Woods Equipment MAN0680, BB6000X, BB7200X, BB8400X User Manual

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Page 1

BRUSHBULL

ROTARY CUTTER

BB6000X BB7200X BB8400X

MAN0680

(Rev. 4/24/2009)

Page 2

TO THE DEALER:

Assembly and proper installation of this product is the responsibility of the Woods 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 Product Registration online at the Woods Dealer Website or complete the mail-in form included with the Operator’s Manual. If using the mail-in form, the dealer is to return the prepaid postage portion to Woods, give one copy to the customer, and retain one copy. Failure to register the product does not diminish

customer’s warranty rights.

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 adjustment and operating procedures before attempting to operate. Replacement manuals can be obtained from your dealer. To locate your nearest dealer, check the Dealer Locator at www.WoodsEquipment.com, or in the United States and Canada call 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:

dealer. Read manual instructions

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 NOTICE 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.

2 Introduction

Gen’l (Rev. 2/19/2008)

Page 3

TABLE OF CONTENTS

Si no lee Ingles, pida ayuda a

alguien que si lo lea para que le

traduzca las medidas de seguridad.

LEA EL INSTRUCTIVO!

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SAFETY VIDEO ORDER FORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

OWNER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

DEALER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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

DEALER CHECK LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

INDEX TO PARTS LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

BOLT TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

BOLT SIZE CHART & ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 46

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

PRODUCT WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

REPLACEMENT PARTS WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

MAN0680 (11/30/2007)

Introduction 3

Page 4

SPECIFICATIONS

WARNING

Cutting Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2" - 12"

Blade Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Number of Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heat Treated Alloy Steel

Blade Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CCW

Tractor PTO rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540

Universal Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Category 5

Cutter Frame Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/4"

Tailwheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5" x 16"

Specification BB6000X BB7200X BB8400X

Cutting Width 60" 72" 84"

Overall Width 67.5" 79.5" 91.5"

Weight (Approximate lbs.) 1300 lbs 1500 lbs 1790 lbs

Blade Speed (Feet per minute) 13,575 13,950 14,250

Gearbox 1:1.6 1:1.37 1:1.2

Recommended Maximum Tractor HP 40 - 150 50 - 150 65 - 150

3-Point Hitch I - II I - II II - III

GENERAL INFORMATION

 Some illustrations in this manual show the equipment with safety shields removed to provide a better view. This equipment should never be operated with any necessary safety shielding removed.

The purpose of this manual is to assist you in operating and maintaining your cutter. 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

4 Introduction

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.

Throughout this manual, references are made to right and left directions. These are determined by standing behind the equipment facing the direction of forward travel. Blade rotation is counterclockwise as viewed from the top of the cutter.

MAN0680 (11/30/2007)

Page 5

Free Mower Safety Video

Fill out and return the order form and we will send you a FREE VHS or DVD video outlining

Industrial and Agricultural Mower Safety

Practices

. The 22 minute video, developed in cooperation with AEM (Association of Equipment Manufacturers), reinforces the proper procedures to follow while operating your mowing equipment. The video does not replace the information contained in the Operator’s Manual, so please review this manual thoroughly before operating your new mowing equipment.

Safety Training Does Make a Difference.

BE SAFE!

BE ALERT!

BE ALIVE!

BE TRAINED Before Operating Mowers!

ASSOCIATION OF EQUIPMENT MANUFACTURERS

Safety Video Order Form

Safety Video Order Form (8/2/2005)

Safety 5

Page 6

Also, available from the Association of Equipment Manufacturers:

A large variety of training materials (ideal for groups) are available for a nominal charge from AEM. Following is a partial list:

● Training Package for Rotary Mowers/Cutters-English

Contains: DVD & VHS (English)

Guidebook for Rotary Mowers/Cutters (English) AEM Industrial/Agricultural Mower Safety Manual (English) AEM Agricultural Tractor Safety Manual (English)

● Training Package for Rotary Mowers/Cutters-English/Spanish

Contains: DVD & VHS (English/Spanish)

Guidebook for Rotary Mowers/Cutters (English/Spanish) AEM Industrial/Agricultural Mower Safety Manual (English/Spanish) AEM Agricultural Tractor Safety Manual (English/Spanish)

AEM training packages are available through:

AEM at:

or Universal Lithographers, Inc. Email: aem@ulilitho.com

800-369-2310 tel 866-541-1668 fax

www.aem.org



Free Mower/ Cutter Safety Video Order Form

3 (Select one)

VHS Format - VHS01052 Safety Video

Please send me

Name: ________________________________________ Phone: __________________

Address: _____________________________________

_____________________________________

Mower/Cutter Model: ______________________ Serial #: ________________________

Send to: ATTENTION: DEALER SERVICES

WOODS EQUIPMENT COMPANY

PO BOX 1000 OREGON IL 61061-1000 USA



DVD Format - DVD01052 Safety Video



6 Safety

Safety Video Order Form (Rev. 2/6/2006)

Page 7

TRAINING

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.

SAFETY RULES

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

 Safety instructions are important! Read all attachment and power unit manuals; follow all safety rules and safety decal information. (Replacement manuals and safety decals are available from your dealer. To locate your nearest dealer, check the Dealer Locator at www.WoodsEquipment.com, 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.

 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.

 Make sure driveline guard tether chains are attached to the tractor and equipment as shown in the pamphlet that accompanies the driveline. Replace if damaged or broken. Check that driveline guards rotate freely on driveline before putting equipment into service.

 Before starting the power unit, check all equipment driveline guards for damage. Replace any damaged guards. Make sure all guards rotate freely on all drivelines. If guards do not rotate freely on drivelines, repair and replace bearings before putting equipment into service.

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

 Inspect chain, rubber, or steel band shielding before each use. Replace if damaged.

 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.)



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.

 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 getting caught in moving parts. Wear sturdy, rough-soled work shoes and protective equipment for eyes, hair, hands, hearing, and head; and respirator or filter mask where appropriate.

Single Spindle HD (Rev. 9/15/2006)



Make sure shields and guards are properly

installed and in good condition. Replace if damaged.

 Do not put this equipment into service unless all side skids 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.

(Safety Rules continued on next page)

Safety 7

Page 8

(Safety Rules continued from previous page)

SAFETY RULES

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

OPERATION

 Full chain, rubber, or steel band shielding must be installed when operating in populated areas or other areas where thrown objects could injure people or damage property.

• If this machine is not equipped with full chain, rubber, or steel band shielding, operation must be stopped when anyone comes within 300 feet (92 m).

• This shielding is designed to reduce the risk of thrown objects. The mower deck and protective devices cannot prevent all objects from escaping the blade enclosure in every mowing condition. and escape, traveling as much as 300 feet (92 m).

 Do not allow bystanders in the area when operating, attaching, removing, assembling, or servicing 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 or transport 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 system in “locked up” position at all times.

 Always sit in power unit seat when operating controls or starting engine. Securely fasten seat

It is possible for objects to ricochet

belt, place transmission in neutral, engage brake, and ensure all other controls are disengaged before starting power unit engine.

 Operate tractor PTO at 540 RPM (1000 RPM on Q Series cutters). Do not exceed.

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

 Do not operate or transport 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.

 Leak down or failure of mechanical or hydraulic system can cause equipment to drop.

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, front tractor wheels could raise up resulting in loss of steering. The weight may be attained with 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.

MAINTENANCE

 Before dismounting power unit or performing any service or maintenance, follow these steps:

8 Safety

Single Spindle HD (Rev. 9/15/2006)

Page 9



SAFETY RULES

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

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 performing any service or maintenance, disconnect driveline from tractor PTO.

 Before working underneath, disconnect driveline, raise cutter, lock in transport position, and block cutter securely. Hydraulic system leak down and failure of mechanical or hydraulic system can cause equipment to drop.

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

 Your dealer can supply original equipment hydraulic accessories and repair parts. Substitute parts may not meet original equipment specifications and may be dangerous.

 Do not allow bystanders in the area when operating, attaching, removing, assembling, or servicing equipment.

 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.

 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.

 Leak down or failure of mechanical or hydraulic system can cause equipment to drop.

STORAGE

 Disconnect cutter driveshaft and secure up off ground. Raise cutter with 3-point hitch. Place blocks under cutter side skids. Lower cutter onto blocks. Disconnect cutter from tractor 3-point hitch and carefully drive tractor away from cutter.

 Keep children and bystanders away from storage area.

Single Spindle HD (Rev. 9/15/2006)

Safety 9

Page 10

1 - SERIAL NUMBER PLATE

12 - PN 57123 RED REFLECTOR 9"

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 guards in place and in good condition.

BLADE CONTACT OR THROWN OBJECTS CAN CAUSE

SERIOUS INJURY OR DEATH.

DANGER

ROTATING DRIVELINE

CONTACT CAN CAUSE DEATH

KEEP AWAY!

DO NOT OPERATE WITHOUT -

 All driveline guards, tractor and

equipment shields in place

 Drivelines securely attached at both

ends

 Driveline guards that turn freely on

driveline

1006682-A

DANGER

8 - PN1006682

BE CAREFUL!

Use a clean, damp cloth to clean safety decals.

Avoid spraying too close to decals when using a pressure washer; high-pressure water can enter through very small scratches or under edges of decals causing them to peel or come off.

Replacement safety decals can be ordered free from your Woods dealer, or in the United States and Canada call 1-800-319-6637.

SAFETY & INSTRUCTIONAL DECALS

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Replace Immediately If Damaged!

MODEL NO. SER IAL NO.

Woods Equipment Company

Oregon, Illinois, U.S.A.

10 Safety

MAN0680 (11/30/2007)

Page 11

10 - PN 33347

GUARD MISSING.

DO NOT OPERATE.

DANGER

33347E

DANGER

GUARD MISSING.

DO NOT OPERATE.

14 - PN 1004114

CRUSHING AND PINCHING HAZARD

 Be extremely careful handling various parts of the machine.

