts, which will be free of defect in material and workmanship for a period of 12 months.

This Warranty is extended solely to the original purchaser of the product. Should the original purchaser sell or otherwise transfer this product to a third party, this Warranty does not transfer to the third party purchaser in any way. There are no third party beneficiaries of this Warranty.

WOODS’ obligation under this Warranty is limited to, at WOODS’ option, the repair or replacement, free of charge, of the product if WOODS, in its sole discretion, deems it to be defective or in noncompliance with this Warranty. The product must be returned to WOODS with proof of purchase within thirty (30)

days after such defect or noncompliance is discovered or should have been discovered, routed through the dealer and distributor from whom the purchase was made, transportation charges prepaid.

WOODS shall complete such repair or replacement within a reasonable time after WOODS receives the product. THERE ARE NO OTHER REMEDIES UNDER THIS WARRANTY. THE REMEDY OF REPAIR OR REPLACEMENT IS THE SOLE AND EXCLUSIVE REMEDY UNDER THIS WA R RA N TY.

THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE OF THIS WARRANTY. WOODS MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED, AND WOODS SPECIFICALLY DISCLAIMS ANY IMPLIED WARRANTY OF MERCHANTABILITY AND/ OR ANY IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

WOODS shall not be liable for any incidental or consequential losses, damages or expenses, arising directly or indirectly from the product, whether such claim is based upon breach of contract, breach of warranty, negligence, strict liability in tort or any other legal theory. Without limiting the generality

of the foregoing, Woods specifically disclaims any damages relating to (i) lost profits, business, revenues or goodwill; (ii) loss of crops; (iii) loss because of delay in harvesting; (iv) any expense or loss incurred for labor, supplies, substitute machinery or rental; or (v) any other type of damage to property or economic loss.

This Warranty is subject to any existing conditions of supply which may directly affect WOODS’ ability to obtain materials or manufacture replacement parts.

No agent, representative, dealer, distributor, service person, salesperson, or employee of any company, including without limitation, WOODS, its authorized dealers, distributors, and service centers, is authorized to alter, modify, or enlarge this Warranty.

Answers to any questions regarding warranty service and locations may be obtained by contacting:

Woods Equipment Company

2606 South Illinois Route 2 Post Office Box 1000 Oregon, Illinois 61061

815-732-2141 tel 815-732-7580 fax www.WoodsEquipment.com

F-8494 (Rev. 7/15/2004)

Page 49

WARRANTY

(All Models Except Mow’n Machines)

Please Enter Information Below and Save for Future Reference.

Date Purchased: __________________________ From (Dealer): ________________________________________

Model Number: __________________________ Serial Number:________________________________________

WEC Company, d/b/a Woods Equipment Company (“WOODS”), warrants this product to be free from defect in material and workmanship. Except as otherwise set forth below, the duration of this Warranty shall be for TWELVE (12) MONTHS COMMENCING ON THE DATE OF DELIVERY OF THE PRODUCT TO THE ORIGINAL PURCHASER.

The warranty periods for certain gearboxes are listed below:

Model No. Part Warranted Duration

PHD25, PHD35, PHD65, PHD95, 1260, 2120, 2162, 3180, 3240, BB600, BB720, BB840, BB6000, BB7200, BB8400, BW180, RM550-2, RM660-2, RM990-3, RD6000-2, RD7200-2, RD8400-2, 7144RD-2, 9180RD-2, 9204RD-2

BB48, BB60, BB72, BB84, RCC42

BW180

Under no circumstances will this Warranty apply in the event that the product, in the good faith opinion of WOODS, has been subjected to improper operation, improper maintenance, misuse, or an accident. This Warranty does not apply in the event that the product has been materially modified or repaired by someone other than WOODS, a WOODS authorized dealer or distributor, and/or a WOODS authorized service center. This Warranty does not cover normal wear or tear, or normal maintenance items. This Warranty also does not cover repairs made with parts other than those obtainable through WOODS.

WOODS makes no warranty, express or implied, with respect to engines, batteries, tires or other parts or accessories not manufactured by WOODS. Warranties for these items, if any, are provided separately by their respective manufacturers.

WOODS with proof of purchase within thirty (30) days after such defect or noncompliance is discovered or should have been discovered, routed through the dealer and distributor from whom the purchase was made, transportation charges prepaid.

THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE OF THIS WARRANTY. WOODS MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED, AND WOODS SPECIFICALLY DISCLAIMS ANY IMPLIED WARRANTY OF MERCHANTABILITY AND/OR ANY IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

business, revenues or goodwill; (ii) loss of crops; (iii) loss because of delay in harvesting; (iv) any expense or loss incurred for labor, supplies, substitute machinery or rental; or (v) any other type of damage to property or economic loss.

This Warranty is subject to any existing conditions of supply which may directly affect WOODS’ ability to obtain materials or manufacture replacement parts.

No agent, representative, dealer, distributor, serviceperson, salesperson, or employee of any company, including without limitation, WOODS, its authorized dealers, distributors, and service centers, is authorized to alter, modify, or enlarge this Warranty.

Answers to any questions regarding warranty service and locations may be obtained by contacting:

Gearbox

components

Gearbox

components

Gearbox

components

5 years from the date of delivery to the original purchaser.

3 years from the date of delivery to the original purchaser.

1 year from the date of delivery to the original purchaser if used in rental or commercial applications.

Woods Equipment Company

2606 South Illinois Route 2 Post Office Box 1000 Oregon, Illinois 61061

815-732-2141 tel 815-732-7580 fax www.WoodsEquipment.com

F-3079 (Rev. 7/15/2004)

Page 50

PART NUMBE R

MAN0137

Woods Equipment Company

2606 Illinois Route 2 South Post Office Box 1000 Oregon, Illinois 61061

815-732-2141 tel 815-732-7580 fax