They are heavy and hands, fingers, feet, and other body parts could be crushed or pinched between tractor and implement.

 Operate tractor controls from tractor seat only.

 Do not stand between tractor and implement when tractor

is in gear.

 Make sure parking brake is engaged before going between

tractor and implement.

 Stand clear of machine while in operation or when it is

being raised or lowered.

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.

 Do not transport towed or semi-mounted units over 20 mph.

WARNING

FALLING OFF CAN RESULT IN BEING RUN OVER.

 Tractor must be equipped with ROPS (or ROPS CAB) and

seat belt. Keep foldable ROPS systems in "locked up" position at all times.

 Buckle Up! Keep seat belt securely fastened.

 Allow no riders.

RAISED EQUIPMENT CAN DROP AND CRUSH.

 Before working underneath, follow all instructions and

safety rules in operator's manual and securely block up all corners of equipment with jack stands.

 Securely blocking prevents equipment from dropping from

hydraulic leakdown, hydraulic system failures or mechanical component failures.

1006681

WARNING

DO NOT EXCEED PTO SPEED OF

540 RPM

PTO speeds higher than 540 RPM can cause

equipment failure and personal injury.

3 - PN1006681

11 - PN18864

CONTACT WITH ROTATING PARTS

CAN CAUSE SERIOUS INJURY.

WARNING

15502--B

ROTATING COMPONENTS

Do not operate without cover in place. Look and listen for rotation. Do not

open cover until all components have stopped.

5 - PN 15502

If shaft connection is visible, shield is missing. Replace shield before operating equipment.

DANGNGERER

1004114

SAFETY & INSTRUCTIONAL DECALS

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Replace Immediately If Damaged!

DANGER

ROTATING DRIVELINE

CONTACT CAN CAUSE DEATH

KEEP AWAY!

DO NOT OPERATE WITHOUT -

 All driveline guards, tractor and

equipment shields in place

 Drivelines securely attached at both ends

 Driveline guards that turn freely on

driveline

18864-C

MAN0680 (11/30/2007)

Safety 11

Page 12

OPERATION

DANGER

WARNING

CAUTION

WARNING

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

11. Be sure to complete the Pre-Operation Check List on page 16 before operating this cutter.

This heavy-duty cutter is designed for grass and weed mowing and shredding.

Recommended mowing speed for most conditions is from 2 to 5 mph.

 Full chain, rubber, or steel band shielding must be installed when operating in populated areas or other areas where thrown objects could injure people or damage property.

• If this machine is not equipped with full chain, rubber, or steel band shielding, operation must be stopped when anyone comes within 300 feet (92 m).

It is possible for objects to ricochet

TRACTOR STABILITY

Figure 1. Tractor Stability

CONNECTING CUTTER TO TRACTOR

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

 Never allow riders on power unit or attachment.

 Make sure spring-activated locking pin or collar

slides freely and is seated firmly in tractor PTO spline groove.

 Operate tractor PTO at 540 RPM. Do not exceed.

 Do not allow bystanders in the area when oper-

ating, attaching, removing, assembling, or servicing equipment.

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

■ Make sure driveline will not bottom out at the

shortest length and that it has at least 1/3 overlap at the longest length.

■ With cutter adjusted to transport position, set

upper stop on tractor lift quadrant to prevent cutter from contacting the driveline when being raised.

1. Attach tractor 3-point lift arms to category I or

category II (Cat II or Cat III for BB8400X) side of hitch pins (5) and secure.

2. Attach tractor top link (1) to cutter top link attachment point (2). See Figure 2.

3. Raise cutter to transport position and adjust tractor top link until cutter is level in this position.

4. Adjust the tractor lower 3-point arm anti-sway devices to prevent cutter from swinging side to side during transport.

5. Adjust tractor drawbar so that it will not interfere with cutter or driveline.

12 Operation

MAN0680 (11/30/2007)

Page 13

Figure 2. Cutter to Tractor Connection

1. Tractor top link

2. Cutter top link attachment point

5. Hitch pin

BB6000X, BB7200X

BB8400X

CAT II Position

CAT I Position

CAT II Position

CAT III Position

QUICK HITCH SET-UP

Refer to Figure 3 and Figure 4.

Figure 4. Mounting Pin Installation

DRIVELINE ADJUSTMENT

Category I and II for BB6000X, BB7200X

1. CAT I: No adjustment is required.

2. CAT II: Remove hardware securing lift arms to

mounting lugs. Move lift arms forward to second holes and insert caps screws. Tighten hardware.

3. Install mounting pins as shown in Figure 4 for correct hitch configuration.

Category II and III for BB8400X

1. CAT II: No adjustment is required.

2. CAT III: Remove hardware securing lift arms to

mounting lugs. Move lift arms forward to second holes and insert cap screws. Tighten hardware.

3. Install mounting pins as shown in Figure 4 for correct hitch configuration.

NOTICE

■ Avoid contact with driveline when raising cut-

ter.

■ Make sure driveline will not bottom out at the

shortest length and that it has at least 1/3 overlap at the longest length.

■ With cutter adjusted to transport position, set

upper stop on tractor lift quadrant to prevent cutter from contacting the driveline when being raised.

Attach the cutter to the tractor 3-point hitch (or quick hitch if available). Do not attach driveline. Raise and lower cutter to determine maximum and minimum distance between the tractor PTO shaft and the gearbox input shaft. If the distance is too large, the driveline will be too short for proper engagement. If distance is too small, the driveline may bottom out in operation and damage the cutter or tractor.

The driveline length must be sufficient to provide at least 1/3 driveline length of engagement during operation. There must be at least 4 inches of engagement at the cutter’s lowest possible point of operation. The driveline must not bottom out when raised to the maximum height possible.

Figure 3. Left Rail Mounting Lug

MAN0680 (11/30/2007)

If driveline is too short, please call your Woods dealer for a longer driveline.

If driveline is too long, please follow the instructions for shortening the driveline.

Operation 13

Page 14

Shortening Driveline

DP2

1-9/16"

DP3

DP4

DP5

1. Move cutter up and down to get the shortest possible distance between tractor PTO shaft and gearbox input shaft.

2. Separate driveline into two halves and connect them to the tractor PTO and gearbox.

3. Place driveline halves parallel to one another to determine how much to shorten the driveline.

Figure 7. Cut Shield

6. Place the cutoff portion of the shield against the

end of the shaft and use as a guide. Mark and cut the shaft.

Figure 5. Drive Halves Placed Parallel

4. Measure from end of the upper shield to the base

of the bell on the lower shield (A). Add 1-9/16" to dimension (A). See Figure 6.

Figure 6. Determine Shield Length

5. Cut the shield to the overall dimension.

Figure 8. Cut Shaft to Length

7. Repeat step 6 for the other half of the drive.

8. File and clean cut ends of both drive halves.

Do not use tractor if proper driveline engagement cannot be obtained through these methods.

Connect driveline to tractor PTO shaft, making sure the spring-activated locking collar slides freely and locks driveline to PTO shaft.

NOTICE

■ If attaching with quick hitch, the distance

between the tractor PTO and gearbox input shaft will increase. Please follow the steps as you would for a 3-point hitch to insure proper engagement.

14 Operation

MAN0680 (11/30/2007)

Page 15

DRIVELINE INTERFERENCE CHECK

WARNING

3" Desired cutting height

+ 11.5" Distance blade cutting edge is below deck

= 14.5"

2. Check chain bracket

3. Check chain

1. Check for clearance between driveline and cutter deck.

2. Slowly lift cutter and observe driveline. If clearance between driveline and cutter deck is less than 1 inch, shorten top link or limit upper travel of lower hitch arms. Refer to tractor operator's manual for instructions.

CUTTING HEIGHT ADJUSTMENT

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

■ Avoid low cutting heights. Striking the ground

with blades produces one of the most damaging shock loads a cutter can encounter. Allowing blades to contact ground repeatedly will cause damage to cutter and drive.

c) Adjust the front-to-rear attitude from 1/2" to

3/4" higher than the front.

CHECK CHAIN ADJUSTMENT

1. Refer to Check Chain Installation (Optional), page

33 for check chain installation.

2. After making cutting height adjustment, adjust both chains (3) in check chain bracket (2) so you have the same number of links on each side. This will keep your cutting level.

When selecting a cutting height, you should consider the area of operation. If the ground is rolling and has mounds the blades could contact, set the cutting height accordingly.

1. Level cutter from side to side. Check by measuring from cutter frame to the ground at each deck rail.

2. Adjust, using tractor 3-point arm leveling device.

NOTE: Keep the front of cutter level with or slightly

lower than rear for best mowing.

3. Control cutting height with tractor 3-point arms, rear tailwheel adjustment, or optional check chains.

4. To raise rear of cutter, move tailwheel down.

5. To raise front of cutter, raise tractor 3-point arms or

shorten optional check chains.

The cutting height is the distance between the blade and the ground. The blades are approximately 11.5" below the deck. To check cutting height, do the following:

a) Place a straight edge along top edge of deck.

b) Select a cutting height; as an example, for an

approximate cutting height of 3", set the center of the deck 14.5" above the ground:

Figure 9. Check Chain Adjustment

DRIVELINE INSTALLATION (TRACTOR PTO)

To Install:

Pull locking collar back and at the same time push driveline onto tractor PTO shaft until locking device engages.

To Remo v e:

Hold driveline into position, pull locking collar back, and slide driveline off tractor PTO shaft.

Figure 10. Lock Collar

MAN0680 (11/30/2007)

Operation 15

Page 16

OPERATING TECHNIQUE

WARNING



1. Power for operating the cutter is supplied by the tractor PTO. Operate PTO at 540 rpm. Know how to stop the tractor and cutter quickly in an emergency.

2. Engage PTO at a low engine rpm to minimize stress on the drive system and gearbox. With PTO engaged, raise PTO speed to 540 rpm and maintain throughout cutting operation.

STORAGE

 Keep children and bystanders away from storage area.

Gearbox protection is provided by a slip clutch with replacement fiber disc. The slip clutch is designed to slip when excessive torsional loads occur.

3. Move slowly into material. Adjust tractor ground speed to provide a clean cut without lugging the tractor engine. Use a slow ground speed for better shredding.

Proper ground speed will depend on the terrain and the material’s height, type, and density.

Normally, ground speed will range from 2 to 5 mph. Tall, dense material should be cut at a low speed; thin, medium-height material can be cut at a faster ground speed.

4. Always operate tractor PTO at 540 rpm to maintain proper blade speed and to produce a clean cut.

5. Under certain conditions tractor tires may roll down some grass and prevent cutting at the same height as the surrounding area. When this occurs, reduce your ground speed but maintain PTO at 540 rpm. The lower ground speed will permit grass to rebound partially.

SHREDDING MATERIAL

For shredding, set the cutter lower at rear. Determine how much lower to set the rear by experimenting in different situations.

PRE-OPERATION CHECK LIST

OWNER’S RESPONSIBILITY

___ Review and follow all safety rules and safety

decal instructions on page 7 through page 11.

___ Check that equipment is properly and securely

attached to tractor.

___ Make sure driveline spring-activated locking pin

or collar slides freely and is seated firmly in tractor PTO spline groove.

___ Set tractor PTO at 540 rpm.

___ Lubricate all grease fitting locations. Make sure

PTO shaft slip joint is lubricated.

___ Check to be sure gear lube runs out the small

check plug on side of gearbox.

___ Check that all hardware is properly installed and

secured.

___ Check that blades are sharp and secure and cut-

ting edge is positioned to lead in a counterclockwise rotation.

___ Check that shields and guards are properly

installed and in good condition. Replace if damaged.

___ Check cutting height, front-to-rear attitude, and

top link adjustment.

___ Place tractor PTO and transmission in neutral

before starting engine.

___ Inspect area to be cut and remove stones,

branches, or other hard objects that might be thrown and cause injury or damage.

16 Operation

MAN0680 (11/30/2007)

Page 17

OWNER SERVICE

WARNING

CAUTION

WARNING

1. Front U-joint- - - - - - - - - - - - 8 hrs.

2. Slip joint (apply grease to square shaft) - - - - - - - - - 8 hrs.

3. Rear U-joint - - - - - - - - - - - - 8 hrs.

4. Gearbox - - - - - - - - - - - - - - -Daily

5. Tailwheel pivot tube - - - - - - 8 hrs.

6. Tailwheel - - - - - - - - - - - - - - 8 hrs.

11. Plastic shield bearings - - - 10 hrs.

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.

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

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

BLOCKING METHOD

4. The working surface must be level and solid to

support the weight on the jackstands. Make sure jackstands are stable, both top and bottom. Make sure cutter is approximately level.

5. With full cutter weight lowered onto jackstands, test blocking stability before working underneath.

6. If cutter is attached to tractor when blocking, set the brakes, remove key, and block cutter before working underneath.

7. Securely block rear tractor wheels, in front and behind. Tighten tractor lower 3-point arm anti-sway mechanism to prevent side-to-side movement.

To minimize the potential hazards or working underneath the cutter, follow these procedures:

1. Jackstands with a load rating of 1000 lbs or more are the only approved blocking device for this cutter. Install a minimum of four jackstands (shown by Xs in Figure 11) under the cutter before working underneath unit.

2. Do not position jackstands under wheels, axles, or wheel supports. Components can rotate and cause cutter to fall.

3. Consider the overall stability of the blocked unit. Just placing jackstands underneath will not ensure your safety.

MAN0680 (11/30/2007)

Figure 11. Jackstand Placement & Lubrication Points

LUBRICATION INFORMATION

Use a lithium grease of #2 consistency with a MOLY (molybdenum disulfide) additive for all locations unless otherwise noted. Be sure to clean fittings thoroughly before attaching grease gun. One good pump of most guns is sufficient when the lubrication schedule is followed.

Do not let excess grease collect on or around parts, particularly when operating in sandy areas.

See Figure 11 for lubrication points and frequency or lubrication based on normal operating conditions. Severe or unusual conditions may require more frequent lubrication.

Owner Service 17

Page 18

Gearbox Lubrication

1. Flange yoke

2. Friction disc

3. Hub, 1-3/4" 20 Spline

4. Drive plate

5. Drive plate

6. Thrust plate

7. 12 mm x 115 mm GR8.8 HHCS

8. Compression spring

9. Flat washer

10. 12 mm x 1.25P Nylok lock nut

11. 12 mm x 65 mm GR8.8 HHCS

12. 12 mm x 1.5P Nylok lock nut

For gearbox, use a high quality gear oil with a viscosity index of 80W or 90W and an API service rating of GL-4 or -5 in gearboxes. Fill gearbox until oil runs out the side plug on gearbox. Check gearbox daily for evidence of leakage, and contact your dealer if leakage occurs.

Driveline Lubrication

1. Lubricate the driveline slip joint every eight

operating hours. Failure to maintain proper lubrication could result in damage to U-joints, gearbox, and driveline.

2. Lower cutter to ground, disconnect driveline from tractor PTO shaft, and slide halves apart but do not disconnect from each other.

3. Apply a bead of grease completely around male half where it meets female half. Slide drive halves over each other several times to distribute grease.

SLIP CLUTCH ADJUSTMENT

The slip clutch is designed to slip so that the gearbox and driveline are protected if the cutter strikes an obstruction.

A new slip clutch or one that has been in storage over the winter may seize. Before operating the cutter, make sure it will slip by performing the following operation:

1. Turn off tractor engine and remove key.

2. Remove driveline from tractor PTO.

3. Loosen six 12 mm cap screws (7) to remove all

tension from the compression springs (8).

4. Hold clutch hub (3) solid and turn shaft to make sure clutch slips.

5. If clutch does not slip freely, disassemble and clean the flange yoke (1), clutch hub (3), drive plate (4), drive plate (5), and thrust plate faces (6).

6. Reassemble clutch.

7. Compress each of the six compression springs (8)

by tightening the six cap screws (7) and lock nuts (10). The compression springs should be compressed to a height of 1-7/16", not including washer (9). The minimum spring height is 1.36". See Figure 12.

8. If a clutch continues to slip when the springs are compressed to 1.36", check friction discs (2) for excessive wear. Discs are 1/8" when new. Replace discs after 1/16" wear.

Figure 12. Slip Clutch Assembly

18 Owner Service

MAN0680 (11/30/2007)

Page 19

BLADE SERVICE

1. Blade pin

2. Blade

3. Crossbar assembly

4. 18ga x 1-1/2 Shim

5. 20ga x 1-1/2 Shim

6. Key hole plate

7. Blade pin lock clip

8. 1/2 x 1-1/4 Cap screw GR5

CAUTION

Blade Installation

Blade Removal

Figure 13. Blade Assembly

NOTICE

■ If blade pin (1) is seized in crossbar and

extreme force will be needed to remove it, support crossbar from below to prevent gearbox damage.

1. Disconnect driveline from tractor PTO.

2. Raise cutter and block securely (see Figure 11).

3. Open blade access cover and align crossbar

assembly (3) with blade access hole in the cutter frame. Remove cap screw (8) blade pin lock clip (7) keyhole plate (6) and shims (5 & 4). Carefully drive blade pin out of crossbar.

4. Rotate crossbar and repeat for opposite blade.

Refer to Figure 13.

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

NOTICE

■ Crossbar rotation is counterclockwise when

looking down on cutter. Be sure to install blade cutting edge to lead in counterclockwise rotation.

■ Always replace or sharpen both blades at the

same time.

1. Inspect blade pin (1) for nicks or gouges, and if you

find any, replace the blade pin.

2. Insert blade pin through the blade. Blade should swivel on blade pin; if it doesn’t, determine the cause and correct.

3. Align crossbar assembly (3) with blade access hole in cutter frame. Apply a liberal coating of Never

Seez

or equivalent to blade pin and crossbar

hole. Make sure blade offset is away from cutter.

4. Insert blade pin (1) through blade. Push blade pin through crossbar.

5. Install shims (4 & 5) over blade pin.

NOTE: Only use enough shims to allow keyhole

plate (6) to slide into blade pin groove.

6. Install blade clip (7) over keyhole plate and into blade pin groove.

7. Secure into position with cap screw (8). Torque cap screw to 85 lbs-ft.

8. Repeat steps for opposite side.

NOTE: Blade should be snug but should swivel on

pin without having to exert excessive force. Keep any spacers not used in the installation as replacements or for future installation.

MAN0680 (11/30/2007)

Owner Service 19

Page 20

Blade Sharpening

DANGER



NOTICE

■ When sharpening blades, grind the same

amount on each blade to maintain balance. Replace blades in pairs. Unbalanced blades will cause excessive vibration, which can damage gearbox bearings. Vibration may also cause structural cracks to cutter.

1. Sharpen both blades at the same time to maintain

balance. Follow original sharpening pattern.

condition. and escape, traveling as much as 300 feet (92 m).

It is possible for objects to ricochet

Rear Band

Inspect rear band each day of operation, replace if bent, cracked, or broken.

Rubber Shielding

Inspect rubber shielding each day of operation and replace if cracked or broken.

Chain Shielding (Optional)

2. Do not sharpen blade to a razor edge—leave at

least a 1/16" blunt edge.

3. Do not sharpen back side of blade.

Figure 14. Blade Sharpening

SHIELDING REPAIR

Inspect chain shielding each day of operation and replace any broken or missing chains as required.

CLEANING CUTTER

After Each Use

● Remove large debris such as clumps of dirt, grass,

crop residue, etc. from machine.

● Inspect machine and replace worn or damaged

parts.

● Replace any safety decals that are missing or not

readable.

Periodically or Before Extended Storage

● Clean large debris such as clumps of dirt, grass,

crop residue, etc. from machine.

● Remove the remainder using a low-pressure water

spray.

1. Be careful when spraying near scratched or torn safety decals or near edges of decals as water spray can peel decal off surface.

 Full chain, rubber, or steel band shielding must be installed when operating in populated areas or other areas where thrown objects could injure people or damage property.

• If this machine is not equipped with full chain, rubber, or steel band shielding, operation must be stopped when anyone comes within 300 feet (92 m).

• This shielding is designed to reduce the risk of thrown objects. The mower deck and protective devices cannot prevent all objects from escaping the blade enclosure in every mowing

20 Owner Service

2. Be careful when spraying near chipped or

scratched paint as water spray can lift paint.

3. If a pressure washer is used, follow the advice of the pressure washer manufacturer.

● Inspect machine and replace worn or damaged

parts.

● Sand down scratches and the edges of areas of

missing paint and coat with Woods spray paint of matching color (purchase from your Woods dealer).

● Replace any safety decals that are missing or not

readable (supplied free by your Woods dealer).

● See Safety Decals section for location drawing.

MAN0680 (11/30/2007)

Page 21

TROUBLESHOOTING

MOWING CONDITIONS

PROBLEM POSSIBLE CAUSE SOLUTION

Grass cut lower in center of swath than at edge

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

Material discharges from cutter unevenly; bunches of material along swath

Height of cutter lower at rear or front

Blades unable to cut that part of grass pressed by path of tractor tires

Dull blades Sharpen or replace blades.

Material too high and too much material

Adjust cutter height and attitude so that cutter rear and front are within 1/2" of same height. See Cutting Height Adjustment, page 15.

Slow ground speed of tractor but keep engine running at full PTO rpm. Cutting lower will help.

Reduce ground speed but maintain 540 rpm at tractor PTO or make two passes over material. Raise cutter for the first pass and lower to desired height for the second and cut at 90° to first pass. Raise rear of cutter high enough to permit material to discharge but not so high to cause conditions listed above.

Cutter will not cut all the time (Slip clutch drive only)

Grass wet Allow grass to dry before mowing.

Slow ground speed of tractor but keep engine running at full PTO rpm. Cutting lower will help.

Rear of cutter too low, trapping material under cutter

Slip clutch slipping Adjust slip clutch according to

Adjust cutter height and attitude.

instructions in SLIP CLUTCH ADJUSTMENT, page 18.

MAN0680 (11/3/2007)

Troubleshooting 21

Page 22

DEALER SERVICE

WARNING

CAUTION

1. Seal

2. Pipe or tube

3. Seal seat

4. Casting

Pipe or tube must press at outer edge of seal.

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.

 Before working underneath, read manual instructions, securely block up, and check stability. Secure blocking prevents equipment from dropping due to hydraulic leak down, hydraulic system failure, or mechanical component failure.

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

Leakage can occur at the vertical or horizontal gaskets and shaft seals.

Leakage at the horizontal gasket or seal can be repaired without removing the gearbox from the cutter.

Seal Installation

Refer to Figure 17.

NOTE: Proper seal installation is important. An improp-

erly installed seal will leak.

1. Clean area in housing where seal outer diameter (OD) seats. Apply a thin coat of Permatex

2. Inspect area of shaft where seal seats. Remove any burrs or nicks with an emery cloth.

3. Lubricate gear shaft and seal lips.

4. Place seal squarely on housing, spring-loaded lip

toward housing. Select a piece of pipe or tubing with an OD that will sit on the outside edge of the seal but will clear the housing. Tubing with an OD that is too small will bow seal cage and ruin seal.

GEARBOX MAINTENANCE

NOTE: Read this entire section before starting any

repair. Many steps are dependent on each other.

1. Fill gearbox with SAE 80W or 90W gear lube until it runs out the side level plug.

NOTE: Repair to this gearbox is limited to replacing bearings, seals, and gaskets. Replacing gears, shafts, and a housing is not cost effective. Purchasing a complete gearbox is more economical.

2. Inspect gearbox for leakage and bad bearings. Leakage is a very serious problem and must be corrected immediately.

Bearing failure is indicated by excessive noise and side-to-side or end-play in gear shafts.

Seal Replacement

Recommended sealant for gearbox repair is Permatex Aviation 3D Form-A-Gasket or equivalent.

5. Carefully press seal into housing, avoiding distortion to the metal seal cage.

Figure 17. Seal Installation

22 Dealer Service

MAN0680 (11/30/2007)

Page 23

Vertical Shaft Repair

1. Crown gear

2. Gearbox housing

3. Input shaft

4. Output shaft

5. Gear pinion

6. Bearing

7. Input bearing

8. Protective seal

9. Cotter pin

10. Snap ring

11. Snap ring

12. Shim, 45.3 x 2.5

13. Shim, 70.3 x 84.7

14. Nut

15. Castle nut

16. Shim, 50.3 x 70.3

17. Shim

18. Oil seal (Vertical Shaft)

19. Oil seal (Horizontal Shaft)

20. Cap

22. Top cover

23. Cap screw 8 mm x 16 (8.8)

24. Vent plug

25. Cotter pin

26. Washer

Refer to Figure 18.

1. Disconnect and remove the driveline from the

gearbox.

5. Fill gearbox with SAE 80W or 90W gear lube until it runs out the level plug.

6. Remove and replace any seal damaged in installation.

2. Remove vent plug (24) and siphon gear lube from housing through this opening.

3. Remove crossbar (see Crossbar Removal, page

25).

4. Remove protective seal (8) and vertical shaft seal (18). Replace seal (18) with new seal (see Seal Replacement, page 22).

Vertical seal should be recessed in housing. Horizontal seal (19) should be pressed flush with outside of housing.

NOTE: Distortion to seal cage or damage to seal lip will cause seal to leak.

Horizontal Shaft Leak Repair

Refer to Figure 18.

1. Disconnect and remove the driveline from the

gearbox.

2. Remove vent plug (24) and siphon gear lube from housing through this opening.

3. If the leak occurred at either end of horizontal shaft, remove oil cap (20) and/or oil seal (19). Replace with new one (refer to Seal Replacement, page

22).

4. Fill gearbox with SAE 80W or 90W gear lube until it

runs out the level plug.

MAN0680 (11/30/2007)

Figure 18. Gearbox Assembly

Dealer Service 23

Page 24

GEARBOX REPAIR

Remove Gearbox from Cutter

Refer to Figure 18.

1. Disconnect and remove the rear driveline from the

gearbox.

2. Remove breather level plug (24) and siphon gear lube from housing through this opening.

3. Remove 9 ga. wire and nut from vertical shaft and remove crossbar (see Crossbar Removal, page

25).

4. Remove the six bolts that attach gearbox to cutter

and remove gearbox.

Forged gear surfaces are rough when new. Check that wear pattern is smooth.

16. Inspect vertical and horizontal shafts for grooves, nicks, or bumps in the areas where the seals seat. Resurface any damage with emery cloth.

17. Inspect housing and caps for cracks or other damage.

Gearbox Assembly

Refer to Figure 18.

NOTE: Repair to this gearbox is limited to replacing

bearings, seals, and gaskets. Replacing gears, shafts, and a housing is not cost effective. Purchasing a complete gearbox is more economical.

Disassemble Gearbox

Refer to Figure 18.

1. Remove plug from side of gearbox and pour out

gear oil.

2. Remove oil cap (20) (to be replaced).

3. Remove snap ring (10) and shim (13) from input

shaft (3).

4. Support gearbox in hand press and push on input shaft (3) to remove bearing (7).

5. Remove six cap screws (23) and top cover (22) from housing. Remove gear (1) from inside housing.

6. Remove oil seal (19) from front of housing (to be replaced).

7. Remove snap ring (10) and shim (13) from front of housing (2).

8. Remove input bearing (7) by using a punch and hammer from outside of housing.

9. Support housing in vise in a horizontal position.

10. The castle nut (15), 9 ga. wire (25), and hub are

already removed with the stump jumper/crossbar. Remove the protective seal (8), and oil seal (18).

11. Remove cotter pin (9), castle nut (14), and washer (17) from output shaft (4).

12. Remove output shaft (4) by using a punch and hammer and tap on top to drive down. Remove gear (5) and shim (16) from inside housing.

13. Remove bottom bearing (6) by using a punch and hammer from the top, outside the housing.

14. Support housing upside down (top cover surface) and remove second bearing (6) by using a punch and hammer from the bottom side of the housing.

15. Inspect gears for broken teeth and wear. Some wear is normal and will show on loaded side.

1. Clean housing, paying specific attention to areas where gaskets will be installed.

2. Wash housing and all components thoroughly. Select a clean area for gearbox assembly. Replace all seals, bearings, and gaskets. All parts must be clean and lightly oiled before reassembling.

3. Insert both output bearings (6) in the housing, using a round tube of the correct diameter and a hand press.

4. Slide output shaft (4) through both bearings (6) until it rests against top bearing (6).

5. Slide shim (16) over output shaft (4).

6. Press gear (5) onto output shaft (4) and secure

with washer (17), castle nut (14), and cotter pin (9).

7. Apply grease to lower seal lips (18) and press seal (18) over output shaft (4), using a tube of the correct diameter. Be sure not to damage the seal lip.

Press in housing so that seal is recessed. Press protective seal (8) until seated flush with housing. Verify that the seal (8) is seated correctly.

8. Press bearing (7) into the housing, using a round tube of the correct diameter and a hand press. Secure with shim (13) and snap ring (10).

9. Secure snap ring (11) on input shaft (3) if not already secure.

10. Place gear (1) through top of housing and align gear (1) and gear (5) so that gear teeth are a match.

11. While holding gear (1) in place, slide input shaft (3) through gear (1) and bearing (7). Align splines on shaft (3) and gear (1).

12. Slide spacer (12) over input shaft (3) and press bearing (7) onto input shaft (3), using a round tube of the correct diameter and a hand press.

24 Dealer Service

MAN0680 (11/30/2007)

Page 25

13. Slide shim (13) over input shaft (3) and secure with snap ring (10).

14. Check input shaft end float by moving the input shaft (3) by hand. If end float is higher than 0.012", insert shim between input shaft (3) and rear bearing (7). Repeat until end float is less than

0.012". Check rotational torque by hand. The torque should be less than 2.2 lbs-inch.

15. Check that the gear backlash is between 0.006" and 0.016". You should not have to adjust the backlash.

16. Press in input oil seal (19), using tube of correct diameter. Be careful not to damage seal lip.

17. Press oil cap (20) on to cover the rear of housing, using a tube of the correct diameter.

18. Place top cover (22) on top of housing and secure with six cap screw (23).

19. Check gearbox housing for leaks by plugging all holes except one. Apply 4 psi compressed air and immerse the gearbox in water to verify that there are no leaks.

20. Remove gearbox from water and dry off with compressed air. Add SAE 80W or 90W EP oil until it runs out of side level hole. Tighten all plugs.

Reinstall Gearbox

NOTE: Gearbox is heavy: do not attempt to move with-

out mechanical assistance.

1. Set gearbox on cutter and fasten with bolts and nuts. Torque bolts to 300 lbs-ft.

2. Attach crossbar (see Crossbar Installation, page

26).

CROSSBAR REMOVAL

1. It is necessary to gain access to bottom side of cutter for crossbar removal. See BLOCKIiNG METHOD, page 17.

NOTE: You will need to use either the puller screw

(Item 6, Figure 19) or a small hydraulic jack to remove the crossbar.

2. Remove blade pin hardware, blade pins and blades from crossbar.

3. Remove retaining wire from bottom of crossbar and remove nut and washer.

4. Refer to Figure 19. Attach clevis (1) to each end of crossbar, using blade pins, spacers, keyhole plates, and blade pin clips.

Figure 19. Crossbar Removal

6. For removal with puller screw, attach tube (5) to

each clevis with bolts (2) and nuts (3). Place pad (4) in nut and thread puller screw (6) into nut from bottom. Tighten until pad is solid against gearbox shaft. For best results, strike head of puller screw with a hammer while tightening with a wrench.

7. For removal with a jack, attach tube to each clevis with puller links (7), bolts (2), and nuts (3). Place jack on tube with end of jack pressing against gearbox shaft. Slowly apply force with jack.

5. Position tube assembly (5) with threaded nut toward crossbar for puller screw removal or down for hydraulic jack removal.

MAN0680 (11/30/2007)

NOTE: Hydraulic jack will not operate if tipped more than 90°. Use care to prevent bending crossbar during removal.

Dealer Service 25

Page 26

CROSSBAR INSTALLATION

1. Yoke

2. Bearing cup

3. Retaining ring

4. Bearing cross

UNIVERSAL JOINT REPAIR

Using emery cloth (220 or finer), remove surface rust, Loctite splined gearbox, vertical shaft, and crossbar as shown in Figure 20.

Refer to Figure 21.

and foreign material from hub,

Figure 20. Example

Figure 22. U-Joint Exploded View

U-Joint Disassembly

1. Remove external snap rings from yokes in four

locations as shown in Figure 23.

8. Install crossbar (2) on splined shaft. Install washer (5) and nut (3). Torque nut to 450 lbs-ft.

9. Install cotter pin (4) (supplied) through gearbox shaft and slots in nuts. Twist end of pin around nut (3).

Figure 23. Remove Snap Ring

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 24.

Figure 21. Example

26 Dealer Service

Figure 24. Remove Bearing Cups

MAN0680 (11/30/2007)

Page 27

3. Clamp cup in vise as shown in Figure 25 and tap



on yoke to completely remove cup from yoke. Repeat Step 2 & 3 for opposite cup.

Figure 25. Remove Bearing Cups

4. Place universal cross in vise as shown in Figure 26

and tap on yoke to remove cup. Repeat Step 3 for final removal. Drive remaining cup out with a drift and hammer.

U-Joint Assembly

1. Place seals securely on bearing cups. Insert cup

into yoke from outside and press in with hand pressure as far as possible. Insert journal cross into bearing cup with grease fitting away from shaft. Be careful not to disturb needle bearings. Insert another bearing cup directly across from first cup and press in as far as possible with hand pressure.

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. Tapping the yoke will help.

2. Seat cups by placing a drift or socket (slightly smaller than the cup) on cup and rap with a hammer. See Figure 27. Install snap ring and repeat on opposite cup.

3. Repeat Step 1 & Step 2 to install remaining cups in remaining yoke.

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

Figure 26. Remove Bearing Cups

MAN0680 (11/30/2007)

Figure 27. Install Bearing Cups

Dealer Service 27

Page 28

NOTES

28 Dealer Service

MAN0680 (11/30/2007)

Page 29

ASSEMBLY

DANGER

WARNING

CAUTION

3. Tailwheel bracket

6. A-Frame arm

11. Break link

8. Brace arms

17. Tailwheel

29. Clutch shield

A. Tailwheel mounting hole B. Brace arm mounting hole

C. Height adjustment holes

DEALER SET-UP INSTRUCTIONS

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

Complete Dealer Check Lists, page 34 when you have completed the assembly.

The cutter is shipped partially assembled. Assembly will be easier if aligned and loosely assembled before tightening hardware. Recommended torque values for hardware are located in the Bolt Torque Chart, page

45.

 Full chain, rubber, or steel band shielding must be installed when operating in populated areas or other areas where thrown objects could injure people or damage property.

• If this machine is not equipped with full chain, rubber, or steel band shielding, operation must

be stopped when anyone comes within 300 feet (92 m).

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

 Operate tractor PTO at 540 RPM. Do not exceed.

 Always wear relatively tight and belted clothing

to avoid getting caught in moving parts. Wear sturdy, rough-soled work shoes and protective equipment for eyes, hair, hands, hearing, and head; and respirator or filter mask where appropriate.

It is possible for objects to ricochet

Figure 29. Shipping Configuration

MAN0680 (11/30/2007)

Assembly 29

Page 30

Disassemble Shipping Unit

A. Tailwheel pivot hole B. Brace arm mounting hole C. Height adjustment holes

3. Tailwheel bracket

8. Brace arms

17. Tailwheel assembly

35. 5/8 NC x 2 Cap screw

36. 5/8 NC Flange lock nut

49. Washer, .18 x 1.62 x 3

50. O-Ring

51. Washer

52. Spiral pin 3/8 x 2

DP33

6. A-Frame arms

7. Break link

8. Brace arms

11. Sleeve, .628 x 1.0 x 1.25

36. 5/8 NC Flange lock nut

42. 5/8 NC x 2-3/4 HHCS GR5

Refer to Figure 29.

1. Position cutter flat and place a block underneath

the rear of the cutter to raise it off the ground.

2. Remove all parts that are wired or strapped to cutter. Remove parts from manual tube and hardware that is securing tailwheel bracket (3) and brace arms (8) to cutter.

ASSEMBLE CUTTER

1. Attach tailwheel bracket (3) to cutter at the

tailwheel pivot holes (A) using cap screws (35) and flange lock nuts (36).

2. Select desired height adjustment holes (C), and secure tailwheel bracket with cap screws (35) and flange lock nuts (35). Cutting height adjustment will be necessary when cutter is fully assembled. See “Cutting Height Adjustment” on page 15.

3. Raise rear of cutter and insert tailwheel assembly (17) with two washers (49) into tailwheel bracket (3). Secure with o-ring (50), washer (51), and spiral pin (52).

Install Tailwheel

4. Place diagonal brace bars (4) on the inside of

frame rails and attach to diagonal brace mounting holes (A). Secure using cap screws (13) and flange lock nuts (14).

Connect A-Frame Arms

1. Rotate A-frame arms (6) and break link (7) forward

and up.

2. Attach brace arms (8) to the break link (8) using cap screw (42), sleeve (11), and flange lock nut (36). See Figure 31.

30 Assembly

Figure 30. Tailwheel Installation

Figure 31. Brace Arm Connection

MAN0680 (11/30/2007)

Page 31

Install Slip Clutch Driveline

A. Anti-rotation chain

29. Clutch shield

33. Vent plug/Dipperstick

60. 12 mm x 1.5P x 65 mm Cap screw GR8.8

61. 12 mm x 1.5P Hex lock nut

62. 5/16 Flat washer

63. 5/16 Lock washer

64. M8 x 1.25P x 20 mm HHCS

DANGER

1. Rubber deflector

2. Link

3. 3/8 NC 1 Carriage bolt

4. 3/8 NC Flange lock nut

Figure 32. Slip Clutch Driveline Assembly

A new slip clutch, or one that has been in storage over the winter, may seize.

escaping the blade enclosure in every mowing condition. and escape, traveling as much as 300 feet (92 m).

The optional chain shielding assemblies are ready for installation when you receive them.

1. Refer to Front & Rear Chain Shielding, page 42 and attach as shown by inserting the bolts from inside the cutter frame out through the shielding.

2. Install hardware as shown in the parts drawing.

It is possible for objects to ricochet

Install Rubber Deflector

1. Attach rubber deflector (1) and link (2) to front of

cutter using carriage bolts (3) and flange lock nuts (4).

2. Insert bolts from inside the cutter frame out through the shielding.

NOTICE

■ A grade 8.8 metric bolt must be used to attach

clutch driveline to gearbox.

1. Before operating slip clutch, make sure it will slip.

Refer to SLIP CLUTCH ADJUSTMENT, page 18.

2. Place the shield (29) against gearbox and secure using four cap screws (64), lock washers (63) and flat washers (62). Torque bolts (64) to 12 lbs-ft.

3. Install driveline onto gearbox input shaft and secure with bolts (1) and nuts (2).

INSTALL SAFETY SHIELDING

Install Optional Chain Shielding

 Full chain, rubber, or steel band shielding must be installed when operating in populated areas or other areas where thrown objects could injure people or damage property.

• If this machine is not equipped with full chain, rubber, or steel band shielding, operation must be stopped when anyone comes within 300 feet (92 m).

• This shielding is designed to reduce the risk of thrown objects. The mower deck and protective devices cannot prevent all objects from

MAN0680 (11/30/2007)

Figure 33. Rubber Deflector Installation

FILL GEARBOX

NOTICE

■ Gearbox is not filled at the factory. Prior to

delivery to customer, make sure gearbox is filled only half-full with 80W or 90W API GL-4 or GL-5 gear lube. Use side hole to remove any excess oil.

1. Remove vent plug/dipperstick (9) on top of gearbox

and plug on side of gearbox. Use 5/16" allen wrench to remove plug.

2. Make sure vent plug hole is clear.

3. Fill gearbox until oil runs out the side hole on

gearbox. Use a high quality gear oil with a viscosity index of 80W or 90W and an API service rating of GL-4 or GL-5.

4. Install side plug and vent plug.

Assembly 31

Page 32

BAFFLE KIT INSTALLATION (OPTIONAL)

1. Baffle kit, BB6000X, BB7200X, BB8400X

2. Mounting bracket

3. 3/8 NC x 1 Carriage bolt GR5

4. 3/8 NC Flange lock nut

Model ABCD

BB6000X 2.72" 6.56" 6.22" 27°

BB7200X 2.45" 5.99" 8.32" 22.5°

BB8400X 2.32" 5.23" 10.55" 19°

NOTE: An optional baffle kit may be installed to the front of the cutter to prevent excessive blow-out when cutter is used on a non-cab tractor. The baffle can also be installed in the rear of the cutter to spread out discharge.

1. From the bottom of the cutter, drill two 21/64" holes in the rectangular tubes using dimensions A, B and C from chart in Figure 34. Drill holes in either front or rear of cutter.

2. Attach L-shaped mounting brackets (2) to the bottom of the deck using self-tapping screws (5).

3. Place baffle (1) against mounting brackets (2) and secure using two carriage bolts (3) and flange lock nuts (4).

4. Baffles located in the front of cutter: Push end of baffle against cutter side frame drill hole through side frame using hole in baffle as a guide. Secure baffle to side frame using carriage bolts (3) and flange lock nuts (4).

5. Baffle located in the rear of cutter: Secure baffle to side frame using carriage bolts (3) and flange lock nuts (4).

NOTE: Mounting brackets must be welded to the deck, screws alone will not be enough to hold mounting brackets in place.

6. Weld mounting brackets to bottom of deck. Weld solid on three sides.

32 Assembly

Figure 34. Baffle Installation

MAN0680 (11/30/2007)

Page 33

DUAL TAILWHEEL INSTALLATION

1. Dual tailwheel

17. 5/8 NC x 2-1/2 HHCS

18. 5/8 Flange lock nut A. Tailwheel pivot hole D. Deck, BB7200X &

BB8400X

2. Check chain bracket

3. 3/8 Chain, 32-link

4. 3/4 NC x 6 HHCS GR5

5. 3/4 NC Lock nut

6. 5/8 NC x 2-1/4 HHCS GR5

7. 5/8 Flat washer

8. 5/8 NC Hex nut

9. Mast Plate

10. Tractor top link bracket



BB7200X, BB8400X (OPTIONAL)

CHECK CHAIN INSTALLATION (OPTIONAL)

1. Attach dual tailwheel (1) to main frame (D) using

position A and desired height location as shown in Figure 35.

2. Secure with cap screws (17) and hex nuts (18).

3. Torque hardware to 175 lbs-ft.

Check chains are used to carry the front of cutter at a set height. See Figure 36.

1. Thread check chains (3) through check chain bracket (2).

2. Attach lower end of check chain (3) to mast plate (9) with bolt (6), washer (7), and nut (8).

3. Attach keyhole brackets (2) to each side of tractor top link bracket (10) with bolt (4) and nut (5).

Figure 35. Dual Tailwheel Installation

(Rev. 4/24/2009)

MAN0680 (11/30/2007)

Figure 36. Optional Check Chain Assembly

Assembly 33

Page 34

DEALER CHECK LISTS



PRE-DELIVERY CHECK LIST

(DEALER’S RESPONSIBILITY)

NOTICE

■ Gearbox was not filled at the factory. It must be

serviced before operating cutter. (See Fill Gearbox, page 31). Failure to service will result in damage to gearbox.

Inspect cutter 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 are properly installed

and secured.

___ Check that PTO shaft is properly installed.

___ Check that gearbox is properly serviced and

seals are not leaking.

___ Check and grease all lubrication points as identi-

fied in, Lubrication Information, page 17.

___ Check that blades have been properly installed.

DELIVERY CHECK

(DEALER’S RESPONSIBILITY)

___ Show customer how to make adjustments.

Describe the options available for this cutter and explain their purpose.

___ Explain importance of lubrication to customer and

point out lubrication points on cutter.

___ Present Operator's Manual and request that cus-

tomer 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.

___ Point out all guards and shielding. Explain their

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

___ For mounted units, add wheel weights, ballast in

front tires, and/or front tractor weight to enhance front end stability. A minimum 20% of tractor and equipment gross weight must be on front tractor wheels. When adding weight to attain 20% of tractor and equipment weight on front tractor wheels, you must not exceed the ROPS weight certification. Weigh the tractor and equipment. Do not estimate!

___ Explain to customer that when equipment is

transported on a road or highway, safety devices should be used to give adequate warning to operators of other vehicles.

34 Dealer Check List

MAN0654 (Rev. 10/19/2007)

Page 35

BRUSHBULL Rotary Cutters BB6000X, BB7200X, BB8400X

BB6000X, BB7200X, BB8400X ASSEMBLY. . . . . . . . . . . . . . . . . 36 - 37

GEARBOX ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 - 39

SLIP CLUTCH DRIVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

BB7200X & BB8400X DUAL TAILWHEEL ASSEMBLY (OPTIONAL). . 41

FRONT & REAR CHAIN SHIELDING (OPTIONAL) . . . . . . . . . . . . . . . 42

RUBBER SHIELDING (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . 43

CHECK CHAIN ASSEMBLY (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . 43

CROSSBAR PULLER (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

FRONT OR REAR BAFFLE (OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . 44

PARTS INDEX

(Rev. 4/24/2009)

MAN0680 (11/30/2007)

Parts 35

Page 36

BB6000X, BB7200X & BB8400X ASSEMBLY

67 - SAFETY DECAL SET

68 - COMPLETE DECAL SET

36 Parts

(Rev. 10/24/2008)

MAN0680 (11/30/2007)

Page 37

BB6000X, BB7200X & BB8400X PARTS LIST

REF PART QTY DESCRIPTION

1 ----- 1 Deck Weldment 2 57050 1 Blade Access Cover 3 57040 1 Tailwheel Weldment 4 57118 1 Right Skid - BB6000X 4 57048 1 Right Skid - BB7200X 4 57078 1 Right Skid - BB8400X 5 57119 1 Left Skid - BB6000X 5 57049 1 Left Skid - BB7200X 5 57079 1 Left Skid - BB8400X 6 57134 2 A-Frame Arm - BB6000X, BB7200X 6 1024631 2 A-Frame Arm - BB8400X 7 57130 1 Break Link 8 57135 2 Lift Arm - BB6000X 8 57136 2 Lift Arm - BB7200X 8 1002047 2 Lift Arm - BB8400X 9 57133 2 Link, .50 x 2.0 x 4.48

10 57095 1 Sleeve, .64 x 1.0 x 2.6

BB6000X, BB7200X

10 1001520 1 Sleeve, .64 x 1.0 x 2.33 - BB8400X 11 66661 1 Sleeve, .628 x 1.0 x 1.25 12 67222 2 Sleeve, 5/8 x 1 x 43/64

BB6000X, BB7200X

12 12313 2 Sleeve, 5/8 x 1 x 13/16 BB8400X 13 1001519 2 Sleeve, 5/8 x 1 x 1 14 15573 1 Sleeve, 1.0ID x 1.25OD x 5.81 15 15575 1 Sleeve, 1.25ID x 1.5OD x 1.86 16 15574 1 Sleeve, 1.25ID x 1.5OD x .903 17 12577 1 4 x 8 Tire w/ Rim, 5" wide 18 15277 1 Wheel Hub Assembly

(includes 18b, 18c & 18d) 18a 15591 1 Wheel hub w/cups (includes 18d) 18b 18c 18d

19 15580 1 Tailwheel Clevis Weldment 20 1024136 1 Crossbar Assembly

20 1024139 1 Crossbar Assembly - BB8400X 21 57099KT 1 Blade Kit - BB6000X 21 1003675KT 1 Blade Kit, Flat - BB6000X 21 19160KT 1 Blade Kit - BB7200X, BB8400X 21 19162KT 1 Blade Kit, Flat -

22 32616 2 Blade pin 23 10520 2 18 GA 1-1/2 Blade pin shim 24 13946 2 20 GA 1-1/2 Blade pin shim 25 32603 2 Keyhole plate 26 32604 2 Blade pin lock clip 27 ----- 1 Gearbox (see page 38) 28 57419 1 Driveline - BB6000X 28 57422 1 Driveline - BB7200X, BB8400X 29 1002048 1 Clutch Shield 30 1003828 1 Manual Tube 31 1026542 2 Hitch Pin, Cat 1 & 2 -

31 39064 2 Hitch Pin, Cat 2 & 3 - BB8400X

314 2 Seal for 1-1/2 shaft 310 2 Bearing cone 309 2 Bearing cup

BB6000X, BB7200X

BB7200X, BB8400X

BB6000X, BB7200X -or-

REF PART QTY DESCRIPTION

32 35124 2 7/16 x 2 Klik pin 33 57312 1 Dipstick 34 14350 * 3/8 NC Flange lock nut 35 902 * 5/8 NC x 2 HHCS GR5 36 19025 * 5/8 NC Flanged lock nut 37 5607 * 5/8 NC x 1-1/2 Carriage bolt GR5 38 2855 * 5/8 NC x 2 Carriage bolt GR5 -

BB6000X, BB7200X

38 5836 * 5/8 NC x 2-1/2 Carriage bolt GR5 -

BB8400X

39 692 * 5/8 Flat washer 40 57096 Washer, 1.03 x 2.0 x .38 41 23638 * 5/8 NC x 7 HHCS GR5 42 986 * 5/8 NC x 2-3/4 HHCS GR5 43 854 * 1/2 Flat washer 44 5621 * 1/2 NC x 2-3/4 HHCS GR5 45 11900 * 1/2 NC Flanged lock nut 46 15087 1 NC x 9.0 HHCS GR5 47 1386 1 NC Jam nut 48 34279 * 1 NC Lock nut 49 2370 Washer, 1.62 x 3 x .18 50 12889 51 12881 Washer cap 52 4674 3/8 x 2 Spirol pin 53 12296 * 1/4 - 28 Grease fitting 54 57308 M36 x 3 Castle nut 55 6185 * 1/4 x 2-1/4 Cotter pin 56 6100 * 1/2 NC x 1-1/4 HHCS GR5 57 30068 * 3/4 NC x 2-1/2 HHCS GR5 58 57798 3/4 Hardened flat washer 59 302207 3/4 NC Flange lock nut 60 57262 12mm x 1.75P x 65mm HHCS 61 57261 12mm x 1.75P Hex lock nut 62 35155 * 5/16 Flat washer 63 2472 * 5/16 Lock washer 64 24801 * M8 x 1.25 x 20mm HHCS 65 24409 * 5/16 NC x 1 Carriage bolt 66 4529 * 5/16 NC Hex nut 67 15358 1 Safety decal set 68 1000622 1 Complete decal set 69 57122 1 Rear Band - BB6000X 69 57046 1 Rear Band - BB7200X 69 57084 1 Rear Band - BB8400X 70 4119 1/2 NF x 1 HHCS GR5 71 57353 †

2 5-Ft Heavy-duty skid, right or left

O-Ring, 3/32 x 1-9/16 OD

(optional) -or-

71 57327 †

2 6-Ft Heavy-duty skid, right or left

(optional) -or-

71 57306 †

2 7-Ft Heavy-duty skid, right or left

(optional)

HHCS Hex Head Cap Screw

* Standard hardware, obtain locally

†Not Shown

(Rev. 10/24/2008)

MAN0680 (11/30/2007)

Parts 37

Page 38

GEARBOX ASSEMBLY

38 Parts

MAN0680 (11/30/2007)

Page 39

GEARBOX ASSEMBLY PARTS LIST

REF PART QTY DESCRIPTION

A 58807 1 Complete Gearbox assembly -

BB6000X

A 58808 1 Complete Gearbox assembly -

BB7200X

A 1024795 1 Complete Gearbox assembly -

BB8400X

1 57445 1 Gear crown 24T M7.25 - BB6000X

1 57446 1 Gear crown 22T M8.0 - BB7200X

1 1025617 2 Gear crown 21T M7.8 - BB8400X

2 39411 2 Bearing, cup & cone

3 57318 1 Oil seal 45 x 85 x 10

4 57450 1 Input shaft

5 57320 2 Snap ring, 85 x 88.5 x 3

6 57471 2 Shim 70.3 x 84.7 (57471 kit)

7 57321 1 Snap ring, 50 x 47 x 2

8 57329 1 Castle nut M40 x 1.5

9 57471 1 Shim 5033 x 70.3 (57471 kit)

10 39263 1 Bearing, cup & cone

11 57451 1 Seal protector

REF PART QTY DESCRIPTION

12 57452 1 Dust lip 60 x 110 x 10 -

BB6000X, BB7200X

12 1025612 1 Dust lip 60 x 110 x 12 - BB8400X

13 57453 1 Bearing, cup & cone

14 57454 1 Output shaft

15 ----- * B5 x 60 Cotter pin

16 57371 1 Oil cap 80 x 10

17 57455 1 Gear pinion 15T M7.25 - BB6000X

17 57447 1 Gear pinion 16T M8.0 - BB7200X

18 57456 1 Shim 45.3 x 65.3 x 2.5

19 57471 1 Shim 40.3 x 61.7 (57471 kit)

20 57457 1 Cover - BB6000X, BB7200X

20 1025613 1 Cover - BB8400X

21 ----- * M10 x 14 GR8.8 HHCS -

BB6000X, BB7200X

21 ----- * M8 x 25 GR8.8 HHCS - BB8400X

22 27326 * 3/8 NPT Solid plug

23 57308 1 Castle nut M36 x 3

24 6185 * 1/4 x 2-1/4 Cotter pin

25 57312 1 Dipstick

HHCS Hex Head Cap Screw

* Standard hardware, obtain locally

MAN0680 (11/30/2007)

Parts 39

Page 40

SLIP CLUTCH DRIVE ASSEMBLY

REF PART QTY DESCRIPTION

57419

57422

40563

40566

40765

40750

40752

44676

40751

57421

40766

40777

18864

33347

40778

40767

40779

40758

40727

Complete 540 RPM drive assembly

BB6000X

Complete 540 RPM drive assembly

BB7200X, BB8400X

Yoke, 1-3/8 - 6 Spline ASG

Cross and bearing

Spring pin 10 X 90 mm

Inboard yoke S4

Inner profile S4

Outer profile & sleeve S5

Inboard yoke S5

Friction clutch 1340, 1-3/4, 20 spline

Bearing ring SC25

Anti-rotation chain

Decal, danger rotating driveline

Decal, danger guard missing

Screw

Support bearing

Grease fitting

Slide lock collar repair kit

Outer guard half BB6000X

REF PART QTY DESCRIPTION

57270

57273

57271

40754

57423

57420

57424

57441

57432

57442

57443

57256

57257

57263

57258

57265

57264

57262

57261

Outer guard half BB7200X, BB8400X

Inner guard half BB6000X

Inner guard half BB7200X, BB8400X

Male drive half, complete BB6000X

Male drive half, complete

BB7200X, BB8400X

Female drive half, complete

BB6000X

Female drive half, complete

BB7200X, BB8400X

Flange yoke

Friction disc

Hub 1-3/4 - 20 I.C. -SN

Drive plate

Drive plate - SN

Thrust plate

M12 x 115 mm Hex head cap screw

Spring

Flat washer

M12 Hex nut

M12 x 65 mm Hex head cap screw

M12 Hex nut

40 Parts

MAN0680 (11/30/2007)

Page 41

BB7200X & BB8400X DUAL TAILWHEEL (OPTIONAL)

REF PART QTY DESCRIPTION

1 57101 1 Dual tailwheel assembly

2 12881 2 Washer T160 etc w/cap

3 12889 2 3/32 x 1-9/16 OD O-ring

4 2370 4 Washer, 1.62 x 3 x .18

5 4674* 2 3/8 x 2 Spirol pin

6 15580 2 Tailwheel clevis

7 15087 2 1 NC x 9.0 HHCS GR5

8 15573 2 Sleeve, 1.0 ID x 1.25 OD x 5.81

9 15575 2 Sleeve, 1.25 ID x 1.50 OD x 1.86

10 15591 2 Wheel hub assembly (includes item 21)

11 15574 2 Sleeve, 1.25 ID x 1.50 OD x .903

12577

855*

(Rev. 4/24/2009)

MAN0680 (11/30/2007)

4 x 8 Tire w/rim 5" wide

1/2 Lock washer

REF PART QTY DESCRIPTION

4119*

1386

34279

11854*

19025

314

310

309

15277

HHCS Hex head cap screw

1/2 NF x 1 HHCS GR5

1" NC Jam nut

1" NC Lock nut

5/8 NC x 2-1/2 HHCS GR8

5/8 NC Flange lock nut

Seal for 1-1/2 shaft

Bearing cone

Bearing cup

Wheel hub assembly

(includes items 19, 20, & 21)

* Standard Hardware, Obtain Locally

Parts 41

Page 42

FRONT & REAR CHAIN SHIELDING (OPTIONAL)

REF QTY BB6000X BB7200X BB8400X DESCRIPTION

4A/R

9A/R

10 16

11 1 6

57143 57090 1023048 Right front chain plate

57144 57091 1023047 Left front chain plate

1003645 1007850 1007851 .243 Dia bent pin (front)

5496 5496 5496 5/16 7-Link chain (front)

57142 57088 57125 Right rear chain plate

57141 57089 57149 Left rear chain plate

57138 57085 57146 .243 Dia rolled bent pin (rear)

4069 4069 4069 5/16 4-Link chain (rear)

6697 * 6697 * 6697 * 3/8 NC x 1 Carriage bolt

14350 * 14350 * 14350 * 3/8 NC Flange hex nut

Standard Hardware, Obtain Locally

A/R

As Required

42 Parts

MAN0680 (11/30/2007)

Page 43

RUBBER SHIELDING (STANDARD)

REF PART QTY DESCRIPTION

A 1013208 1 Rubber shield kit 5 foot BB6000X

(includes items 1-4)

A 1013209 1 Rubber shield kit 6 foot BB7200X

(includes items 1-4)

A 1023042 1 Rubber shield kit 7 foot BB8400X

(includes items 1-4)

1 1004129 2 Rubber deflector 31.25 BB6000X

1 1004130 2 Rubber deflector 37.25 BB7200X

1 1024119 2 Rubber deflector 43.25 BB8400X

2 1013214 2 Link, .25 x 1.00 x 28.75 BB6000X

2 1013215 2 Link, .25 x 1.00 x 34.75 BB7200X

2 1024118 4 Link, .25 x 1.00 x 16.00 BB8400X

3 6697 * 8 3/8 NC x 1 Carriage bolt

4 14350 * 8 3/8 NC Flange hex lock nut

* Standard hardware, obtain locally

REF PART QTY DESCRIPTION

1 10521 1 Check chain complete

2 7906 2 Check chain bracket, lower

3 18048 2 3/8 Chain, 32-Link and check lug

4 2377 * 3/4 NC x 6 HHCS GR5

5 2371 * 3/4 NC Hex lock nut

6 12274 * 5/8 NC x 2-1/4 HHCS GR5

7 3632 * 5/8 Flat washer, standard

8 6239 * 5/8 NC Hex lock nut

HHCS Hex head cap screw

* Standard hardware, obtain locally

CHECK CHAIN ASSEMBLY (OPTIONAL)

(Rev. 4/24/2009)

MAN0680 (11/30/2007)

Parts 43

Page 44

CROSSBAR PULLER (OPTIONAL)

REF PART QTY DESCRIPTION

1019865

Baffle kit complete BB6000X

-or-

1019866

Baffle kit complete BB7200X

-or-

1019867

Baffle kit complete BB8400X

1004132

Baffle - BB6000X -or-

1004133

Baffle - BB7200X -or-

1004134

Baffle - BB8400X

1002046

Mounting bracket

6697

3/8 NC x 1 Carriage bolt GR5

14350

3/8 NC Flange lock nut

Standard hardware, obtain locally

BAFFLE KIT (OPTIONAL)

REF PART QTY DESCRIPTION

8811

19914

3097

230

Crossbar puller, complete

Crossbar puller clevis

5/8 NC x 4-1/2 HHCS GR5

5/8 NC Hex nut

REF PART QTY DESCRIPTION

24879

24876

24881

24885

* Standard hardware, obtain locally

Crossbar puller pad assembly

Crossbar puller tube assembly

Crossbar puller screw assembly

Crossbar puller link

44 Parts

MAN0680 (11/30/2007)

Page 45

BOLT TORQUE CHART

SAE SERIES TORQUE CHART

SAE Bolt Head

Identification

SAE Grade 2

(No Dashes)

SAE Grade 5

(3 Radial Dashes)

SAE Grade 8

(6 Radial Dashes)

METRIC SERIES TORQUE CHART

Metric Bolt Head

Identification

8.8

Metric

Grade 10.9

10.9

Metric

Grade 8.8

Typical Washer Installations

Lock Washer

Flat Washer

8/9/00

Bolt

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 MAR 99 & J1701M JUL 96.

MARKING ON HEAD

Diameter

(Inches)

1/4" 7/16" 6 8 10 13 14 18

5/16"1/2"121719262737

3/8"9/16"233135474967

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" 1-5/16" 306 416 474 642 669 907

1" 1-1/2" 467 634 722 979 1020 1383

Wrench

Size

SAE 2 SAE 5 SAE 8

lbs-ft N-m lbs-ft N-m lbs-ft N-m

Diameter &

Thread Pitch

(Millimeters)

Bolt Torque & Size Charts (Rev. 3/28/2007)

Coarse Thread Fine Thread

Marking on Head Marking on Head

Wrench

Size

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

Metric 8.8 Metric 10.9 Metric 8.8 Metric 10.9

N-m lbs-ft N-m lbs-ft N-m lbs-ft N-m lbs-ft

Appendix 45

Diameter &

Thread Pitch

(Millimeters)

Page 46

BOLT SIZE CHART

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

SAE Bolt Thread Sizes

MM 25 50 75 100 125 150 175

IN 1 7

Metric Bolt Thread Sizes

8MM 18MM14MM12MM10MM 16MM

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

ABBREVIATIONS

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

ASABE .................... American Society of Agricultural &

Biological Engineers (formerly ASAE)

ASAE....... American Society of Agricultural Engineers

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

FT.............................................................. Full Thread

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

46 Appendix

Bolt Torque & Size Charts (Rev. 3/28/2007)

Page 47

INDEX

ASSEMBLY

Dealer Set-up Instructions 29 Fill Gearbox 31 Install Safety Shielding

Install Optional Chain Shielding 31 Install Rubber Deflector 31

Optional Equipment

Baffle Kit Installation 32 Check Chain Installation 33 Dual Tailwheel Installation 33

DEALER CHECK LISTS

Delivery Check List (Dealer’s Responsibility) 34 Pre-Delivery Check List

(Dealer’s Responsibility) 34

DEALER SERVICE

Crossbar Installation 26 Crossbar Removal 25 Gearbox Maintenance 22

Horizontal Shaft Leak Repair 23 Seal Installation 22 Seal Replacement 22 Vertical Shaft Repair 23

Gearbox Repair

Assemble Gearbox 24 Disassemble Gearbox 24 Reinstall Gearbox 25 Remove Gearbox from Cutter 24

Universal Joint Repair

U-Joint Assembly 27 U-Joint Disassembly 26 U-Joint Repair 26

GENERAL

Abbreviations 46 Bolt Size Chart 46 Bolt Torque Chart 45 General Information 4 Introduction 2 Obtaining Replacement Manuals 2 Specifications 4 Table of Contents 3 Warranty

Product 74 Replacement Parts 75

OPERATION

Check Chain Adjustment 15 Connecting Cutter to Tractor 12 Cutting Height Adjustment 15 Driveline Adjustment 13

Shortening Driveline 14 Driveline Interference Check 15 Operating Technique 16 Pre-Operation Check List

(Owner’s Responsibility) 16 Quick Hitch Set-Up

Category I and II BB6000X, BB7200X 13

Category II and III BB8400X 13 Shredding Material 16 Tractor Stability 12

OWNER SERVICE

Blade Service

Blade Installation 19

Blade Removal 19

Blade Sharpening 20 Blocking Method 17 Cleaning Cutter

After Each Use 20

Periodically or Before Extended Storage 20 Lubrication Information 17

Driveline Lubrication 18

Gearbox Lubrication 18 Shielding Repair

Chain Shielding (Optional) 20

Rear Band 20

Rubber Shielding 20 Slip Clutch Adjustment 18

PARTS

Parts Index 35

SAFETY

Blocking Method 17 Check Lists

Delivery (Dealer’s Responsibility) 34

Pre-Delivery (Dealer’s Responsibility) 34

Pre-Operation (Owner’s Responsibility) 16 Free Mower Safety Video Order Form 5, 6 Safety & Instructional Decals 10, 11 Safety Rules 7 Safety Symbols Explained 2

MAN0680 (11/30/2007)

TROUBLESHOOTING

Mowing Conditions 21

Index 47

Page 48

WARRANTY

(All Models Except Mow’n MachineTM Zero-Turn Mowers and Woods BoundaryTM Utility Vehicles)

Please Enter Information Below and Save for Future Reference.

Date Purchased: ____________________________ From (Dealer): __________________________________________

Model Number: ____________________________ Serial Number: __________________________________________

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.

Woods backhoe models BH70-X, BH80-X, and BH90-X are warranted for two (2) years from the date of delivery to the original purchaser.

The warranty periods for specific parts or conditions are listed below:

Part or

Condition

Warranted

BW1260, BW1620, BW1800, BW2400 8 years

BW240HD, BW180HD, BW180HB, BW126HB 7 years

BB48X, BB60X, BB72X, BB84X, BB600X, BB720X, BB840X, BB6000X, BB7200X,

Gearbox

components

Blade

spindles

Rust-through

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

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

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

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

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

replacement within a reasonable time after WOODS receives the product. THERE ARE NO OTHER REMEDIES UNDER THIS WARRANTY. THE REMEDY OF REPAIR OR REPLACEMENT IS THE SOLE AND EXCLUSIVE REMEDY UNDER THIS WARRANTY.

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

WOODS shall not be liable for any incidental or consequential losses, damages or expenses, arising directly or indirectly from the product, whether such claim is based upon breach of contract, breach of warranty, negligence, strict liability in tort or any other legal theory. Without limiting the generality of the foregoing, Woods specifically disclaims any damages relating to (i) lost profits, business,

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

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

No agent, representative, dealer, distributor, serviceperson, salesperson, or employee of any company, including without limitation, WOODS, its authorized dealers, distributors, and service centers, is authorized to alter, modify, or enlarge this Warranty. Answers to any questions regarding warranty service and locations may be obtained by contacting:

BB8400X, DS1260, DSO1260, DS1440, TS1680, BW126-3, BW180-3, BW240

PHD25, PHD35, PHD65, PHD95, 2162, 3240, DS96, DS120, RCC42, RM550-2, RM660-2, RM990-3, PRD6000, PRD7200, PRD8400, 7144RD-2, 9180RD-2, 9204RD-2, S15CD, S20CD, S22CD, S25CD, S27CD

RDC54, RD60, RD72, TBW150C

RM550-2, RM660-2, RM990-3, PRD6000, PRD7200, PRD8400, 7144RD-2, 9180RD-2, 9204RD-2

BB600, BB720, BB840, BB6000, BB7200, BB8400, BW126-3, BW126HB, BW180-3, BW180HB, BW180HD, BW1260, BW1800, BW240, BW240HD, 2162, 3240, DS1260, DSO1260, DS1440, TS1680

Model Number

Woods Equipment Company

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

800-319-6637 tel 800-399-6637 fax www.WoodsEquipment.com

Duration (from date of delivery

to the original purchaser)

6 years

5 years

3 years (1 year if used in rental or commercial applications)

3 years

10 years

Page 49

WARRANTY

(Replacement Parts For All Models Except Mow’n Machine

Zero-Turn Mowers and Woods BoundaryTM Utility Vehicles)

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.

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.

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:

F-8494 (Rev. 6/23/2005)

Page 50

PART NO.

MAN0680

© 2007 Woods Equipment Company. All rights reserved. WOODS, and the Woods logo are trademarks of Woods Equipment Company. All other trademarks, trade names, or service marks not owned by Woods Equipment Company that appear in this manual are the property of their respective companies or mark holders. Specifications subject to change without notice.

Woods Equipment Company

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

800-319-6637 tel 800-399-6637 fax www.WoodsEquipment.com

Woods Equipment MAN0680, BB6000X, BB7200X, BB8400X User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual