Woods Equipment BW180XHDQ, BW180XHD, BW126XHD, BW126XHDQ User Manual

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Page 1

BATWING-

ROTARY CUTTER

BW180XHD

BW180XHDQ

BW126XHD

BW126XHDQ

MAN0963

(Rev. 2/16/2012)

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 online Product Registration form at the Woods Dealer Website which certifies that all Dealer Check List items have been completed. Dealers can register all Woods product at dealer.WoodsEquipment.com under Product Registration.

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. 12/5/2011)

Page 3

TABLE OF CONTENTS

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

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

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

SAFETY VIDEO ORDER FORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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

SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

OWNER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

DEALER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

ASSEMBLY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

DEALER CHECK LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

INDEX TO PARTS LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

BOLT TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

BOLT SIZE CHART & ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 83

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

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

REPLACEMENT PARTS WARRANTY . . . . . . . . . . . . . . . . . . . BACK COVER

LEA EL INSTRUCTIVO!

Si no lee Ingles, pida ayuda a

alguien que si lo lea para que le

traduzca las medidas de seguridad.

MAN0963 (2/16/2012)

This Operator’s Manual should be regarded as part of the machine. Suppliers of both new and second-hand machines must make sure that this manual is provided with the machine.

Introduction 3

Page 4

SPECIFICATIONS

WARNING

BW180XHD / BW180XHDQ BW126XHD / BW126XHDQ

Cutting Height (Varies with tire selection) . . . . . . . . . . . . . . . . . . . 1" - 15" 1" - 15"

Cutting Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180" (15’) 126" (10.5’)

Overall Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190" 140"

Transport Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96" 93"

Tractor HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65-250 65-250

Blade Spindle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2

Blade Overlap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6" 6"

Number of Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 4

Blade Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Left Spindle: CW; Right & Center Spindles: CCW

Main Driveline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cat 5 Heavy Cat 5 Heavy

CV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cat 6 Cat 6

Side Frame Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/4" 1/4"

Weight (approximate lbs.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4200 4000

Wheel Size. . . . . . . . . . . . . 15" Rims (BW180XHD and BW180XHDQ only) or 21" OD Solid Tires, Airplane

Torsion Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Slip Clutch Slip Clutch

Tractor PTO rpm 540 1000

Blade Speed (Feet per minute) 15,700 16,000

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

BW180XHD BW126XHD

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 clockwise (left wing) and counterclockwise (right wing and center section) as viewed from the top of the cutter.

BW180XHDQ BW126XHDQ

4 Introduction

MAN0963 (2/16/2012)

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

INSTALLATION

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!

 Hydraulics must be connected as instructed in this manual. Do not substitute parts, modify, or connect in any other way.

TRAINING

 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.



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

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

 Make sure that all operating and service personnel know that if hydraulic fluid penetrates skin, it must be surgically removed as soon as possible by a doctor familiar with this form of injury or gangrene, serious injury, or death will result. CON-

BW180_ SR (Rev. 12/10/2007)

TACT A PHYSICIAN IMMEDIATELY IF FLUID ENTERS SKIN OR EYES. DO NOT DELAY.

 Never allow children or untrained persons to operate equipment.

PREPARATION

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

 Air in hydraulic systems can cause erratic operation and allows loads or equipment components to drop unexpectedly. When connecting equipment or hoses or performing any hydraulic maintenance, purge any air in hydraulic system by operating all hydraulic functions several times. Do this before putting into service or allowing anyone to approach the equipment.

 Make sure all hydraulic hoses, fittings, and valves are in good condition and not leaking before starting power unit or using equipment. Check and route hoses carefully to prevent damage. Hoses must not be twisted, bent sharply, kinked, frayed, pinched, or come into contact with any moving parts. Operate moveable components through full operational range to check clearances. Replace any damaged hoses immediately.

 After connecting hoses, check that all control lever positions function as instructed in the Operator's Manual. Do not put into service until control lever and equipment movements are correct.

 Set tractor hydraulic relief valve at 2500 psi (170 bars) (17,000 kPa) to prevent injury and equipment damage due to hydraulic system failure.

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

 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.

 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.

(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!

 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 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.

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

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



Make sure shields and guards are properly

installed and in good condition. Replace if damaged.

 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.

TRANSPORTATION

 Always raise unit and install transport locks before transporting. Leak down or failure of mechanical or hydraulic system can cause equipment to drop.

 Always attach safety chain to tractor drawbar when transporting unit.

 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.

 Do not operate or transport on steep slopes.

 Do not operate or transport equipment while

under the influence of alcohol or drugs.

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

• Loss of control of the implement and tractor

• Reduced or no ability to stop during braking

• Implement tire failure

• Damage to the implement or its components.

 Use additional caution and reduce speed when under adverse surface conditions, turning, or on inclines.

 Never tow this implement with a motor vehicle.

OPERATION

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

 Never walk, stand, or place yourself or others under a raised wing or in the path of a lowering wing. Hydraulic system leak-down, hydraulic system failures, mechanical failures, or movement of control levers can cause wings to drop unexpectedly and cause severe injury or death.

 Full chain or rubber 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 or rubber 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).

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

It is possible for objects to ricochet

8 Safety

BW180_SR (Rev. 12/10/2007)

Page 9

 Do not operate or transport equipment while

SAFETY RULES

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

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 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.

 Raise or lower wings slowly to prevent personal injury or damage to cutter.

 Connect PTO driveline directly to power unit PTO shaft. Never use adapter sleeves or adapter shafts. Adapters can cause driveline failures due to incorrect spline or incorrect operating length and can result in personal injury or death.

 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.

 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.

 Continuous operation while the clutch is slipping could cause heat build-up resulting in fire. Adjust slip clutch pressure by tightening springs to the dimension shown in the “Owner Service” section. If clutch is set to minimum spring length, replace the friction disks as shown.

 On pull-type or semi-mounted units with optional hydraulic cutting height adjustment, use a single-acting cylinder with a maximum extended

length of 28-1/4" (718 mm) from attaching point center to center.

MAINTENANCE

 Before servicing, adjusting, repairing or unplugging, stop tractor engine, place all controls in neutral, set park brake, remove ignition key, and wait for all moving parts to stop.

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



Before working underneath, disconnect driveline from tractor, lower wings to ground, raise cutter, and pin transport bar in raised position. Attach parking jack and lower to ground. Securely block all four corners of center section and each wing with jackstands. Blocking up prevents the cutter from dropping due to hydraulic leak down, hydraulic system failure, or mechanical component failure.

 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.

 To prevent contamination during maintenance and storage, clean and then cover hose ends, fittings, and hydraulic ports with tape.

 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.

(Safety Rules continued on next page)

BW180_ SR (Rev. 12/10/2007)

Safety 9

Page 10

(Safety Rules continued from previous page)



SAFETY RULES

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

 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.

 Service and maintenance work not covered in OWNER SERVICE must be done by a qualified dealership. Special skills, tools, and safety procedures may be required. Failure to follow these instructions can result in serious injury or death.

 Explosive separation of tire and rim parts can cause serious injury or death. Release all air pressure before loosening bolts on wheel.

STORAGE

 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.

 Never perform service or maintenance with engine running.

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

 Before disconnecting and storing, follow these instructions:

• Store on level, solid ground.

• Disconnect driveline and secure up off the ground.

• Lower wings to ground.

• Raise cutter center section and pin transport bar in raised position.

• Attach parking jack and raise tongue weight off tractor drawbar.

• Place wedge blocks at front and rear of wheels on center section and each wing to prevent wheel rotation.

• Securely block all four corners of center section and each wing with jackstands.

• Remove hydraulic hoses after tractor is turned off and all system pressure is released by operating valve levers several times.

• Remove safety tow chain.

• Remove retainer pin and high strength drawbar pin.

 Keep children and bystanders away from storage area.

10 Safety

BW180_SR (Rev. 12/10/2007)

Page 11

4 - PN 18869

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. 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.

2 - FRONT AMBER REFLECTOR

(PN 1002940)

3 - REAR RED REFLECTOR

(PN 57123)

1 - SERIAL NUMBER PLATE

PN 1006348 - Located on Wheel Rims

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

MODEL NO. SER IAL NO.

SAFETY & INSTRUCTIONAL DECALS

Replace Immediately If Damaged!

Woods Equipment Company

Oregon, Illinois, U.S.A.

MAN0963 (2/16/2012)

DO NOT OPERATE - PUT SHIELD ON

DANGER

SHIELD MISSING

Safety 11

18869-B

Page 12

7 - PN 15503

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 dropping from hydraulic leakdown, hydraulic system failures or mechanical component failures.

FALLING OFF OR FAILING TO BLOCK SECURELY CAN RESULT IN SERIOUS INJURY OR DEATH.

WARNING

18865--C

9 - PN 18865

HIGH-PRESSURE HYDRAULIC OIL LEAKS CAN PENETRA TE SKIN

RESULTING IN SERIOUS INJURY , GANGRENE OR DEA TH.

Check for leaks with cardboard; never use hand.

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

Consult physician immediately if skin penetration occurs.

WARNING

19924-B

11 - PN 19924

8 - PN 18864

DO NOT EXCEED PTO SPEED OF

540 RPM

PTO speeds higher than 540 RPM can cause

equipment failure and personal injury.

WARNING

18866-D

WARNING

DO NOT EXCEED PTO SPEED OF

1000 RPM

PTO speeds higher than 1000 RPM can cause equipment failure and personal injury.

15922-C

5 - PN 15922

(1000 RPM)

6 - PN 18866

(540 RPM)

17 - PN 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

DANGER

ROTATING BLADES AND

THROWN OBJECTS

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

engine is running.

 Before mowing, clear area of objects that may be

thrown by blade.

 Keep bystanders away.

 Keep guards in place and in good condition.

BLADE CONTACT OR THROWN OBJECTS CAN

CAUSE SERIOUS INJURY OR DEATH.

15503-C

12 Safety

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

1004114

MAN0963 (2/16/2012)

Page 13

SAFETY & INSTRUCTIONAL DECALS

12 - PN 1004991

ds.

sta

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.

FAILURE TO FOLLOW THESE

INSTRUCTIONS COULD RESULT IN

SERIOUS INJURY OR DEATH.

WARNING

1003751-A

13 - PN 1003751

RAISED WING EXPOSES BLADE AND INCREASES THROWN OBJECT HAZARDS.

Only raise for transport. Stop cutter and lock wing(s) up.

RAISED WING CAN FALL AND CRUSH.

Keep away.

Lock up with wing transport bars.

Lower wing(s) after transport and for storage.

FAILURE TO FOLLOW INSTRUCTIONS CAN RESULT IN SERIOUS INJURY OR DEATH.

WARNING

18964-A

15 - PN 18964

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.

16 - PN 15502

14 - PN 18877

GUARD MISSING.

DO NOT OPERATE.

DANGER

33347E

DANGER

GUARD MISSING.

DO NOT OPERATE.

10 - PN 33347

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Replace Immediately If Damaged!

1004991

WARNING

RAISED CUTTER CAN DROP AND CRUSH

rs must be equipped with transport lock

Cutt

ansport components must be functional, kept in goodAll t

hydraulic system failures, or mechanical component failures.

FAILURE TO FOLLOW INSTRUCTIONS CAN

RESULT IN SERIOUS INJURY OR DEATH.

 Read Operator's Manual (available

 Keep all shields in place and in good

 Operate mower from tractor seat only.

 Lower mower, stop engine and remove

 Allow no children or untrained persons

 Do not transport towed or

TRANSPORT LOCK

AND CYLINDER

REQUIREMENTS

SINGLE-ACTING FULL

EXTENSION

28-1/4"

TRANSPORT LOCK

WARNING

TO AVOID SERIOUS

INJURY OR DEATH:

from dealer) and follow all safety precautions.

condition.

key before dismounting tractor.

to operate equipment.

semi-mounted units over 20 mph.

FAILURE TO OPERATE SAFELY

CAN RESULT IN

INJURY OR DEATH.

18877-C

MAN0963 (2/16/2012)

Safety 13

Page 14

OPERATION

DANGER

WARNING

CAUTION

The designed and tested safety of this machine depends on it being operated within the limitations as explained in this manual. Be familiar with and follow all safety rules in the manual, on the cutter and on the tractor.

The safe operation of this cutter is the responsibility of the operator, who must be properly trained. The operator should be familiar with the equipment and all safety practices before starting operation. Read the safety information on page 7 through page 13.

Recommended tractor ground speed for most conditions is from 1 to 6 mph.

Always operate tractor PTO at 540 rpm on BW180XHD and BW126XHD; on BW180XHDQ and BW126XHDQ operate PTO at 1,000 rpm.

 Full chain or rubber 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 or rubber shielding, operation must be stopped when anyone comes within 300 feet (92 m).

It is possible for objects to ricochet

sturdy, rough-soled work shoes and protective equipment for eyes, hair, hands, hearing, and head; and respirator or filter mask where appropriate.

CONNECTING CUTTER TO TRACTOR

NOTICE

■ For tractors with a 1-3/8" diameter PTO shaft,

the horizontal distance from the end of the tractor PTO shaft to the center of drawbar pin should be 14" for 540 rpm cutter and 16" for the 1000 rpm cutters. This will minimize joint knock and damage to drive components.

NOTE: Remove CV drive shipping bracket before

operation and discard. This bracket is only supplied on factory assembled units with a CV drive installed.

Figure 1. Cutter to Tractor Connection

 Never allow children or untrained persons to operate equipment.

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

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

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

 Always wear relatively tight and belted clothing to avoid getting caught in moving parts. Wear

14 Operation

1. Attach cutter using a 1-1/2" clevis pin and clip.

2. Attach safety tow chain (32) to drawbar support.

Leave enough slack for turning (Figure 1).

3. Connect cutter driveline to tractor PTO shaft, making sure the spring-activated lock pin slides freely and is seated in tractor PTO splined groove.

4. Attach driveline shield tether chain to tractor drawbar to prevent rotation.

NOTE: CV driveline does not require a tether chain.

5. Remove parking jack (29) from the tongue and attach it to the storage post on the front of the left wing.

NOTE: Equal Angle Drive Only: With cutting height established, adjust the 3-joint H-frame bearing height so that the front driveline is parallel to the ground.

MAN0963 (2/16/2012)

Page 15

Hydraulic Connection

WARNING

1. Inspect hydraulic hoses to ensure they are in good condition.

Cutting Height Adjustment

2. Clean the fittings before connecting them to the

tractor hydraulic ports.

3. Route the hose through the hose holder at the hitch and be sure the hose can slide freely in the holder. Do not allow hose slack to drag on the ground or become caught on tractor protrusions.

4. Attach the hydraulic hose to the tractor.

5. From the operator position, start tractor and raise

and lower deck several times to purge trapped air from the hydraulic cylinder.

Interference Check

1. Be sure that tractor 3-point lift links do not interfere

with hydraulic hoses, cutter driveline, or cutter frame.

2. Check for straight-ahead operation and at full turning angles. If there is any interference, remove the lower lift links.

3. Contact between tractor lift links and cutter parts can cause damage, especially when turning.

CV Driveline Turning Limits

 On pull-type or semi-mounted units with optional hydraulic cutting height adjustment, use a single-acting cylinder with a maximum extended length of 28-1/4" (718 mm) from attaching point center to center.

NOTICE

■ Avoid ground contact with blades. Striking

ground with blades produces one of the most damaging shock loads a cutter can encounter. If this occurs repeatedly, the cutter, driveline, and gearboxes will be damaged.

Cutting height range is from 1" to 15". A hydraulic cylinder or ratchet jack is available for cutting height adjustment.

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. The cutting height (blade edge) is approximately 1" above the bottom of the side skid.

Cutting Height (Normal Mowing) - Center Section

1. Position the cutter on a hard level surface and

select an approximate cutting height, Example 6".

2. Raise wings and lock them in the UP position.

NOTICE

■ You must not exceed a turning angle of 80

degrees at the head of the Constant Velocity driveline or damage will occur.

NOTE: Remove CV drive shipping bracket before

operation and discard. This bracket is only supplied on factory assembled units with a CV drive installed.

1. To check for potential excessive turn angle, disconnect the driveline from tractor.

2. Start engine and turn as far right or left as possible.

3. Shut engine off and try to connect CV driveline to

tractor. If it cannot be connected, the turn angle is too severe.

4. Restart engine and straighten angle slightly, shut off engine and try to connect CV driveline to tractor.

5. Repeat the process until the driveline can be connected. The point at which the driveline can be connected is the maximum turn that should be made.

3. Use any of the optional cutting height mechanisms to raise or lower the center section to obtain a distance of 5" from bottom edge of skid shoe to the ground.

4. Loosen jam nuts on the attitude rod that runs from the wheel yoke to the tongue.

5. Adjust rod in or out until the rear of the cutter is approximately 1/2" higher than the front.

6. Tighten jam nuts against sleeve.

Cutting Height (Normal Mowing) - Wings

1. Lower wings to normal mowing position.

2. Loosen the jam nut on the adjustable link (turn

buckle).

3. Lengthening the link will raise the wing, shortening the link will lower the wing. The rear edge of the wing should be parallel to the ground.

When using the cutter to shred, the rear of the cutter deck should be approximately 1/2" to 1" lower than the front.

NOTE: Equal Angle Drive Only: With the cutting height established, adjust the driveline carrier bearing in the H-frame to ensure the front driveline is parallel to the ground with cutter in cutting position.

MAN0963 (2/16/2012)

Operation 15

Page 16

TRACTOR OPERATION

WARNING

CAUTION

Use care when operating around tree limbs and other low objects. Avoid being knocked off tractor and being injured.

Only use a tractor with a Roll Over Protection Structure (ROPS) and seat belt. Securely fasten seat belt.

The cutter is operated with tractor controls. Engage the PTO at a low rpm to prevent excessive loads on the cutter drive system. Increase throttle to recommended PTO operating RPM.

Be sure operator is familiar with all controls and can stop tractor and cutter quickly in an emergency. The operator should give complete, undivided attention to operating tractor and cutter.

CUTTER OPERATION

When beginning operation of the cutter, make sure that all persons are in a safe location.

Power for operating the cutter is supplied by the tractor PTO. Operate PTO at 540 (1000 RPM for "Q" models).

Know how to stop the tractor and cutter quickly in an emergency.

Engage PTO at a low engine, rpm to minimize stress on the drive system and gearbox.

Mowing Tips

 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.

Maximum recommended ground speed for cutting or shredding is 6 miles per hour. Adjust tractor ground speed by using higher or lower gears to provide a clean cut without lugging tractor engine.

With PTO engaged, raise PTO speed to 540 or 1000 RPM depending on model and maintain throughout cutting operation.

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

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.

Always operate tractor PTO at proper RPM (540 or 1000 depending on model) to maintain blade speed and to produce a clean cut.

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 or 1000 RPM. The lower ground speed will permit grass to rebound partially.

Tall material should be cut twice. Cut material higher the first pass. Cut at desired height at 90 degrees the second pass.

Remember, sharp blades produce cleaner cuts and use less power.

Before entering an area, analyze it to determine the best procedure. Consider the height and type of material to be cut and the terrain type (hilly, level or rough, etc.).

Shredding

The cutter may be used to shred various crops including green manure, straw, stubble, asparagus residue, corn stalks and similar crops in preparation for tilling. It may also be used to shred pruning in orchards, groves and vineyards.

Each shredding operation may require a different setup. Start with front edge of cutter high. Adjust up or down as necessary with attitude rod. Experiment until you obtain the results you want.

When shredding attitude is set, check that the distance from the bottom rear edge of the wing to the ground matches the bottom edge of the rear center section to the ground. With the cutting height and attitude established, adjust the driveline carrier bearing in the Hframe to ensure the front driveline is parallel to the ground.

16 Operation

MAN0963 (2/16/2012)

Page 17

TRANSPORTING

WARNING

CAUTION

DP4a

DP7

 Always raise unit and install transport locks before transporting. Leak down or failure of mechanical or hydraulic system can cause equipment to drop.

 Always attach safety chain to tractor drawbar when transporting unit.

 Never exceed 20 mph (32.2 km/h) during transport.

 Never allow riders on power unit or attachment.

Figure 2. Transport Lock-Up Bar - Right Wing

Center Section Lock-Up

1. Raise cutter with hydraulic cylinder to maximum

height.

2. Rotate transport lock into position over cylinder rod (Figure 3).

 Do not operate PTO during transport.

 Do not operate or transport on steep slopes.

 Do not operate or transport equipment while

under the influence of alcohol or drugs.

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

Lock-Up

Always transport with wings and center frame in the raised, locked position.

Wing Lock-Up

1. Raise wing to the up position.

2. Remove safety pin and lock-up bar from storage

position.

Figure 3. Transport Lock In Transport Position

3. Lower cutter against transport lock.

4. To lower cutter for operation, extend hydraulic

cylinder to raise cutter. Rotate transport lock back away from cylinder rod (Figure 4).

5. Lower cutter to desired cutting height.

3. Place lock-up bar over cylinder pin and secure with

safety pin.

4. Repeat steps 1 to 3 for opposite wing.

5. Lower cylinder against lock-up bars (Figure 2).

MAN0963 (2/16/2012)

Figure 4. Transport Lock In Operation Position

Operation 17

Page 18

STORAGE



Follow these steps when storing your cutter:

1. Clean cutter before storing. See page 23 for cleaning instructions. Store on level, solid ground.

2. Disconnect driveline and secure up off the ground.

the PTO slip joint is lubricated and that the gearbox fluid levels are correct.

___ Set tractor PTO at correct rpm for your equip-

ment.

___ Lubricate all grease fitting locations. Make sure

PTO shaft slip joint is lubricated.

3. Lower wings to ground.

4. Raise cutter center section and pin transport bar in

raised position.

5. Attach parking jack and raise tongue weight off tractor drawbar.

6. Place wedge blocks at front and rear of wheels on center section and each wing to prevent wheel rotation.

7. Securely block all four corners of center section and each wing with jack stands.

8. Remove hydraulic hoses after tractor is turned off and all system pressure is released by operating valve levers several times.

9. Remove safety tow chain.

10. Remove retainer pin and high strength drawbar

pin.

11. Keep children and bystanders away from storage area.

PRE-OPERATION CHECK LIST

(OWNER'S RESPONSIBILITY)

___ Review and follow all safety rules and safety

decal instructions on page 7 through page 13.

___ Check that all safety decals are installed and in

good condition. Replace if damaged.

___ Check that equipment is properly and securely

attached to tractor.

___ Check that all hydraulic hoses and fittings are in

good condition and not leaking before starting tractor. Check that hoses are not twisted, bent sharply, kinked, frayed, or pulled tight. Replace any damaged hoses immediately.

___ Check that all hardware is properly installed and

secured.

___ Check cutting height and attitude adjustment.

___ Raise and lower equipment to make sure air is

purged from hydraulic cylinders and hoses. Raise and lower equipment to make sure air is purged from hydraulic cylinders and hoses.

___ Check that blades are sharp and secure and cut-

ting edge is positioned to lead in a counterclockwise rotation.

___ Make sure tractor ROPS or ROPS cab and seat

belt are in good condition. Keep seat belt securely fastened during operation.

___ Check that shields and guards are properly

installed and in good condition. Replace if damaged.

___ Before starting engine, operator must be in trac-

tor seat with seat belt fastened. Place transmission in neutral or park, engage brake and disengage tractor PTO.

___ Inspect area to be cut and remove stones,

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

___ Make sure driveline spring-activated locking pin

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

___ Check all lubrication points and grease as

instructed in lubrication information. Make sure

18 Operation

___ Inspect rubber or chain shielding and replace any

damaged rubber shield or missing links.

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

with hydraulic hoses or driveline throughout full turning range.

MAN0963 (2/16/2012)

Page 19

OWNER SERVICE

WARNING

CAUTION

WARNING

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.

 Before working underneath, disconnect driveline from tractor, lower wings to ground, raise cutter, and pin transport bar in raised position. Attach parking jack and lower to ground. Securely block all four corners of center section and each wing with jack stands. Blocking up prevents the cutter from dropping due to hydraulic leak down, hydraulic system failure, or mechanical component failure.

BLOCKING METHOD

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

 Before performing any service or maintenance, lower equipment to ground or block securely, turn off engine, remove key, and disconnect driveline from tractor PTO.

 Before servicing, adjusting, repairing or unplugging, stop tractor engine, place all controls in neutral, set park brake, remove ignition key, and wait for all moving parts to stop.

 Never perform service or maintenance with engine running.

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

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

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

1. Jackstands with a load rating of 1000 lbs. or more are the only approved blocking device for this cutter. Install jackstands (shown by Xs in Figure 5) under the cutter before working underneath unit.

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

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.

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

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

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

MAN0963 (2/16/2012)

Owner Service 19

Page 20

Figure 5. Jackstand Placement and Lubrication Points

1. Driveline U-joint 10 Hours

2. Telescoping shaft 10 Hours

3. Carrier bearing block 40 Hours

4. CV body assembly 10 hours (10 pumps minimum)

5. Driveline shield 10 Hours

6. Splined yoke 10 Hours

7. Gearbox (above lower Daily line on dipstick)

8. Tongue pivot 40 Hours

9. Wheel yoke pivot 40 Hours

10. Tailwheel spindle 20 Hours

11. Turnbuckle 40 Hours

LUBRICATION

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

See Figure 5 for lubrication points and frequency or lubrication based on normal operating conditions. Severe or unusual conditions may require more frequent lubrication.

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.

Gearbox Lubrication

For gearbox, use a high quality gear oil with a viscosity index of 80W or 90W and an API service rating of GL–

20 Owner Service

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. Use sealant on vent plug threads during installation. Check vent plug periodically and clean if it does not relieve pressure.

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.

MAN0963 (2/16/2012)

Page 21

Seasonal Lubrication

WARNING

9. Blade pin

10. Crossbar assembly

11. Shim, 18 ga

12. Shim, 20 ga

13. Keyhole plate

14. Blade lock clip

52. 1/2 NC x 1-1/4 HHCS GR5

CAUTION

In addition to the daily recommended lubrication, a more extensive application is recommended seasonally.

1. Fill CV double yokes with 20 pumps of grease with the joints in a straight line.

2. Articulate CV body to maximum angle several times to ensure full coverage of joints.

3. Place joints in the straight position and a add 10 additional pumps of grease to both joints.

4. Wipe telescoping drive clean of all old grease and contaminants.

5. Add a thin layer of new grease over telescoping drive.

lock clip (14), keyhole plate (13), and shims (11 &

12). Carefully drive blade pin (9) out of crossbar.

4. Rotate crossbar and repeat for opposite blade.

NOTICE

■ If blade pin (9) is seized in crossbar and extreme

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

Blade Installation (Figure 6)

 Your dealer can supply genuine replacement blades. Substitute blades may not meet original

equipment specifications and may be dangerous.

BLADES

 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.

Blade Removal (Figure 6)

NOTICE

■ Crossbar rotation has clockwise rotation on left

gearbox and counterclockwise rotation on the right and center gearboxes when looking down on cutter. Be sure to install blade cutting edge to lead in correct rotation.

NOTE: Always replace or sharpen both blades at the

same time.

1. Inspect blade pin (9) 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 (10) 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 down away from cutter.

4. Insert blade pin (9) through blade. Push blade pin through crossbar.

5. Install shims (11 & 12) over blade pin.

NOTE: Only use enough shims to allow keyhole

plate (13) to slide into blade pin groove.

Figure 6. Blade Assembly

1. Disconnect driveline from tractor PTO.

2. Raise cutter and block securely (see Figure 5).

3. Align crossbar (10) with blade access hole in the

cutter frame. Remove cap screw (52), blade pin

MAN0963 (2/16/2012)

6. Install blade clip (14) over keyhole plate and into blade pin groove.

7. Secure into position with cap screw (52). 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. Blade should not move more than a 1/4 inch up or down at the tip. Keep any spacers not used in the installation as replacements or for future installation.

Owner Service 21

Page 22

Blade Sharpening

1. Flange yoke

2. Friction disc

3. Hub 1-3/8 round bore

4. Thrust plate

5. Belleville spring plate

6. 10 mm x 1.5P x 50 mm Cap screw

7. 10 mm x 1.5P Hex nut

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

9. 12 mm x 1.5P Hex nut

SLIP CLUTCH ADJUSTMENT (FIGURE 8)

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.

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.

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 10 mm cap screws (6) to remove all

tension from Belleville spring plate (5).

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 thrust plate faces (4), flange yoke (1), and clutch hub (3).

6. Reassemble clutch.

7. Tighten Belleville spring (5) until it is against the

thrust plate (4) of the clutch, and then back off each of the six nuts by 2 full revolutions. The gap between Belleville spring and thrust plate should be 1/8" as shown in Figure 8.

Figure 7. Blade Sharpening

Figure 8. Slip Clutch Assembly

22 Owner Service

8. If a clutch continues to slip when the spring is

compressed to 1/8" gap, check friction discs (2) for excessive wear. Discs are 1/8" when new. Replace discs after 1/16" wear. Minimum disc thickness is 1/16".

MAN0963 (2/16/2012)

Page 23

SHIELDING REPAIR

DANGER

WARNING

PN 1006348

 Full chain or rubber 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 or rubber shielding, operation must be stopped when anyone comes within 300 feet (92 m).

Repairing Rubber Shielding

1. Inspect belting and rear bands each day of

operation.

2. Replace if bent, cracked, or broken.

3. Replace any missing hardware.

Repairing Optional Chain Shielding:

It is possible for objects to ricochet

Check wheels for low pressure, cuts, bubbles, damaged rims, or missing lug bolts and nuts.

Never remove split rim assembly hardware (A) with the tire inflated.

Figure 9. Split Rim Tire Servicing

CLEANING

1. Inspect chain shielding each day of operation and

replace any broken or missing chains as required.

2. Replace any missing hardware.

SERVICING TIRES SAFELY

Used Aircraft Tires (Figure 9)

Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job.

Always maintain the correct tire pressure. Do not inflate tires above the recommended pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure and result in a tire explosion. Welding can structurally weaken or deform the wheel.

When inflating tires, use a clip-on chuck and an extension hose long enough to allow you to stand to the side — not in front of or over the tire assembly. Use a safety cage if available.

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.

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.

MAN0963 (2/16/2012)

Owner Service 23

Page 24

TROUBLESHOOTING

PROBLEM POSSIBLE CAUSE SOLUTION

Does not cut Dull blades Sharpen blades.

Worn or broken blades Replace blades. (Replace in pairs

only.)

Incorrect PTO speed Set at rated PTO speed.

Ground speed too fast Reduce ground speed.

Drive not functioning (blades do not turn when PTO is running)

Gearbox malfunction Repair gearbox.

Excessive clutch slippage Adjust clutch.

Incorrect blade direction Check to be sure blade edge is

Streaks or ragged cut Broken or worn blades Replace or sharpen blades.

Attitude incorrect Level machine.

Ground speed too fast Reduce ground speed.

Excessive cutting height Lower cutting height. (Note: Set

Excessive lush and tall vegetation Recut at 90° to first pass.

Excessive side skid wear Running with skids continuously

on ground

Excessive clutch slippage Clutch out of adjustment Adjust clutch.

Clutch discs worn; wear stops contacting opposite plate

Check drive shaft connection. Check gearbox.

correct for direction of rotation.

height so blades do not frequently hit ground.)

Raise cutting height or adjust.

Replace discs.

Blades hitting ground Raise cutting height.

Vibration Broken blade Replace blades in pairs.

Bearing failure Check gearbox shafts for side play.

Hitch length incorrect Reset hitch length.

Universal drive Adjust pedestal bearing height to

be parallel to ground.

Blades hitting deck Bent blades or crossbar Replace bent blades or crossbar.

Unit will not raise Low oil Add hydraulic oil.

Unit doesn’t cut level Wing section cuts lower than

center

Wing section cuts higher than center

24 Troubleshooting

Lengthen turnbuckle connecting center yoke to wing wheel yoke.

Shorten turnbuckle connecting center yoke to wing wheel yoke.

MAN0963 (2/16/2012)

Page 25

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.

Incorrect Installation

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.

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

Seal Replacement (Figure 11)

Recommended sealant for gearbox repair is Permatex

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.

Aviation 3D Form-A-Gasket or equivalent.

Seal Installation

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.

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

GEARBOX MAINTENANCE - STYLE A

NOTE: Read this entire section (pages 25 - 28) before

starting any repair. Many steps are dependent on each other. See parts list on pages 62 thru 65 to determine gearbox style. Style "A" has a crowned top. Style"B" has a flat top.

1. Fill gearbox with SAE 80W or 90W gear lube. Proper oil level is between lowest ring and end of dipstick.

NOTE: Replacing gears, shafts, and housing may not be cost effective. Purchasing a complete gearbox may be more economical.

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

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

Figure 11. Seal Installation

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Dealer Service 25

Page 26

Vertical Shaft Seal Replacement

Refer to Figure 12, page 28.

1. Disconnect and remove the driveline from the

gearbox.

2. Remove dipstick breather assembly (30) and siphon gear lube from housing through this opening.

3. Remove crossbar (see page 36).

4. Remove retaining ring (33) and output oil seal (15).

Replace output oil seal (15) with new seal. Install retaining ring (33).

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

5. Fill gearbox with SAE 80W or 90W gear lube to the center of the horizontal shaft.

8. Fill gearbox with SAE 80W or 90W gear lube to the center of the horizontal shaft.

GEARBOX REPAIR - STYLE A

Gearbox Removal From Cutter

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

out mechanical assistance.

1. Disconnect and remove the driveline from the gearbox that is to be removed.

2. Remove cotter pin and nut from vertical shaft and remove crossbar (see page 36).

3. Remove the eight bolts that attach gearbox to cutter and remove gearbox.

6. Remove and replace any seal damaged in installation.

Horizontal Shaft Seal Replacement

Refer to Figure 12.

1. Disconnect and remove the driveline from the

gearbox.

2. Remove dipstick breather assembly (30) and siphon gear lube from housing through this opening.

3. Remove input oil seal (6). Replace with new one.

4. Fill gearbox with SAE 80W or 90W gear lube to the

center of the horizontal shaft.

Gearbox Cap Leak Repair

Refer to Figure 12.

1. Disconnect and remove the driveline from the

gearbox.

2. Remove dipstick breather assembly (30) and siphon gear lube from housing through this opening.

3. Remove cap where leak is occurring (4, 21 or 26).

4. Clean mating surfaces with a gasket remover.

Gearbox Disassembly

Refer to Figure 12.

1. Remove six cap screws (25) and cover (26) from

gearbox and pour out gear oil.

2. Remove caps (21 and 4).

3. Support gearbox in hand press and push on the

gear end of the input shaft (5) to remove bearing (20).

4. Remove gear (32) from inside housing.

5. Remove bearing (20) by using a punch and

hammer from outside of housing.

6. Support housing in vise in a horizontal position.

7. The castle nut (14), cotter pin (13), and hub were

already removed with the stump jumper/crossbar. Remove the ring (33), and oil seal (15).

8. Remove cotter pin (19), nut (18) from output shaft (16).

9. Remove output shaft (16) by using a punch and hammer and tap on top to drive down. Remove gear (17) and shims (9, 10, 11) from inside housing.

10. Remove bottom bearing (12) by using a punch and hammer from the top, outside the housing.

5. Replace gaskets (7, 8, 22, 23) as required to meet the following specifications:

● End float should be less than 0.012".

● Rotational torque should be less than 2.2 lbs-

inch.

● Gear backlash should be between 0.006" and

0.016".

6. Install cap (4, 21 or 26) using a gasket sealant.

7. Install cap screws (3 or 25) and torque to 29 lbs-ft.

26 Dealer Service

11. Support housing upside down (top cover surface)

and remove bearing (20) by using a punch and hammer from the bottom side of the housing.

12. Inspect gears for broken teeth and wear. Some wear is normal and will show on loaded side. Forged gear surfaces are rough when new. Check that the wear pattern is smooth.

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

MAN0963 (2/16/2012)

Page 27

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

Gearbox Assembly

Refer to Figure 12.

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 (12, 20) in the housing, using a round tube of the correct diameter and a hand press.

4. Slide output shaft (16) from the bottom through both bearings (12, 20) until it rests against bottom bearing (12).

5. Slide shims (9, 10, 11) over output shaft (16). Use the same thickness of shims that were removed as a starting point.

6. Place gear (17) onto output shaft (16) and secure with the nut (18) and cotter pin (19). The output shaft must have zero end play and rotational torque of 20 to 30 LBS-IN without the lower seal. Tighten nut (18) as needed.

7. Press bearing cup (20) into end of the housing closest to the gear, using a round tube of the correct diameter and a hand press. Install cap (4 or

21) and gaskets (7, 8 or 22, 23).

8. Place gear (32) and spacers (29, 24) through top of housing and align gear (32) and shaft (5) so that gear spline match the shaft spline.

9. While holding gear (32) in place, slide input shaft (5) through gear (32) and press onto bearing cone (20).

10. Press bearing (20) over input shaft (5).

11. Slide shims (7, 8 or 22, 23) over input shaft. Install

cap (4 or 21).

12. Check input shaft end float by moving the input shaft (5) by hand. If end float is higher than 0.004", insert shim between housing and cap that is closest to the gear. Repeat until end float is less than 0.004". Check rotational torque by hand. The torque should be less than 2.2 lbs-inch.

13. Check that the gear backlash is .015/.025 at O.D. of gear. Adjust the backlash by adding or removing shims (9, 10, 11) from the output shaft (16).

14. Apply grease to lower seal lips (15) and press seal (15) over output shaft (16), using a tube of the correct diameter. Be sure not to damage the seal lip.

15. Press in housing so that seal is recessed. Install retaining ring (33).

16. Press in input oil seal (6), using tube of correct diameter. Be careful not to damage seal lip.

17. Place top cover (26) on top of housing and secure with six cap screws (25).

18. 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.

19. Remove gearbox from water and dry off with compressed air. Fill gearbox with SAE 80W or 90W gear lube to the center of the horizontal shaft. Tighten all plugs.

Gearbox Installation

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 (Crossbar Installation, page 37).

MAN0963 (2/16/2012)

Dealer Service 27

Page 28

2. 10 mm Lock washer

3. M10 x 1.5P x 30 HHCS

4. Input cap

5. Input shaft

6. Input oil seal

7. Input cap gasket .10 mm

8. Input cap gasket .25 mm

9. Shim .30 mm

10. Shim .40 mm

11. Shim .50 mm

12. Bearing assembly (cup & cone)

13. 3/16 x 3 Cotter pin

14. M36 Castle nut

15. Output oil seal

16. Output shaft

17. Output gear

18. Bearing adjustment nut

19. 1/8 x 2-1/2 Cotter pin

20. Bearing assembly (cup & cone)

21. Blank adjusting cap

22. Blank cap gasket .10 mm

23. Blank cap gasket .25 mm

24. Bearing spacer

25. M10 x 1.5P x 25 mm HHCS

26. Inspection cover cap

27. Sealing washer

28. M18 x 1.5P Hex head plug

29. Input shaft spacer

30. Dipstick breather assembly

31. Inspection cover gasket

32. Input gear

33. Retaining ring

28 Dealer Service

Figure 12. Style A Gearbox

MAN0963 (2/16/2012)

Page 29

GEARBOX MAINTENANCE - STYLE B

1. Seal

2. Pipe or tube

3. Seal seat

4. Casting

Pipe or tube must press at outer edge of seal.

Incorrect Installation

NOTE: Read this entire section (pages 29- 31) before starting any repair. Many steps are dependent on each other. See parts list on pages 62 thru 65 to determine gearbox style. Style "A" has a crowned top. Style"B" has a flat top.

1. Fill gearbox with SAE 80W or 90W gear lube. Proper oil level is between lowest ring and end of dipstick.

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.

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

Figure 13. Seal Installation

Seal Replacement (Figure 13)

Recommended sealant for gearbox repair is Per matex

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

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

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

Aviation 3D Form-A-Gasket or equivalent.

Vertical Shaft Seal Replacement

Refer to Figure 14, page 31.

1. Disconnect and remove the rear driveline from the

gearbox.

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

3. Remove crossbar (see page 36).

4. Remove protective seal (8) and vertical shaft seal

(18). Replace seal (18) with new seal.

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.

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.

Horizontal Shaft Seal Replacement

Refer to Figure 14.

1. Disconnect and remove the rear 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.

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

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Dealer Service 29

Page 30

GEARBOX REPAIR - STYLE B

Gearbox Removal From Cutter

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

out mechanical assistance.

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.

1. Disconnect and remove the rear driveline from the gearbox.

2. Remove cotter pin and nut from vertical shaft and remove crossbar (see page 36).

3. Remove the six bolts that attach gearbox to cutter and remove gearbox.

Disassembly

Refer to Figure 14.

1. Remove top cover (22) from 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), cotter pin (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 shim (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 (21) by using a punch and hammer from the top, outside the housing.

14. Support housing upside down (top cover surface) and remove 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. Forged gear surfaces are rough when new. Check that wear pattern is smooth.

Assembly

Refer to Figure 14.

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 & 21) in the housing, using a round tube of the correct diameter and a hand press.

4. Slide output shaft (4) through both bearings (6 &

21) 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 shim (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.

8. 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.

9. 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).

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

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

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

13. Slide shim (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.

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

15. 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.

30 Dealer Service

MAN0963 (2/16/2012)

Page 31

16. Check that the gear backlash is between 0.006"

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

21. Bearing

22. Top Cover

23. Cap screw 8 mm x 16 (8.8)

24. Vent plug

25. Cotter pin

26. Washer

27. Side plug

and 0.016". You should not have to adjust the backlash.

21. 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.

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

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

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

20. 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.

Reinstallation

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 (Crossbar Installation, page 37).

MAN0963 (2/16/2012)

Figure 14. Style B Gearbox

Dealer Service 31

Page 32

SPLITTER GEARBOX REPAIR - STYLE A

Splitter Gearbox Assembly

Refer to Figure 15, page 33.

See pages 60 and 61 to determine gearbox style. Style "A" has removable shaft covers. Style "B" has a top cover.

Splitter Gearbox Removal From Cutter

1. Disconnect and remove all drivelines from

gearbox.

2. Remove the four cap screws and lock washers that secure gearbox to cutter, and remove gearbox.

NOTE: Gearbox is heavy: do not attempt to move it without mechanical assistance.

Splitter Gearbox Disassembly

Refer to Figure 15.

Center Shaft

1. Remove plug from side of gearbox and pour out

the gear oil.

2. Remove seal (6, to be replaced) from the front and rear of the center shaft (5).

3. Remove front cap (4) and gaskets (8, 9, 10) from the front and rear of the center shaft (5).

4. Support gearbox in a hand press and push on the rear of the center shaft.

5. Remove bearing cones (7), and gear (18) from center shaft (5).

6. Remove bearing cups (7) from housing and cap using a punch and hammer.

Side Shaft

7. Remove seal (12, to be replaced) from the output

shaft (13).

8. Remove 8 cap screws (3) and side shaft assembly.

9. Remove cotter pin (21), bearing adjustment nut

(20), and gear (19).

10. Support side shaft assembly in hand press. Press shaft (13) through the cap (11) from the threaded end of the shaft.

11. Repeat steps 10 through 12 for opposite side shaft.

Inspect Components

12. Inspect gears for broken teeth and wear. Some

wear is normal and will show on the loaded side of the teeth. Forged gear surfaces are rough when new. Check that wear pattern is smooth.

13. Inspect shafts for grooves, nicks, or bumps in the areas where seals seat. Resurface any damage with emery cloth or replace shaft.

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

Refer to Figure 15.

1. Clean housing, pay specific attention to areas

where gaskets are installed.

2. Wash housing and all components thoroughly.

3. Select a clean work area to assemble gearbox.

4. Replace all seals, bearings, and gaskets.

5. All parts must be clean and lightly oiled before

assembly.

Side Shaft

6. Insert bearing cups (7) in hub cap(11) using a

round tube of the same size diameter and a hand press.

7. Press bearing cone (7) on to output shaft (13), slide output shaft (13) through hub cap (11) and press bearing cone (7) on to output shaft (13).

8. Slide gear (19) over output shaft (13) and secure with nut (20) and cotter pin (21).

9. Check end play of shaft by moving it in and out. If end play is more than 0.012", tighten nut (20). Repeat process until end play is less than 0.012".

10. Check rotational torque. Torque should be less than 2.2 lbs-inch gear.

11. Place seal (12) over shaft and press into housing using a tube of the same diameter. Seal should be flush with housing when properly installed.

12. Repeat steps 6 through 10 for opposite side shaft.

Center Shaft

13. Insert bearing cups (7) in housing and front cap (4)

using a round tube of the same size diameter and a hand press.

14. Press spacer (14), gear (18), shims (15, 16, 17) and bearing cones (7) on to input shaft (5).

15. Slide input shaft (5) through housing and install gaskets (8, 9, 10) and cap (4).

16. Check end play of shaft by moving it in and out. If end play is more than 0.012", remove a gasket (8, 9, or 10). Repeat process until end play is less than

0.012".

17. Check rotational torque. Torque should be less than 2.2 lbs-inch gear.

18. Check gear backlash, backlash should be between

0.006" and 0.016". Adjust the backlash by adding or removing shims (15, 16, 17) from the input shaft (5).

19. Place seal (6) over shaft and press into housing using a tube of the same diameter. Seal should be flush with housing when properly installed. Repeat process for opposite end shaft.

32 Dealer Service

MAN0963 (2/16/2012)

Page 33

Splitter Gearbox Inspection

2. 10 mm Lock washer

3. M10 x 1.5P x 30 HHCS

4. Input cap

5. Input shaft

6. Input oil seal

7. Bearing assembly (cup & cone)

8. Gasket .15 mm

9. Gasket .25 mm

10. Gasket .40 mm

11. Hub c ap

12. Oil seal

13. Output shaft

14. Spacer

15. Shim .30 mm

16. Shim .40 mm

17. Shim .50 mm

18. Center gear

19. Wing gear

20. Bearing adjustment nut

21. 1/8 x 2-1/2 Cotter pin

22. Sealing washer

23. M18 x 1.5P Level plug

24. M18 x 1.5P Breather plug

1. Check gearbox for leaks by: plugging all holes except one, applying 4 psi of compressed air, and immersing gearbox in water. Verify gearbox does not leak.

NOTE: Excessive air pressure will damage seals.

2. Remove gearbox from water and dry off.

3. Remove upper plug on right side of housing. Add

SAE 80W or 90W EP oil until it runs out side level hole. Replace plug.

4. Install breather (24) in top cover.

Splitter Gearbox Installation

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

out mechanical assistance.

Use loctite when mounting gearbox. Set gearbox on cutter and fasten with bolts and nuts. Torque bolts to 170 lbs-ft.

MAN0963 (2/16/2012)

Figure 15. Splitter Gearbox - Style A

Dealer Service 33

Page 34

SPLITTER GEARBOX REPAIR - STYLE B

Refer to Figure 16, page 35.

See pages 60 and 61 to determine gearbox style. Style "A" has removable shaft covers. Style "B" has a top cover.

Splitter Gearbox Removal from Cutter

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

15. Inspect shafts for grooves, nicks, or bumps in the areas where seals seat. Resurface any damage with emery cloth or replace shaft.

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

1. Disconnect and remove all drivelines from gearbox.

2. Remove the four cap screw and lock nuts that secure gearbox to cutter, and remove gearbox.

NOTE: Gearbox is heavy: do not attempt to move it without mechanical assistance.

Splitter Gearbox Disassembly

Refer to Figure 16.

Center Shaft

1. Remove plug from side of gearbox and pour out

the gear oil.

2. Remove seal (3, to be replaced) from the front and rear of the center shaft (9).

3. Remove snap ring (4) and shim (5) from the front and rear of the center shaft (9).

4. Support gearbox in a hand press and push on the rear of the center shaft.

5. Remove bearing (1) from center shaft (9).

6. Remove six cap screws (11) and top cover (10)

from the gearbox housing.

7. Remove gear (8) and bearing (1).

Side Shaft

8. Remove seal (3, to be replaced) from the output

shaft (7).

9. Remove snap ring (4) and shim (5) from front output shaft (7). Remove snap ring (4) from the rear of shaft.

10. Support gearbox in hand press. Using a punch through the front opening of the gearbox and, push shaft (7) and bearing (1) out the backside of housing.

11. Remove gear (6) from inside housing.

12. Remove bearing (1) and shim (5) by using a

hammer and punch through front opening of the gearbox and force them out the backside of the housing.

13. Repeat steps 7 through 11 for opposite side shaft.

Inspect Components

14. Inspect gears for broken teeth and wear. Some

wear is normal and will show on the loaded side of

Splitter Gearbox Assembly

Refer to Figure 16.

1. Clean housing, pay specific attention to areas

where gaskets are installed.

2. Wash housing and all components thoroughly.

3. Select a clean work area to assemble gearbox.

4. Replace all seals, bearings, and gaskets.

5. All parts must be clean and lightly oiled before

assembly.

Side Shaft

6. Insert bearing (1) and shim (5) in housing using a

round tube of the same size diameter and a hand press.

7. Place gear (6) inside the housing and slide output shaft (7) through gear (6) and into bearing (1). Secure with snap ring (4).

8. Slide bearing (1) and shim (5) over output shaft. Secure with snap ring (4).

9. Check end play of shaft by moving it in and out. If end play is more than 0.012", insert another shim (8) between snap ring and bearing. Repeat process until end play is less than 0.012".

10. Check rotational torque. Torque should be less than 2.2 lbs-inch gear.

11. Place seal (3) over shaft and press into housing using a tube of the same diameter. Seal should be flush with housing when properly installed.

12. Repeat steps 6 through 10 for opposite side shaft.

Center Shaft

13. Place gear (8) inside housing and slide center shaft

(9) through the gear from the front of the housing.

14. Slide bearings (1) and shims (5) over each end of the center shaft (9). Secure bearings into position using snap rings (4).

15. Check end play of shaft by moving it in and out. If end play is more than 0.012", insert another shim (5) between snap ring and bearing. Repeat process until end play is less than 0.012".

16. Check rotational torque. Torque should be less than 2.2 lbs-inch gear.

34 Dealer Service

MAN0963 (2/16/2012)

Page 35

17. Check gear backlash, backlash should be between

1. Bearing

3. Oil seal

4. Snap ring

5. Shim

6. Pinion gear

7. Shaft 1-3/4, 20 spline, wing

8. Gear

9. Shaft 1-3/4, 20 spline, center

10. Cover

11. M10 x 30 Cap screw 8.8

12. 1/2 Breather

0.006" and 0.016". You should not have to adjust for backlash.

18. Place seal (3) over shaft and press into housing using a tube of the same diameter. Seal should be flush with housing when properly installed. Repeat process for opposite end shaft. Splitter Gearbox Inspection

1. Place top cover (10) on housing and secure into position using six cap screws (11).

2. Check gearbox for leaks by: plugging all holes except one, applying 4 psi of compressed air, and immersing gearbox in water. Verify gearbox does not leak.

NOTE: Excessive air pressure will damage seals.

3. Remove gearbox from water and dry off.

4. Remove upper plug on right side of housing (oil

level hole). Add SAE 80W or 90W EP oil until it runs out side level hole. Replace plug.

5. Install breather (12) in top cover.

Reinstallation on Cutter

NOTE: Gearbox is heavy: do not attempt to move it

without mechanical assistance.

1. Place gearbox on cutter and secure into position using four cap screws and lock nuts.

2. Torque hardware to 175 lbs-ft.

3. Attach all drivelines to gearbox.

4. Install all shields.

MAN0963 (2/16/2012)

Figure 16. Splitter Gearbox - Style B

Dealer Service 35

Page 36

CROSSBAR REMOVAL

1. It is necessary to gain access to bottom side of

cutter for crossbar removal. See Blocking Method page 19.

NOTE: You will need to use either the puller screw (Item 6, Figure 18) or a small hydraulic jack to remove the crossbar.

2. Remove blades from crossbar as shown in Figure

17.

Figure 17. Blade Removal

3. Refer to Figure 18

of crossbar and remove nut and washer.

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

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

Remove cotter pin from bottom

Figure 18. 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.

36 Dealer Service

For removal with a jack, attach tube to each cle-

vis 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.

MAN0963 (2/16/2012)

Page 37

NOTE: Hydraulic jack will not operate if tipped more

1. Yoke

2. Cup and bearings

3. Snap ring

4. Journal cross

than 90°. Use care to prevent bending crossbar during removal.

Crossbar Installation

U-Joint Disassembly

1. Remove external snap rings from yokes in four

locations as shown in Figure 21.

1. Using emery cloth (220 or finer), remove surface rust, Loctite splined gearbox vertical shaft, and crossbar.

Refer to Figure 19.

2. Install crossbar assembly (10) on splined shaft.

Install nut (54) and align a slot with hole in splined shaft. Torque nut to 450 lbs-ft.

3. Install cotter pin (55) through slot in nut and bend ends over.

and foreign material from hub,

Figure 21.

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 22.

Figure 19. Crossbar Assembly Installation

UNIVERSAL JOINT REPAIR

Figure 20. U-Joint Exploded View

Figure 22.

3. Clamp cup in vise as shown in Figure 23 and tap

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

Figure 23.

MAN0963 (2/16/2012)

Dealer Service 37

Page 38

4. Place universal cross in vise as shown in Figure 24

WARNING

Decal PN 1006348

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

Figure 24.

4. Repeat Step 1 and Step 2 to install remaining cups

in remaining yoke.

5. 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.

SERVICING TIRES SAFELY

Used Aircraft Tires (Figure 26)

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.

2. 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.

3. Seat cups by placing a drift or socket (slightly smaller than the cup) on cup and rap with a hammer. See Figure 25. Install snap ring and repeat on opposite cup.

Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job.

When inflating tires, use a clip-on chuck and an extension hose long enough to allow you to stand to the side — not in front of or over the tire assembly. Use a safety cage if available.

Check wheels for low pressure, cuts, bubbles, damaged rims, or missing lug bolts and nuts.

Never remove split rim assembly hardware (A) with the tire inflated.

Figure 25.

38 Dealer Service

Figure 26. Split Rim Tire Servicing

MAN0963 (2/16/2012)

Page 39

ASSEMBLY INSTRUCTIONS

WARNING

CAUTION

6. Attitude Rod

52. 1" x 3.75 Spacer, Pipe Schedule 40

107.1" Flat Washer

109.1" Hex Nut

DEALER SET-UP INSTRUCTIONS

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

The cutter is shipped partially assembled. Assembly will be easier if components are aligned and loosely assembled before tightening hardware. Recommended torque values for hardware are located on page 82.

Select a suitable working area. A smooth hard surface, such as concrete, will make assembly much quicker. Open parts boxes and lay out parts and hardware to make location easy. Refer to illustrations, accompanying text, parts lists and exploded view drawings.

Complete the check list on page 51 when assembly is complete and cutter is delivered to the customer.

 Before working underneath, carefully read Operator’s Manual instructions, disconnect driveline, raise mower, securely block up all corners with jackstands, and check stability. Secure blocking prevents equipment from dropping due to hydraulic leak down, hydraulic system failures, or mechanical component failures.

Install Attitude Rods

1. Insert attitude rods (6) under splitter gearbox

support and through pivot casting in wheel yoke arm assembly. The rod is a very tight fit; use care to prevent thread damage during installation.

2. Slide spacer (52) over rod and loosely install washer (107) and two nuts (109) for both rods.

Attitude Rod Length

Small Aircraft Tires

Tongue at 11" 3.5

Tongue at 18" 1.75

Large Aircraft Tires

Tongue at 11" 4.5

Tongue at 18" 2.5

Beyond Nuts (34)

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

Fill Gearboxes

1. Remove top and side plugs from gearbox.

2. Fill gearbox with SAE 80W or 90W EP oil until it

runs out of side level hole. Install plug in the side hole and vented dipstick or vent plug in the top.

3. Allow oil to drain into the lower bearings and recheck oil level.

4. Fill all gearboxes.

MAN0963 (2/16/2012)

Figure 27. Attitude Rod Installed on Wheel Yoke Tube

Install Spring Arm

Refer to Figure 28.

1. Place spring arm (43), spacers (53), and spring (44) on deck as shown.

2. Secure spring arm and spacers to lugs on deck using clevis pin (55) and two cotter pins (62).

3. Install retaining cap screw (85) and flange lock nut (88).

Assembly 39

Page 40

Install Height Adjustment Cylinder

43. Spring Arm

44. Compression Spring, 3.25 x .69 x 9.5

45. Hydraulic Cylinder 3-1/2

46. Transport Lock-Up

48. SMV Mounting Link

49. SMV Socket

50. SMV Bracket

51. SMV Emblem

53. Spacer, 1"

54. 1 x 2.72 Headless Pin

55. 1 x 4.58 Headless Pin

56. 1 x 5.08 Headless Pin

59. 1/4 x 1/4 x 156 Hose

62. 1/4 x 1-1/2 Cotter Pin

67. 1/4 NC x 1/2 Round Head Screw

68. 1/4 NC Hex Nut

69. 1/4 NPT x 1/4 NPT Elbow w/Restrictor

70. 5/16 NC x 3/4 Carriage Bolt

75. 5/16 NC Flange Lock Nut

81. 1/2 NC x 1-1/2 Carriage Bolt

85. 1/2 NC x 5 Hex Head Cap Screw

88. 1/2 NC Flange Lock Nut

90. 1/2 NPT x 1/4 NPT Reducer Bushing

Install SMV Emblem

Refer to Figure 28.

1. Attach base end of cylinder (45) to the spring arm (43) using clevis pin (54) and two cotter pins (62).

2. Extend cylinder rod and place transport lock bracket (46) over cylinder rod clevis.

3. Position cylinder rod and transport lock bracket between lugs on the wheel yoke tube and align holes.

4. Secure cylinder rod and transport lock bracket to the wheel yoke tube using clevis pin (56) and two cotter pins (62).

5. Install bushing (90), elbow, (69) and hose (59) to the base end of cylinder (45). See Install Hose Kit, page 45 for complete instructions.

Refer to Figure 28.

1. Attach SMV mounting bracket (48) to left side of center section as shown using two carriage bolts (81) and flange lock nuts (88).

2. Attach SMV socket (49) to mounting bracket (48) using two carriage bolts (70) and lock nuts (75).

3. Attach SMV emblem (51) to SMV bracket (50) using two round head cap screws (67) and hex nuts (68).

Insert SMV bracket (50) and emblem (51) into socket (49).

40 Assembly

Figure 28. Spring Arm and Cylinder Installation

MAN0963 (2/16/2012)

Page 41

Install Wheel and Hub

1. Center Wheel Yoke Arm

83. 1/2" NC x 3" HHCS GR5

88. 1/2" NC Flange Lock Nut

6. Attitude Rod

8. Safety Chain

21. Parking Jack

22. Tongue

37. Tongue Pivot Pin

41. Clevis Pin, 1" x 2.26"

60. 3/16 x 1-1/2 Cotter Pin

62. 1/4 x 1-1/2 Cotter Pin

97. 3/4 NC x 2-1/4 Hex Head Cap Screw

100.3/4 x 2 x 3/8 Flat Washer

102.3/4 NC Lock Nut

107.1" Flat Washer

Install Tongue

1. Insert wheel hub into outside of wheel yoke arm (1)

and align holes.

2. Secure into position using cap screw (83) and flanged lock nut (88).

3. Attach wheel to hub using five lug nuts. Install the chamfered side of the lug nut toward the inside for steel rim for pneumatic tires and rims. Tighten to 75 lbs-ft. Check that tire air pressure is a maximum of 40 psi.

NOTE: Install the flat side of the nut toward the inside for solid tires and aircraft tires (shown).

4. Install optional dual wheel and hub to inside of wheel yoke arm.

NOTE: Pneumatic (BW180XHD and BW180XHDQ only), notat, and airplane tires are available for this cutter. See page 72 for parts list.

1. Attach tongue (22) to center section using two tongue pivot pins (37) and cotter pins (60).

2. Attach attitude rod (6) to lug on tongue and secure with clevis pin (41), washer (107), and cotter pin (62).

3. Attach parking jack (21) to the side of the tongue.

4. Attach safety chain (8) to the bottom of center

gusset and secure with cap screw (97), washer (100), and lock nut (102).

Figure 29. Center Section Wheel and

Hub Installation

MAN0963 (2/16/2012)

Figure 30. Tongue Installation

Assembly 41

Page 42

Install 3-Joint Drive (540 RPM Only)

5. CV Drive

19. Carrier Bearing Shield

30. H-Frame

32. Front 2/3 of 3-Joint Drive

33. Rear Telescoping Shaft

38. .66 x .88 x 4.50 Sleeve

39. .625 x 1 x .563 HT Sleeve

76. 3/8 NC x 1 Hex Head Cap Screw

77. 3/8 Lock Washer

86. 1/2 NC x 6-1/2 Hex Head Cap Screw

87. 1/2 Flat Washer

88. 1/2 NC Flange Lock Nut

89. .50 x 1.00 x 1.031 Sleeve

93. 5/8 NC x 7 Hex Head Cap Screw

94. 5/8 x 1-3/4 x 14 GA Cup Washer

95. 5/8 NC Hex Lock Nut

Before installing cutter input driveline to gearbox, check the tag wired to the driveline and the tag wired to the input shaft of gearbox. Ensure the tag rpm speeds match the rpm speed decal on front of cutter. After confirming all speeds match, remove and discard tags and then complete driveline assembly.

1. Attach H-frame (30) to tongue with cap screw (93), sleeves (39), cup washers (94), and nut (95).

2. Coat splined end of gearbox input shaft with grease.

4. Secure with bolt and nut supplied with drive.

5. Secure driveline carrier bearing to H-frame with

cap screw (86), washer (87), sleeves (89) and a flanged lock nut (88).

NOTE: When cutting height is established, adjust the 3-joint H-frame bearing height so that the front driveline is parallel to the ground.

6. Attach front driveline (32) to rear driveline (33) and tighten clamp bolt and nut.

7. Attach shield (19) to driveline carrier bearing with two cap screws (76) and lock washers (77).

3. Align hole in drive yoke with groove on gearbox input shaft and slide drive (33) onto shaft.

8. Attach spacer (38) to top hole of H-frame using cap screw (86) and flanged lock nut (88).

42 Assembly

Figure 31. 3-Joint Drive Installation

MAN0963 (2/16/2012)

Page 43

Install CV Drive (Optional)

5. CV Drive

CAUTION

6. Side skid

8. Winglet

15. Hinge Pin

64. Spring Pin 1/4 x 1-1/2

80. 1/2 NC x 1 Crg Bolt

81. 1/2 NC x 1-1/2 Crg Bolt

88. 1/2 NC Flnge Lock Nut

107. 1" Flat Washer

4. Hydraulic Cylinder

16. Wing Lock-Up Bar

18. 1 x 4.08 Clevis Pin

19. Cylinder Link

20. Cylinder Link

21. Spacer, 3/4

22. Lock-Up Pin, 1 x 5

53. Spacer, 1"

54. 1 x 2.72 Clevis Pin

59. 1/4 x 1/4 x 200" Hose

61. 3/16 Safety Pin

62. 1/4 x 1-1/2 Cotter Pin

69. 1/4 x 1/4 Elbow w/Restrictor

90. 1/2 x 1/4 Reducer Bushing

108. 1 x 1-7/8 Washer

1. Align hole in drive yoke with groove on gearbox input shaft and slide rear half of drive (23) onto shaft.

2. Secure with bolt and nut supplied with drive.

Figure 33. Right Wing Installation

Install Wing Cylinder & Lock-up Bar

Figure 32. CV Drive Installation

Install Wing

 Use a suitable lifting device of sufficient capacity. Use adequate personnel to handle heavy components.

The wing must be installed in the following sequence and will require at least two people. A floor jack or a suitable lifting device will be helpful to align decks when installing the hinge pin.

Check RPM tags on wing and center section to make sure they match before proceeding.

1. Remove hinge pin (15) from center section.

2. Place wing assembly adjacent to the center section

and align hinge sections.

3. Insert hinge pin through the hinge sections and secure with spring pin (64) and washer (107) on both ends.

4. Attach side skid (6) to the wing using four carriage bolts (81) and flange lock nuts (88).

5. Repeat procedure of opposite wing. (BW126XHDR only had right wing installed. BW126XHDL only has left wing installed.

MAN0963 (2/16/2012)

Figure 34. Wing Cylinder & Lock-Up Bar Installation

1. Place two cylinder links (19 & 20) on either side of

cylinder lug on center section as shown, align holes and insert clevis pin (18).

NOTE: Items 19 & 20 must be installed with square corners on top and facing cylinder as shown.

Assembly 43

Page 44

2. Slide spacer (53) and lock-up bar (16) over clevis

DP3

16. Wing Lock-Up Bar

18. 1 x 4.08 Clevis Pin

19. Cylinder Link

20. Cylinder Link

53. Spacer, 1"

62. 1/4 x 1-1/2 Cotter Pin

5. Wing wheel yoke arm, right

58. Wheel and hub

83. 1/2 NC x 3 HHCS GR5

88. 1/2 NC Flanged lock nut

pin (18) on back side of cylinder lug & secure with washer (108) and cotter pins (62).

3. Attach base end of wing cylinder (4) to cylinder links (19 & 20) using clevis pin (54) and cotter pins (62).

4. Remove plug from base end of hydraulic cylinder. Align cylinder rod end with cylinder lug on the wing and insert lock-up pin (22).

Install Wing Wheel and Hub (Figure 36)

1. Insert wheel hub into wing wheel yoke arms (5)

and align holes.

2. Secure into position using cap screw (83) and flanged lock nut (88).

5. Slide spacer (21) over lock-up pin (22) on back side of cylinder rod and secure with cotter pins (62).

6. Insert safety pin (61) into the end of lock-up pin (22). The safety pin will secure lock-up bar into position when wing is in the UP position.

7. Extend cylinder fully & replace plug in base end of cylinder. This trapped air will help push wing down.

8. Install bushing (90), elbow, (69) and hose (59) to the rod end of cylinder (4). See Install Hose Kit, page 45 for complete instructions.

9. Repeat procedure for opposite wing.

NOTE: (BW126XHDR has only the right wing

installed. BW126XHDL has only the left wing installed.)

NOTE: Install the flat side of the nut toward the inside for solid tires and aircraft tires (shown).

4. Install optional dual wheel and hub to inside of wheel yoke arm.

NOTE: Pneumatic (BW180XHD and BW180XHDQ only), notat, and airplane tires are available for this cutter. See page 72 for parts list.

Figure 35. Left Wing Lock-Up Bar Installed

44 Assembly

Figure 36. Wing Wheel and Hub Installation - Right

MAN0963 (2/16/2012)

Page 45

Install Wing Wheel Yoke Adjustment Link

CAUTION

104

DP2

7. Adjustable link

104. 1 NC x 4-1/2 HHCS GR5

110. 1 NC Lock nut

110

3. Driveline, Complete

15. Clutch Shield

72. 5/16 SAE Flat Washer

73. 5/16 Lock Washer

113. M8 x 1.25P x 20 mm HHCS

 Use a suitable lifting device of sufficient capacity. Use adequate personnel to handle heavy components.

1. With a lifting device raise right wing and lock in the

up position using the wing lock-up bar. Leave lifting device attached for added support.

2. Attach adjustable link (7) to right side of center wheel yoke arm and secure with cap screw (104) and lock nut (110).

3. Attach opposite end of adjustable link (7) to wing wheel yoke arm and secure with cap screw (104) and lock nut (110).

4. Remove lock-up bar and carefully lower wing using lifting device.

5. Repeat process for left wing. (BW126XHDR only has right wing installed; BW126XHDL only has left wing installed.)

Install Wing Driveline

1. Attach clutch shield (15) to wing gearbox using four

cap screws (113), lock washers (73), and flat washers (72).

2. Slide non clutch end of driveline (3) over wing gearbox shaft and align holes with groove.

3. Secure driveline to shaft using cap screws and lock nuts supplied with driveline.

4. Slide clutch end of driveline over splitter gearbox and secure using cap screws and lock nuts supplied with driveline.

5. Repeat process for left driveline. (BW126XHDR only has right wing installed; BW126XHDL only has left wing installed.)

Figure 37. Left Wing Wheel Yoke

Adjustment Link Installed

MAN0963 (2/16/2012)

Figure 38. Right Driveline Installation

Install Hose Kit

1. Remove plug from rod end of each wing cylinder.

2. With the wings in the down position and cylinder

extended, remove and reinstall the plugs from the base of the wing cylinders. This will trap air behind the piston and help when lowering the wings.

3. Install reducer bushing and restricter elbow into cylinders. Position elbow on center cylinder to point forward; on wing cylinders point elbows to the center.

NOTE: Make sure a breather fitting is installed in the rod end port of the wheel yoke cylinder.

4. Attach hose to each elbow.

Assembly 45

Page 46

Install Chain or Belt Shielding

DANGER

1. Front center chain plate

2. Front right chain plate

3. Front left chain plate

4. Rear chain plate, right

5. Rear chain plate, left

22. 3/8 NC x 1-1/4 Carriage bolt

23. 3/8 NC Flange lock nut

tive devices cannot prevent all objects from escaping the blade enclosure in every mowing condition. and escape, traveling as much as 300 feet (92 m).

It is possible for objects to ricochet

 Full chain 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 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 protec-

Install chain and rubber shields with hardware as shown. (Refer to Figure 39 for Chain Shielding Installation; Figure 41 and Figure 42 for Belt Shielding Installation.)

NOTE: Chain Shielding: link chain sections (17) and four (two per wing) 4-link chain sections (15) to the wing skid shoes. Secure with carriage bolts (19) and flange lock nuts (21).

Install four (two per wing) 6-

Figure 39. Chain Shielding Installation - Center Section

46 Assembly

MAN0963 (2/16/2012)

Page 47

Figure 40. Chain Shielding Installation - Right Wing Shown

6. Front wing chain plate, inner

7. Front wing chain plate, middle

8. Front wing chain plate, outer

9. Rear wing chain plate

15. 5/16 Chain - 4 - link

17. 5/16 Chain - 6 - link

19. 1/2 NC x 1-1/2 Carriage bolt

21. 1/2 NC Flange lock nut

22. 3/8 NC x 1-1/4 Carriage bolt

23. 3/8 NC Flange lock nut

MAN0963 (2/16/2012)

Assembly 47

Page 48

Figure 41. Belt Shielding Installation - Center Section

1. Front center belt shield plate

2. Front right belt shield plate

3. Front left belt shield plate

7. Bent link, .25 x 1.72 x 13.00

8. Bent link, .25 x 9.25 x 9.50

9. Rubber shield, .25 x 8.75 x 40.76

12. Rubber shield, .25 x 9.25 x 28.00

13. Rubber shield, .25 x 9.25 x 18.25

22. 3/8 NC x 1-1/4 Carriage bolt GR5

23. 3/8 NC Flange lock nut

4. Front wing belt shield plate, inside

5. Front wing belt shield plate, middle

6. Front wing belt shield plate, outer

7. Bent link, .25 x 1.72 x 13.00

10. Rubber belt, .25 x 8.75 x 31.11

11. Rubber belt, .25 x 8.75 x 53.87

14. Rubber belt, .25 x 9.25 x 34.00

19. 1/2 NC x 1-1/2 Carriage bolt GR5

21. 1/2 NC Flange lock nut

22. 3/8 NC x 1-1/4 Carriage bolt GR5

23. 3/8 NC Flange lock nut

Figure 42. Belt Shielding Installation - Right Wing

48 Assembly

MAN0963 (2/16/2012)

Page 49

Figure 43. Counterweight Installation

1. Weight Box 750 lbs

2. Brace

3. Skid Shoe

4. Mounting plate

5. Sleeve, 1.25 x 1.5 x 3.40

6. Hinge Pin

7. Clevis Pin, 1 x 2.26

8. 1/4 x 1-1/2 Cotter Pin

9. Spring Pin, 1/4 x 1-1/2

10. 3/8 NC x 1-1/4 Hex Head Cap Screw

11. 3/8 NC x 1-1/4 Self-Tapping Screw

12. 3/8 Flat Washer

13. 3/8 Lock Washer

14. 3/8 NC Flanged Lock Nut

15. 1" Flat Washer

16. 1 x 1-7/8 x 1/4 Washer

WARNING

CAUTION

BW126XHD and BW126XHDL Counterweight Installation

■ The offset model is unstable without adequate

counterweight. Use counterweight box loaded with 750 lbs. of steel.

 Use a suitable lifting device of sufficient capacity. Use adequate personnel to handle heavy components.

MAN0963 (2/16/2012)

This unit may be operated with only one wing - either right or left. With only one wing, the unit is unshielded and unstable. When electing to operate with one wing, you must install a counterweight box, available from your dealer. This box has a dual purpose: it substitutes for the shielding and for the weight of the removed wing.

The counterweight must be installed in the following sequence and will require at least two people. A floor jack or a suitable lifting device will be helpful to align the hinges when installing the hinge pin.

Refer to Figure 43.

1. Remove hinge pin (6) from center section.

Assembly 49

Page 50

2. Place brace (2) inside the front corner of the weight



box (1) and secure with two cap screws (10), two flat washers (12), and two lock nuts (14).

3. Align mounting plate (4) with slots of rear of weight box. Secure with two cap screws (10), two flat washers (12), and two lock nuts (14). Do not tighten hardware at this point.

6. Insert hinge pin through the hinge sections. Install sleeve (5) on hinge pin behind deck hinge section to prevent weight box from sliding rearward. Secure hinge pin with two washers (16) and two spring pins (9).

7. Insert clevis pin (7) through lug on rear of weight box and cylinder lug on center section with two washers (16) as shown. Secure with cotter pin (8).

4. Align skid shoe (3) with holes on bottom and inside of weight box. Secure bottom with the hardware provided with skid shoe. Secure top with two cap screws (10), two flat washers (12) and two lock nuts (14).

5. Place weight box assembly adjacent to the center section and align hinge sections.

8. Insert self-tapping screw (11), lock washer (13), and flat washer (12) through upper-rear hole in mounting plate (4) and hole in side of center section. Tighten hardware from step 3.

Winch Kit Installation (Optional)

Refer to page 81 for Installation and Operation instructions.

50 Assembly

MAN0963 (2/16/2012)

Page 51

DEALER CHECK LISTS

PRE-DELIVERY CHECK LIST

(DEALER’S RESPONSIBILITY)

Inspect the equipment thoroughly after assembly to ensure it is set up properly before delivering it to the customer.

The following check lists are a reminder of points to inspect. Check off each item as it is found satisfactory or after proper adjustment is made.

NOTICE

■ Gearboxes are not filled at the factory. Prior to

delivery, make sure each gearbox is filled between lowest ring and end of dipstick with 80 or 90W API GL-4 or GL-5 gear lube.

___ Check that all safety decals are installed and in

good condition. Replace if damaged.

___ Check that shields and guards are properly

installed and in good condition. Replace if damaged.

___ Check all bolts to be sure they are properly

torqued.

___ Check wheel bolts for proper torque.

___ Check that all cotter pins and safety pins are

properly installed. Replace if damaged.

___ Show customer how to determine the turning lim-

its of the CV PTO driveline.

___ Show customer the safe, proper procedures to be

used when mounting, dismounting, and storing equipment.

___ Make customer aware of optional equipment

available so that customer can make proper choices as required.

___ Instruct customer how to lubricate and explain

importance of lubrication.

___ Point out the safety decals. Explain their meaning

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

___ Explain to customer that when transporting the

cutter, the wing and center sections should be raised and their respective transport bars installed and pinned in place.

___ 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.

___ Check that blades have been properly installed.

___ Check and grease all lubrication points as identi-

fied in lubrication information on page 20.

___ Check the level of gearbox fluids before delivery.

Service, if required, as specified in the lubrication information on page 20.

DELIVERY CHECK LIST

(DEALER’S RESPONSIBILITY)

___ Show customer how to make adjustments and

select proper PTO speed.

___ Show customer how to make sure driveline is

properly installed and that spring-activated locking pin or collar slides freely and is seated in groove on tractor PTO shaft.

___ Explain to customer the potential crushing haz-

ards of going underneath raised equipment. Instruct that before going underneath to disconnect the driveline, securely block up all corners with jack stands and to follow all instructions in the BLOCKING METHOD, page 19 of the operator’s manual. Explain that blocking up prevents equipment dropping from hydraulic leak down, hydraulic system failures or mechanical component failures.

___ Point out all guards and shields. Explain their

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

___ Explain to customer that when towing on a public

road to comply with all state and local lighting/marking laws and to use a safety tow chain.

MAN0963 (2/16/2012)

Dealer Check Lists 51

Page 52

NOTES

52 Notes

MAN0963 (2/16/2012)

Page 53

PARTS INDEX

BATWING® Rotary Cutter

BW180XHD, BW180XHDQ BW126XHD, BW126XHDQ

MAIN FRAME ASSEMBLY (FRONT SECTION) ...................................................... 54-55

(REAR SECTION) ......................................................... 56-57

WING ASSEMBLY ........................................................................................................ 58-59

SPLITTER GEARBOX ASSEMBLY - STYLE A................................................................. 60

SPLITTER GEARBOX ASSEMBLY - STYLE B ................................................................. 61

WING & CENTER GEARBOX ASSEMBLY - STYLE A ................................................ 62-63

WING & CENTER GEARBOX ASSEMBLY - STYLE B ................................................ 64-65

DRIVE ASSEMBLY CENTER DECK ................................................................ 67

BW180XHD & BW126XHD FRONT - EQUAL ANGLE ...... 68

BW180XHD & BW126XHD REAR - EQUAL ANGLE ........ 69

540 RPM & 1000 RPM CV DRIVE..................................... 70

WING ................................................................................. 71

WHEEL & TIRE ASSEMBLY 5-BOLT............................................................................... 72

SHIELDING RUBBER SHIELDING - CENTER SECTION ............................................... 73

RUBBER SHIELDING - WING ..................................................................... 74

CHAIN SHIELDING - CENTER SECTION (OPTIONAL) ............................. 75

CHAIN SHIELDING - WING (OPTIONAL) ................................................... 76

HYDRAULIC CYLINDERS ................................................................................................. 77

HYDRAULIC CYLINDER STROKE CONTROL KIT .......................................................... 78

CROSSBAR PULLER (OPTIONAL) .................................................................................. 78

BW126XHD / BW126XHDQ COUNTERWEIGHT BOX ASSEMBLY (OPTIONAL)........... 79

WINCH KIT (OPTIONAL) ................................................................................................... 81

MAN0963 (2/16/2012)

Parts 53

Page 54

MAIN FRAME ASSEMBLY (FRONT SECTION)

54 Parts

MAN0963 (2/16/2012)

Page 55

MAIN FRAME ASSEMBLY (FRONT SECTION)

REF PART QTY DESCRIPTION

1 19160KT 1 Blade kit, CCW 2 ----- 1 Gearbox (see pages 62 - 65) 3 1034927 1 Driveline complete, 1340, 1.75-20 6.0

w/ clutch (see page 67) 4 ----- 1 Splitter gearbox (see pages 60 - 61) 5 1021103 1 CV Drive - 540 RPM (see page 70) 5 1021104 1 CV Drive - 1000 RPM (see page 70) 6 1003491 2 Attitude rod 7 1033941 2 Front skid 8 19407 1 Safety chain 9 1008190 2 1-1/2 Blade pin kit (includes 13 & 14)

10 1034257 1 Crossbar Assembly 11 10520 2 Shim, 18 GA, 1-1/2 blade pin 12 13946 2 Shim, 20 GA, 1-1/2 blade pin 13 32603 2 Keyhole plate - special 14 32604 2 Blade pin lock clip - special 15 1003495 2 Hinge pin 16 1028585 1 Front shield with hinge 17 1003828 1 Manual tube 18 1033945 1 Rear shield with hinge 19 1003444 1 Front drive shield 20 1003558 1 Shield standoff 21 52232 1 Parking jack 22 1033938 1 Clevis tongue (includes 23, 40, 97,

101 & 103) -or-

22 1033940 1 Swivel tongue (includes 24, 25, 26, 40,

92, 96, 97, 101 & 103) -or-

22 1033944 1 Pintle tongue (includes 26, 27, 28, 29,

92, 96, 106, 107, 110 & 112)

23 1005595 1 Hitch, Cat. 2 clevis 24 1031356 1 Tongue level bracket (optional) 25 1031360 1 Hitch, Cat 2 clevis 26 1031362 1 2.62 x 3.00 x 2.00 Sleeve 27 1031376 1 Pintle hitch (optional) 28 11267 1 Pintle ring (includes washer, nut and

cotter pin)

29 1016969 2 Pintle bushing 30 1003440 1 H-Frame 31 1033597 1 Hydraulic hose holder 32 57282 1 Front 2/3 of 3-joint drive - 540 RPM

only (see page 68)

33 1004932 1 Telescoping shaft (see page 69) 34 32347 1 3-Joint bearing housing (includes 34,

35 & 66)

35 13133 1 1-1/2 ID Ball bearing 36 12128 1 .062 x 72 mm ID Snap ring 37 58982 2 Tongue pivot pin 38 1003435 1 .66 x .88 x 4.50 Sleeve 39 1791 2 .625 x 1 x .563 HT Sleeve 40 13087 2 3/4 x 1 x 9/16 HT Sleeve 41 46605 2 Clevis pin, 1 x 2.26

REF PART QTY DESCRIPTION

60 1266 * 3/16 x 1-1/2 Cotter pin 62 1285 * 1/4 x 1-1/2 Cotter pin 63 6185 * 1/4 x 2-1/4 Cotter pin 64 66016 * Spring pin, 1/4 x 1-1/2 65 12296 * 1/4-28 Grease fitting 66 2985 * 1/4-28 x 90° Grease fitting 71 14562 * 5/16 NC x 1 HHCS GR5 72 35155 * 5/16 SAE Flat washer 73 2472 * 5/16 Lock washer 74 4529 * 5/16 NC Hex nut ZP 76 839 * 3/8 NC x 1 HHCS GR5 77 838 * 3/8 Lock washer 79 66840 3/8 NC 3-Prong knob 82 6100 * 1/2 NC x 1-1/4 HHCS GR5 84 3508 * 1/2 NC x 4-1/2 HHCS GR5 87 3598 * 1/2 Flat washer 88 11900 * 1/2 NC Flange lock nut 89 1003445 .50 x 1.00 x 1.031 Sleeve 91 902 * 5/8 NC x 2 HHCS GR5 92 300457 * 5/8 NC x 3-3/4 HHCS GR5 93 23638 5/8 NC x 7 HHCS GR5 94 10635 5/8 x 1-3/4 x 14 GA Cup washer 95 6239 * 5/8 NC Hex lock nut 96 19025 * 5/8 NC Flange lock nut 97 13759 * 3/4 NC x 2-1/4 HHCS GR5 98 30068 * 3/4 NC x 2-1/2 HHCS GR5

99 57798 3/4 Hardened flat washer 100 8424 3/4 x 2 x 3/8 Flat washer 101 28873 3/4 ID x 1-1/2 OD x 1/4 Thick washer 102 2371 * 3/4 NC Hex lock nut 103 302207 3/4 NC Flange lock nut 106 15278 1 NC x 7-1/2 HHCS GR5 107 1863 * 1" Flat washer 110 34279 1 NC Hex lock nut 111 1024670 1.22 x 2.205 x .236 Washer 112 2370 1.62 x 3 x .16 Washer 113 24801 M8 x 1.25P x 20 mm HHCS 114 307130 M8 x 1.25P x 40 mm HHCS 115 39323 M30 x 2.0P Castle nut 120 1034084 Complete decal set 121 1003679 Safety decal set

HHCS Hex Head Cap Screw

* Standard hardware, obtain locally

MAN0963 (2/16/2012)

Parts 55

Page 56

MAIN FRAME ASSEMBLY (REAR SECTION)

56 Parts

MAN0963 (2/16/2012)

Page 57

MAIN FRAME ASSEMBLY (REAR SECTION)

REF PART QTY DESCRIPTION

2 1017150 2 Solid wheel arm -or-

2 ------- 2 Spring wheel arm (see page 66)

6 1003491 2 Attitude rod

15 1003495 2 Hinge pin

42 1033480 1 Center wheel yoke

43 1027305 1 Spring arm

44 19710 1 Compression spring 3.25 x .69 x 9.5

45 10475 1 Hydraulic cylinder 3-1/2 (see page 77)

46 1004814 1 Transport lock-up

47 24098 1 1-1/4 Cylinder stroke control kit

(optional)

48 1017143 1 SMV Mounting link

49 62484 1 SMV Socket

50 1004251 1 SMV Bracket

51 24611 1 SMV Emblem

52 27267 2 Pipe, 1" Schedule 40 x 3.75

53 65130 2 Spacer, 1"

54 1631 1 1 x 2.72 Headless pin

55 8346 1 1 x 4.58 Headless pin

56 8347 1 1 x 5.08 headless pin

57 57050 1 Access hole cover

58 ----- 2 Tire & hub (see page 72)

59 8669 1 1/4 x 1/4 x 156 Hose

REF PART QTY DESCRIPTION

62 1285 * 1/4 x 1-1/2 Cotter pin

64 66016 * Spring pin, 1/4 x 1-1/2

65 12296 * 1/4-28 Grease fitting

67 1282 * 1/4 NC x 1/2 Round head screw

68 5288 * 1/4 NC Hex nut

69 10290 1/4 x 1/4 Elbow w/1/16 Restrictor

70 16148 * 5/16 NC x 3/4 Carriage bolt

75 14139 * 5/16 NC Flange lock nut

78 14350 * 3/8 NC Flange lock nut

81 29893 * 1/2 NC x 1-1/2 Carriage bolt GR5

83 3489 * 1/2 NC x 3 HHCS GR5

85 23479 * 1/2 NC x 5 HHCS GR5

88 11900 * 1/2 NC Flange lock nut

90 11893 1/2 x 1/4 Pipe reducer bushing

105 1003606 1 NC x 6 HHCS GR5

107 1863 * 1" Flat washer

109 3132 1 NC Hex nut

110 34279 1 NC Hex lock nut

113 2377 * 3/4 NC x 6 HHCS GR5

114 2371 * 3/4 NC Hex lock nut

HHCS Hex Head Cap Screw

* Standard hardware, obtain locally

MAN0963 (2/16/2012)

Parts 57

Page 58

WING ASSEMBLY

58 Parts

MAN0963 (2/16/2012)

Page 59

WING ASSEMBLY

REF PART QTY DESCRIPTION

1 19160KT 1 Blade kit, CCW (Right wing) - or -

1 19161KT 1 Blade kit, CW (Left wing)

2 ----- 1 Gearbox (see page 62 - 65)

3 1034927 1 Driveline complete 1340, 47.6 x 68.1

(see page 71)

4 1031166 1 Hydraulic cylinder 3 x 10

(see page 77)

5 1027448 1 Wing wheel yoke (Right wing) - or -

5 1027449 1 Wing wheel yoke (Left wing)

6 1034098 1 Side skid (Right wing) - or -

6 1034099 1 Side skid (Left wing)

7 1003690 1 Adjustable link

8 1033478 1 Winglet (Right wing) -or-

8 1033479 1 Winglet (Left wing)

9 1008190 2 1-1/2 Blade pin kit (includes 13 & 14)

10 1034069 1 Crossbar Assembly

11 10520 2 Shim, 18 GA, 1-1/2 blade pin

12 13946 2 Shim, 20 GA, 1-1/2 blade pin

13 32603 2 Keyhole plate - special

14 32604 2 Blade pin lock clip - special

15 1002048 1 Clutch shield

16 1003498 1 Wing lock-up bar

17 1003650 2 Wing pivot pin

18 8345 1 1 x 4.08 Headless pin

19 1017075 1 Cylinder link

20 1017095 1 Cylinder link

21 33647 1 Spacer, 3/4

22 32469 1 1 x 5 Lock-Up pin

53 65130 1 Spacer, 1"

54 1631 1 1 x 2.72 Headless pin

58 ----- 1 Tire & hub (see page 72)

59 14552 1 1/4 x 1/4 x 200 Hose

REF PART QTY DESCRIPTION

61 18270 * 3/16 Safety pin

62 1285 * 1/4 x 1-1/2 Cotter pin

63 6185 * 1/4 x 2-1/4 Cotter pin

64 66016 * Spring pin, 1/4 x 1-1/2

65 12296 * 1/4-28 Greaase fitting

69 10290 1/4 x 1/4 Elbow w/1/16 Restrictor

72 35155 * 5/16 SAE Flat washer

73 2472 * 5/16 Lock washer

80 14406 * 1/2 NC x 1 Carriage bolt

81 29893 * 1/2 NC x 1-1/2 Carriage bolt GR5

82 6100 * 1/2 NC x 1-1/4 HHCS GR5

83 3489 * 1/2 NC x 3 HHCS GR5

88 11900 * 1/2 NC Flange lock nut

90 11893 1/2 x 1/4 Pipe reducer bushing

98 30068 * 3/4 NC x 2-1/2 HHCS GR5

99 57798 3/4 Hardened flat washer

102 2371 * 3/4 NC Hex lock nut

104 46752 1 NC x 4-1/2 HHCS GR5

108 11920 1 x 1-7/8 x 1/4 Washer

110 34279 1 NC Hex lock nut

111 1024670 1.22 x 2.205 x .236 Washer

113 24801 M8 x 1.25P x 20 mm HHCS

115 39323 M30 x 2.0P Castle nut

HHCS Hex Head Cap Screw

* Standard hardware, obtain locally

MAN0963 (2/16/2012)

Parts 59

Page 60

STYLE - A SPLITTER GEARBOX ASSEMBLY

REF PART PART QTY DESCRIPTION

540 RPM 1000 RPM

1 1034939 1034940 - Complete splitter gearbox 2 21542 21542 24 10 mm Lock washer 3 307201 307201 24 M10-1.5 x 30 HHCS 4 1019613 1019613 1 Input cap 5 1019575 1019575 1 Input shaft 6 1019589 1019589 2 Input oil seal 7 1019587 1019587 6 Bearing assembly (cup and cone) 8 1019592 1019592 A/S Gasket .15 mm

9 1019593 1019593 A/S Gasket .25 mm 10 1019594 1019594 A/S Gasket .45 mm 11 1019612 1019612 2 Hub cap 12 1019590 1019590 2 Oil seal 13 1019576 1019576 2 Output shaft 14 1019603 1019603 1 Spacer 15 1019609 1019609 Shim .30 mm 16 1019608 1019608 Shim .40 mm 17 1019610 1019610 Shim .50 mm 18 1027170 1027184 1 Center gear 19 1027184 1027170 2 Wing gear 20 1019605 1019605 2 Bearing adjustment nut 21 ------- ------- 2 1/8 x 2-1/2 Cotter pin 22 1009081 1009081 2 Sealing washer 23 1019602 1019602 1 M18 x 1.5 Level plug 24 1019600 1019600 1 M18 x 1.5 Breather plug

A/S As required

60 Parts

MAN0963 (2/16/2012)

Page 61

STYLE - B SPLITTER GEARBOX ASSEMBLY

REF PART PART QTY DESCRIPTION

540 RPM 1000 RPM

1 1031185 1031186 - Complete splitter gearbox 2 39411 39411 6 Bearing 3 ------- ------- 1 Housing 4 1031175 1031175 4 Oil seal, 45 mm x 85 mm x 10 mm 5 1002494 1002494 6 Snap ring 85 mm dia 6 57471 57471 6 Shim 7 1031176 1031178 2 Pinion gear 8 1031177 1031177 2 Shaft 1-3/4 - 20 spline, wing

9 1031178 1031176 1 Gear 10 1031179 1031179 1 Shaft 1-3/4 - 20 spline, center 11 1031180 1031180 1 Cover 12 ------- ------- * M10 x 30 mm HHCS CL8.8 13 57076 57076 1 1/2" Breather

* Standard hardware, obtain locally

MAN0963 (2/16/2012)

Parts 61

Page 62

STYLE - A WING & CENTER GEARBOX ASSEMBLY

62 Parts

MAN0963 (2/16/2012)

Page 63

STYLE - A WING & CENTER GEARBOX ASSEMBLY PARTS LIST

Center

REF QTY 540 RPM 1000 RPM RIGHT WING LEFT WING DESCRIPTION

A 1 1034943 1034942 1034941 1034944 Complete gearbox

1 18 21542 21542 21542 21542 10 mm Lock washer

2 12 307201 307201 307201 307201 M10 x 1.5P x 30 mm HHCS

3 1 1019614 1019614 1019614 1019614 Input cap

4 1 1019577 1019577 1019577 1019577 Input shaft

5 1 1019589 1019589 1019589 1019589 Input seal

6 A/R 1019595 1019595 1019595 1019595 Input gasket .10 mm

7 A/R 1019596 1019596 1019596 1019596 Input gasket .25 mm

8 A/R 1019609 1019609 1019609 1019609 Shim .30 mm

9 A/R 1019608 1019608 1019608 1019608 Shim .40 mm

10 A/R 1019610 1019610 1019610 1019610 Shim .50 mm

11 1 1019588 1019588 1019588 1019588 Bearing assembly (cup & cone)

12 1 ------- ------- ------- ------- 3/16 x 3 Cotter pin

13 1 1019606 1019606 1019606 1019606 M36 Hex flange castle nut

14 1 1019591 1019591 1019591 1019591 Output oil seal

15 1 1019578 1019578 1019578 1019578 Output shaft

16 1 1019581 1019584 1032837 1032837 Output gear

17 1 1019605 1019605 1019605 1019605 Bearing adjustment nut

18 1 ------- ------- ------- ------- 1/8 x 2-1/2 Cotter pin

19 3 1019587 1019587 1019587 1019587 Bearing assembly (cup & cone)

20 1 1019615 1019615 1019615 1019615 Blank adjustment cap

21 A/R 1019598 1019598 1019598 1019598 Blank cap gasket .10 mm

22 A/R 1019599 1019599 1019599 1019599 Blank cap gasket .25 mm

23 1 1019604 1019604 **1019604 1019604 Bearing spacer

24 6 307205 307205 307205 307205 M10 x 1.5P x 25 mm HHCS

25 1‘ 1019616 1019616 1019616 1019616 Inspection cover cap

26 2 1009081 1009081 1009081 1009081 Sealing washer

27 2 1019601 1019601 1019601 1019601 M18 x 1.5P Head plug

28 1 1019603 1019603 **1019603 1019603 Input shaft spacer

29 1 1019607 1019607 1019607 1019607 Dipstick breather assembly

31 1 1019582 1019583 **1032836 1032836 Input gear

32 1 1019617 1019617 1019617 1019617 Retaining ring

A/R As Required

** Input gear (31) with input shaft spacer (28) is placed on opposite end of input shaft from bearing spacer (23)

MAN0963 (2/16/2012)

Parts 63

Page 64

STYLE - B WING & CENTER GEARBOX ASSEMBLY

64 Parts

MAN0963 (2/16/2012)

Page 65

STYLE - B WING & CENTER GEARBOX ASSEMBLY PARTS LIST

Center

REF QTY 540 RPM 1000 RPM RIGHT WING LEFT WING DESCRIPTION

A 1 58807 1031169 1031168 58808 Complete gearbox

1 1 57445 1031164 57446 57446 Gear crown

2 1 ----- ----- ----- ----- Housing

3 1 57450 57450 57450 57450 Input shaft

4 1 57454 57454 57454 57454 Output shaft

5 1 57455 1031159 57447 57447 Gear pinion

6 1 39263 39263 39263 39263 Bearing cup & cone

7 2 39411 39411 39411 39411 Bearing cup & cone

8 1 57451 57451 57451 57451 Seal protector

9 * ----- ----- ----- ----- B5 x 60 Cotter pin

10 2 57320 57320 57320 57320 Snap ring, 85 x 88.5 x 3

11 1 57321 57321 57321 57321 Snap ring, 50 x 47 x 2

12 1 57456 57456 57456 57456 Shim, 40.3 x 65.3 x 2.5

13 2 57471 57471 57471 57471 Shim, 70.3 x 84.7 (57471 kit)

14 1 57329 57329 57329 57329 Castle nut M40 x 1.5

15 1 57308 57308 57308 57308 Castle nut M36 x 3

16 1 57471 57471 57471 57471 Shim, 50.3 x 70.3 (57471 kit)

17 1 57471 57471 57471 57471 Shim, 40.3 x 61.7 (57471 kit)

18 1 1025612 1025612 1025612 1025612 Oil seal 60 x 110 x 12

19 1 57318 57318 57318 57318 Oil seal 45 x 85 x 10

20 1 57371 57371 57371 57371 Cap 80 x 10

21 1 57453 57453 57453 57453 Bearing cup & cone

22 1 1031181 1031181 1031181 1031181 Cover

23 * ----- ----- ----- ----- M8 x 25 GR 8.8 HHCS

24 1 57312 57312 57312 57312 Dipstick

25 * 6185 6185 6185 6185 1/4 x 2-1/4 Cotter pin

26 1 1024670 1024670 1024670 1024670 Washer, 1.22 x 2.205 x .236

27 * 27326 27326 27326 27326 3/8 NPT Solid plug

MAN0963 (2/16/2012)

* Standard hardware, obtain locally

Parts 65

Page 66

1" SPRING WHEEL YOKE ASSEMBLY (OPTIONAL)

(

)

REF PART QTY DESCRIPTION

1 1017140 1 Center wheel yoke arm 2 1024109 2 Center spring wheel yoke arm 3 1023174 1 Wing spring wheel yoke arm

(for Right wing) - or -

3 1024101 1 Wing spring wheel yoke arm

(for Left wing) (not shown)

4 1023170 2 Lower spring arm - tandem

- or -

5 1017266 2 Lower spring arm

6A 1024102 1 Lower spring arm, wing - tandem, right

- or -

6B 1024640 1 Lower spring arm, wing - tandem, left

(not shown) 7 1024108 2 Lower spring arm, wing 8 1023166 4 Walking beam 9 ----- Tire & hub (see page 72)

10 19710 2 Compression spring 3.25 x .69 x 9.5 11 1032100 2 Spring, cmp 3.25x.56x7.3x1113

66 Parts

REF PART QTY DESCRIPTION

12 1017065 4 1-9/16 Flag pin

13 1017149 2 1.25 x 8.85 Pivot pin

14 52087 2 1.25 x 7.56 Pivot pin

16 15087 2 1 NC x 9 HHCS GR5

17 1024122 2 1 NC x 13 HHCS GR5

18 11920 8 1 x 1-7/8 x 1/4 Washer

19 34279 4 1 NC Nut lock

20 10509 * 5/16 NC x 2-1/2 HHCS GR5

21 14139 * 5/16 NC Flange locknut

22 3489 * 1/2 NC x 3 HHCS GR5

23 11900 * 1/2 NC Flange locknut

24 6100 * 1/2 NC x 1-1/4 HHCS GR5

25 854 * 1/2 SAE Flat washer

26 12296 * 1/4-28 Grease fitting

* Standard hardware, obtain locally

MAN0963 (2/16/2012)

Page 67

CENTER DECK DRIVE ASSEMBLY

REF PART QTY DESCRIPTION

1 1019106 - Complete center drive assembly 2 1019107 1 Yoke, 1-3/4, 20 spline 3 38352 2 Cross & bearing kit 4 1019108 1 Double yoke 5 1016484 1 Friction clutch 2400 1-3/4, 20 spline

(includes items 6 through 17) 6 1016489 1 Flange yoke 7 57432 4 Friction disc 8 1016490 1 Hub, 1-3/4, 20 spline

(includes item 9) 9 1016498 1 Lock assembly

REF PART QTY DESCRIPTION

10 57443 1 Drive plate 11 1016491 1 Drive plate 12 1016494 1 Thrust plate 13 1016492 1 Belleville spring 14 1016493 1 Backup plate 15 57261 6 M12 x 1.75 Hex lock nut

w/ nylon insert 16 1016495 4 M8 x 1.25 Hex nut GR10 17 1016496 6 M12 x 1.75 x 85 mm HHCS PC 8.8 18 1005521 1 Grease fitting

MAN0963 (2/16/2012)

Parts 67

Page 68

BW180X & BW126X FRONT DRIVE ASSEMBLY - EQUAL ANGLE

REF PART QTY DESCRIPTION

A 57282 1 Complete 540 rpm (6-spline)

1 40563 1 Yoke 1-3/8, 6-spline (540 rpm)

2 40566 2 Cross & bearing

3 40751 2 Inboard yoke

4 40753 1 Outer profile

5 40765 2 Spring pin 10 x 90

6 57299 1 Yoke 1-1/2, 23-spline I.C.

8 40727 1 Outer shield

9 40728 1 Inner shield

REF PART QTY DESCRIPTION

10 40766 2 Bearing ring SC25

11 40777 2 Anti-rotation chain

12 40778 2 Screw (package of 10)

13 18864 1 Danger decal, rotating driveline

14 33347 1 Danger decal, shield missing

15 19811 1 1/2 NC x 2 HHCS GR8

16 765 1 1/2 NC Hex nut

17 40758 1 Lock collar kit ASG (540 rpm 6-spline

1-3/8)

68 Parts

MAN0963 (2/16/2012)

Page 69

BW180X & BW126X REAR DRIVE ASSEMBLY - EQUAL ANGLE

REF PART QTY DESCRIPTION

A 1004932 1 Complete rear drive assembly

1 1004957 1 Yoke, 1-3/4, 20 spline

2 40566 1 Cross and bearing

3 1003471 1 Inboard yoke

4 1004958 1 Inner profile

5 40765 1 Spring pin 10 x 90

6 1029936 1 Stub shaft

7 40766 2 Bearing ring SC25

8 40778 2 Screw (package of 10)

9 40777 2 Anti-rotation chain

REF PART QTY DESCRIPTION

10 40767 1 Support bearing

11 18864 1 Decal, danger rotating driveline

12 33347 1 Decal, danger guard missing

13 1004960 1 Inner guard half

14 1004959 1 Outer guard half

15 NSS 1 Shaft assembly, male

(complete w/guard)

16 NSS 1 Shaft assembly, female

(complete w/guard)

17 1001042 1 M16 x 2.0P x 90 mm HHCS 8.8

18 1005522 1 M16 x 2.0P Hex lock nut

NSS Not serviced separately

MAN0963 (2/16/2012)

Parts 69

Page 70

540 RPM & 1000 RPM FRONT CV DRIVE

REF PART QTY DESCRIPTION

A 1021103 1 Complete CV drive (540 RPM) A 1021104 1 Complete CV drive (1000 RPM) 1 19851 1 Slide lock repair kit 2 1033103 1 Yoke QD CV 1.375 - 6 (540 RPM) 2 1033104 1 Yoke QD CV 1.375 - 21 (1000 RPM) 3 1033107 2 CV U-Joint repair kit Cat 6 55E 4 1033106 1 CV Body with fitting 5 1033113 1 Yoke and shaft CV splined 25.9

(540 RPM)

5 1033111 1 Yoke and shaft - CV splined 26.6

(1000 RPM) 6 1009065 2 Drive shield bearing kit 7 18864 † 1 Decal, danger rotating driveline

(see page 12) 8 1021314 1 CV shield outer (540 RPM) 8 1021318 1 CV shield outer (1000 RPM)

REF PART QTY DESCRIPTION

9 1021315 1 CV shield inner (540 RPM)

9 1021319 1 CV shield inner (1000 RPM)

10 33347 † 1 Decal, danger guard missing

(see page 13)

11 1021316 1 Yoke 55R x 36.4 x 1.69 - 20

(540 RPM)

11 1021320 1 Yoke 55R x 38.4 x 1.69 - 20

(1000 RPM)

12 58765 1 U-Joint cross and bearing kit

13 1023058 1 Yoke, 55R x 5.06 x SP 1.75 - 20

14 6239 * 1 5/8 NC Lock nut

15 34473 * 1 5/8 NC x 3 HHCS GR5

†Not shown

HHCS Hex Head Cap Screw

* Standard hardware, obtain locally

70 Parts

MAN0963 (2/16/2012)

Page 71

WING DRIVE ASSEMBLY

REF PART QTY DESCRIPTION

A 1034927 Complete wing drive assembly

1 1004963 1 Yoke 1-3/4, 20 Spline

2 110 2 Cross & bearing kit

3 40764 2 Spring pin 10 x 80

4 40575 1 Inboard yoke

5 40587 1 Inner profile

6 1034930 1 Outer profile & sleeve

7 40576 1 Inboard yoke

8 57416 1 Friction clutch 1340 1-3/4, 20 Spline

9 40766 2 Bearing ring

10 40777 2 Anti-rotation chain

11 18864 1 Decal, danger rotating drive

12 33347 1 Decal, danger guard missing

13 40778 2 Screw (package of 10)

14 40767 1 Support bearing

15 40779 1 Grease fitting

REF PART QTY DESCRIPTION

16 1034928 4 Outer guard half

17 1034929 1 Inner guard half

20 57438 1 Flange yoke

21 57432 1 Friction disc (package of 2)

22 57440 1 Hub, 1-3/4, 20 Spline

23 57434 1 Thrust plate

24 57439 1 Belleville spring plate

25 57259 6 M10 x 1.5P x 55 mm HHCS 8.8

26 57260 6 M10 x 1.5P Hex lock nut

27 57261 2 M12 x 1.75P Hex lock nut

28 57262 2 M12 x 1.75P x 65 mm HHCS 8.8

29 58549 2 M12 x 1.75P Hex lock nut

30 307309 2 M12 x 1.75P x 60 mm HHCS 8.8

31 1005508 - Clutch repair kit (includes items 21,

24, 25, 26, 27 & 28)

HHCS Hex Head Cap Screw

MAN0963 (2/16/2012)

Parts 71

Page 72

5-BOLT WHEEL & TIRE ASSEMBLY

REF PART QTY DESCRIPTION

1 1017050 1 Heavy hub assembly

(includes items 1 through 15)

2 1017034 1 Heavy wheel hub with cups

(includes items 6,7,14)

3 1017033 1 Axle

4 1017027 1 Seal

5 1017028 1 Bearing cone

6 1017036 1 Bearing cup

7 1017037 1 Bearing cup

8 1017029 1 Bearing cone

9 1017031 1 Washer

10 1017032 1 Castle nut

11 1017035 1 Hub cap

12 1017038 5 Stud

13 1017069 1 Cotter pin

14 1017067 1 Grease fitting

15 35317 5 Nut, lug 1/2 NF

16 1017088 1 15" Rim for pneumatic tire - 5 bolt -or-

16 1017040 1 6.00 x 9 Solid tire,

rim & hardware - 5 bolt -or-

16 1028820 1 24 x 7.25 x 12 Aircraft tire,

rim & hardware - 5 bolt -or-

REF PART QTY DESCRIPTION

16 1028820F 1 24 x 7.25 x 12 Aircraft tire,

rim & hardware, foam filled - 5 bolt

16 1017030 1 29 x 9 x 15 Aircraft tire,

rim & hardware - 5 bolt

17 1028821 1 12.0 x 6 Rim half

(for 24" aircraft wheel only) -or-

17 1017026 1 15.0 x 6.0 Rim half

(for 29" aircraft wheel only)

18 1028822 1 12.0 x 6 Rim half

(for 24" aircraft wheel only)

18 1017025 1 15.0 x 6.0 Rim half w/ valve hole

(for 29" aircraft wheel only)

19 6100 * 1/2 NC x 1-1/4 HHCS GR5

20 765 * 1/2 NC Lock nut

21 19887 * 3/8 NC x 1 HHCS GR8

22 838 * 3/8 Standard lock washer

23 835 * 3/8 NC Hex nut

- 1015833 1 29 x 9 x 15 Inner tube (for 29" aircraft wheel only)

- 1017042 2 Rim half for 6 x 9 solid tire

* Standard hardware, obtain locally

72 Parts

MAN0963 (2/16/2012)

Page 73

BW180XHD / BW180XHDQ RUBBER SHIELDING - CENTER SECTION

REF PART QTY DESCRIPTION

1 1017057 1 Front center belt shield plate

2 1028588 1 Front right belt shield plate

3 1028589 1 Front left belt shield plate

7 1028506 2 Bent link .25 x 1.72 x 13.00

8 1028507 2 Bent link .25 x 1.72 x 9.50

9 1028592 2 Rubber shield .25 x 8.75 x 40.76

12 1027468 1 Rubber shield .25 x 9.25 x 28.00

13 1027469 2 Rubber shield .25 x 9.25 x 18.25

22 20973 * 3/8 NC x 1-1/4 Carriage bolt GR5

23 14350 * 3/8 NC Flanged lock nut

* Standard hardware, obtain locally

(FRONT & REAR)

(STANDARD ON BW180XHD MODELS)

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Parts 73

Page 74

BW180XHD / BW180XHDQ RUBBER SHIELDING - WING

REF PART QTY DESCRIPTION

4 1028590 1 Front right wing belt shield plate, inside -or-

4 1028591 1 Front left wing belt shield plate, inside

5 1027496 1 Front right wing belt shield plate, middle -or-

5 1027497 1 Front left wing belt shield plate, middle

6 1028504 1 Front right wing belt shield plate, outer -or-

6 1028505 1 Front left wing belt shield plate, outer

7 1028506 4 Bent link .25 x 1.72 x 13.00

10 1028593 2 Rubber belt .25 x 8.75 x 31.11

11 1028594 2 Rubber belt .25 x 8.75 x 53.87

14 1027484 2 Rubber belt .25 x 9.25 x 34.00

19 29893 * 1/2 NC x 1-1/2 Carriage bolt GR5

21 11900 * 1/2 NC Flanged lock nut

22 20973 * 3/8 NC x 1-1/4 Carriage bolt GR5

23 14350 * 3/8 NC Flanged lock nut

* Standard hardware, obtain locally

(FRONT & REAR)

(STANDARD ON BW180XHD MODELS)

74 Parts

MAN0963 (2/16/2012)

Page 75

CHAIN SHIELDING - CENTER SECTION (FRONT & REAR)

(SINGLE ROW STANDARD ON BW126XHD MODELS)

(SINGLE ROW OPTIONAL ON BW180XHD MODELS)

(DOUBLE ROW OPTIONAL ON BW126XHD AND BW180XHD MODELS)

SINGLE ROW DOUBLE ROW

REF PART QTY DESCRIPTION

1 1034850 1 Front center chain plate

2 1034855 1 Front right chain plate

3 1034856 1 Front left chain plate

4 1027460 1 Rear chain plate, right

5 1027461 1 Rear chain plate, left

10 1017309 2 Pin, 4 to 6 chains

11 1003642 2 Pin, 16 to 18 chains

13 1003644 1 Pin, 22 to 24 chains

14 1003645 2 Pin, 25 to 27 chains

15 4069 2 5/16 Chain - 4 link

16 3994 2 5/16 Chain - 5 link

17 5498 2 5/16 Chain - 6 link

18 5496 114 5/16 Chain - 7 link

22 6697 * 3/8 NC x 1 Carriage bolt GR5

23 14350 * 3/8 NC Flanged lock nut

* Standard hardware, obtain locally

REF PART QTY DESCRIPTION

1 1034859 1 Front center chain plate

2 1033916 1 Front right chain plate

3 1033917 1 Front left chain plate

4 1033918 1 Rear chain plate, right

5 1033919 1 Rear chain plate, left

10 1017309 4 Pin, 4 to 6 chains

11 1003642 4 Pin, 16 to 18 chains

13 1003644 2 Pin, 22 to 24 chains

14 1003645 4 Pin, 25 to 27 chains

15 4069 2 5/16 Chain - 4 link

16 3994 4 5/16 Chain - 5 link

17 5498 42 5/16 Chain - 6 link

18 5496 159 5/16 Chain - 7 link

22 6697 * 3/8 NC x 1 Carriage bolt GR5

23 14350 * 3/8 NC Flanged lock nut

* Standard hardware, obtain locally

MAN0963 (2/16/2012)

Parts 75

Page 76

CHAIN SHIELDING - WING (FRONT & REAR)

(SINGLE ROW STANDARD ON BW126XHD MODELS)

(SINGLE ROW OPTIONAL ON BW180XHD MODELS)

(DOUBLE ROW OPTIONAL ON BW126XHD AND BW180XHD MODELS

SINGLE ROW DOUBLE ROW

REF PART QTY DESCRIPTION

6 1034857 1 Front right wing chain plate, inner -or

6 1034858 1 Front left wing chain plate, inner

7 1034851 1 Front right wing chain plate, middle -or

7 1034852 1 Front left wing chain plate, middle

8 1034853 1 Front right wing chain plate, outer - or

8 1034854 1 Front left wing chain plate, outer

9 1028174 2 Rear wing chain plate

11 1003642 2 Pin, 16 to 18 chains

12 1003643 2 Pin, 19 to 21 chains

13 1003644 2 Pin, 22 to 24 chains

14 1003645 2 Pin, 25 to 27 chains

15 4069 2 5/16 Chain - 4 link

17 5498 6 5/16 Chain - 6 link

18 5496 84 5/16 Chain - 7 link

19 29893 * 1/2 NC x 1-1/2 Carriage bolt GR5

20 14406 * 1/2 NC x 1 Carriage bolt

21 11900 * 1/2 NC Flanged lock nut

22 6697 * 3/8 NC x 1-1/4 Carriage bolt GR5

23 14350 * 3/8 NC Flanged lock nut

* Standard hardware, obtain locally

Pin & chain quantities are for one wing

REF PART QTY DESCRIPTION

6 1034864 1 Front right wing chain plate, inner -or

6 1034865 1 Front left wing chain plate, inner

7 1034862 1 Front right wing chain plate, middle -or

7 1034863 1 Front left wing chain plate, middle

8 1034860 1 Front right wing chain plate, outer - or

8 1034861 1 Front left wing chain plate, outer

9 1033915 1 Rear wing chain plate

10 1017309 2 Pin, 4 to 6 Chains

11 1003642 2 Pin, 16 To 18 Chains

12 1003643 2 Pin, 19 To 21 Chains

13 1003644 2 Pin, 22 To 24 Chains

14 1003645 2 Pin, 25 To 27 Chains

15 4069 2 5/16 Chain - 4 Link

16 3994 4 5/16 Chain - 5 Link

17 5498 6 5/16 Chain - 6 Link

18 5496 135 5/16 Chain - 7 Link

19 29893 * 1/2 NC x 1-1/2 Carriage bolt GR5

21 11900 * 1/2 NC Flanged lock nut

22 6697 * 3/8 NC x 1-1/4 Carriage bolt GR5

23 14350 * 3/8 NC Flanged lock nut

* Standard hardware, obtain locally

Pin & chain quantities are for one wing

76 Parts

MAN0963 (2/16/2012)

Page 77

HYDRAULIC CYLINDERS

Wing

3 x 10

REF PART PART QTY DESCRIPTION

2 19810 23540 1 Seal repair kit

-or-

2 19810HD -------- 1 Seal repair kit w/ heavy

2A ‡ ‡ 1 Wiper seal 2C ‡ ‡ 2 1-1/4 ID U-Cup 2D ‡ ‡ 2 Barrel O-ring 2E † † Rod static O-ring 2F ‡ ‡ 2 Piston back-up washer 2G ‡ ‡ 1 Piston seal O-ring

3 NS 23543 1 Rod end housing 4 NS 23544 1 Piston 5 34328 25496 1 Jam nut 6 NS NS 4 Cylinder tie rod 7 4510 -------- 1 1/2 Pipe plug -or- 7 11893* 11893* 1 1/2 x 1/4 Pipe reducer

8 NS NS 1 Cylinder butt end

Center

3.5 x 8

(includes 2A thru 2G)

duty piston seal(includes 2A thru 2G)

bushing

Wing

3 x 10

REF PART PART QTY DESCRIPTION

9 923* 923* 4 1/4 x 1-3/4 Cotter pin 10 1631 1631 2 1 x 3-5/8 Clevis pin 11 11893* -------- 1 1/2 x 1/4 Pipe reducer

11 11975 11975 1 1/2 NPT Vent plug 12 NS NS 1 Cylinder barrel 15 * * 8 Tie rod nut 16 23549 23549 1 Hydraulic cylinder rod clevis 17 6698* 6698* 1 3/8 NC Lock nut 18 23550* 23550* 1 3/8 NC x 1-1/2 Socket head

19 NS 23551 1 Hydraulic cylinder rod 20 1031166 -------- 1 3 x 10 Hydraulic cylinder -

20 -------- 10475 1 3-1/2 x 8 Hydraulic cylinder w/

Center

3.5 x 8

bushing -or-

cap screw

Wing

breather complete - Center

* Obtain Locally † Not used on this cylinder ‡ Included in seal kit

NS Not sold separately

MAN0963 (2/16/2012)

Parts 77

Page 78

HYDRAULIC CYLINDER STROKE CONTROL KIT

REF PART QTY DESCRIPTION

1 24098 1 Stroke control set for 1-1/4" cylinder

rod (contains items 2 - 5)

2 – – – – 2 1-1/2" Segment

3 – – – – 1 1-1/4" Segment

4 – – – – 1 1" Segment

5 – – – – 1 3/4" Segment

CROSSBAR PULLER (OPTIONAL)

REF PART QTY DESCRIPTION

A 8811 1 Crossbar puller, complete

1 19914 2 Crossbar puller clevis

2 3097 * 4 5/8 NC x 4-1/2 HHCS GR5

3 230 * 4 5/8 NC Hex nut

78 Parts

REF PART QTY DESCRIPTION

4 24879 1 Crossbar puller pad assembly

5 24876 1 Crossbar puller tube assembly

6 24881 1 Crossbar puller screw assembly

7 24885 4 Crossbar puller link

* Standard hardware - obtain locally

MAN0963 (2/16/2012)

Page 79

BW126XHD / BW126XHDQ WEIGHT BOX ASSEMBLY (OPTIONAL)

REF PART QTY DESCRIPTION

1 1034063 1 Weight box 900 lbs

2 1034059 1 Brace

3 1010985 1 Skid shoe

4 1028566 1 Mounting plate

5 1003559 1 1.25 x 1.500 x 3.40 Sleeve

6 1003495 1 Hinge pin

7 46605 1 Clevis pin, 1 x 2.26

REF PART QTY DESCRIPTION

8 1285 * 1/4 x 1-1/2 Cotter pin

9 66016 * Spring pin, 1/4 x 1-1/2

10 12169 * 3/8 NC x 1-1/4 HHCS GR5

11 19446 * 3/8 NC x 1-1/4 Self-tapping screw

12 565 * 3/8 flat washer

13 838 * 3/8 Lock washer

14 14350 * 3/8 NC Flange lock nut

15 1863 * 1" Flat washer

16 11920 1 x 1-7/8 x 1/4 Washer

HHCS Hex Head Cap Screw

* Standard hardware, obtain locally

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Parts 79

Page 80

BW180XHD SHREDDER KIT 1033930 (OPTIONAL)

REF PART QTY DESCRIPTION

A 1033930 1 BW180XHD Shredder kit, complete

1 1033932 2 Crossbar (wing) 2 1033931 1 Crossbar (Center section) 3 39002KT 2 Blade, .5 x 4 x 22.5 CW formed 4 39003KT 4 Blade, .5 x 4 x 22.5 CCW formed 5 1017128KT 6 Blade, .5 x 4 x 22.5 flat 6 39089 3 Blade, .38 x 4 x 11.13 double edge 7 1014164 2 Mounting bracket, bent 8 1033935 1 Center blade bracket

REF PART QTY DESCRIPTION

9 39069 6 Blade pin

10 39127 6 Bushing

11 39128 6 Jam nut, 1-1/4

12 7832 * 6 5/8 NC x 1-1/2 HHCS GR5

13 6239 * 6 5/8 NC Lock nut

14 6100 * 12 1/2 NC x 1-1/4 HHCS GR5

15 11900 * 12 1/2 NC Flange lock nut

16 57816 24 1/2 Hardened flat washer

17 57817 12 5/8 Hardened flat washer

* Standard hardware, obtain locally

80 Parts

MAN0963 (2/16/2012)

Page 81

WINCH KIT (OPTIONAL)

REF PART QTY DESCRIPTION

A 1019456 - Winch kit, complete

1 52478 4 Idler bracket

2 6696 2 Chain idler casting

3 409 2 Clevis pin, 1/2 x 2

4 22411 2 Klik pin, 3/16 x 1

5 3379 * - HHCS, 1/2 NC x 1-1/2 GR5

6 11900 * - Lock nut, 1/2 NC flanged

7 1863 * - Washer, 1" SAE flat

8 1008325 2 Headless pin, 1 x 4 drilled

9 1266 * - Cotter pin, 3/16 x 1-1/2

10 1019454 2 Channel. 2.56 x 2.75 x 32.88

11 1019455 1 Channel, 3.12 x 3.25 x 10.00

12 12612 1 Gear winch 5.1 to 1

13 12642 1 Winch cable clamp kit

14 11790 1 C-Hook, 1/4 cable

15 52479 1 Cable, 1/4" x 24-ft

16 11789 2 Clip, 1/4 cable

17 839 * - HHCS, NC x 1 GR5

18 565 * - Washer, 3/8 flat

19 838 * - Washer, 3/8 lock

20 835 * - Hex nut, 3/8 NC plated

* Standard hardware; obtain locally

Winch Kit Installation

1. Locate and drill one 9/16" hole in each wing as

shown. Assemble items 1, 2, 3 and 4 and use to locate and drill remaining holes.

2. Secure idler brackets (1) and rollers (2) to deck with bolts (5) and nuts (6).

3. Assemble channels (10) to cylinder lugs using pins (8), washers (7), and cotter pins (9) as shown.

4. Assemble winch assembly to channels (10) using bolts (5) and lock nuts (6).

5. Move SMV sign and hardware to channel as shown.

6. Tighten all hardware.

Winch Kit Operation

1. Move cutter so wing is on the up slope of a ditch

to aid in wing lift with the winch.

2. Unwind cable and remove roller (2).

3. Place cable around roller (2) and reinstall using

pin (3) and Klik pin (4).

4. Remove cylinder pin from clevis end and raise slowly.

5. Install transport lock before moving unit.

MAN0963 (2/16/2012)

Parts 81

Page 82

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.

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

Diameter &

Thread Pitch

(Millimeters)

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

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

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

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

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

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

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

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

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

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

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

Wrench

Size

Wrench

Size

MARKING ON HEAD MARKING ON HEAD

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

SAE 2 SAE 5 SAE 8

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

COARSE THREAD FINE THREAD

MARKING ON HEAD

Diameter &

Thread Pitch

(Millimeters)

82 Appendix

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

Page 83

BOLT SIZE CHART

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

SAE Bolt Thread Sizes

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

IN 1 7

MM 25 50 75 100 125 150 175

Metric Bolt Thread Sizes

8MM 18MM14MM12MM10MM 16MM

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

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

Appendix 83

Page 84

ADJUSTMENTS

Cutting Height

Slip Clutch 22

ASSEMBLY

Dealer Set-Up Instructions

Fill Gearboxes 39

DEALER CHECK LIST

Check Lists

Delivery (Dealer’s Responsibility) 51 Pre-Delivery (Dealer’s Responsibility) 51

DEALER SERVICE

Crossbar

Installation 37 Removal 36

Gearbox Maintenance - (Style A) 25

Gearbox Cap Leak Repair 26 Horizontal Shaft Seal Replacement 26 Seal Installation 25 Seal Replacement 25

Horizontal Shaft 26

Vertical Shaft Repair 26

Gearbox Repair - (Style A) 26

Gearbox Assembly 27 Gearbox Disassembly 26 Gearbox Installation 27 Gearbox Removal 26

Gearbox Maintenance - (Style B) 29

Horizontal Shaft Seal Replacement 29 Seal Installation 29 Seal Replacement 29

Horizontal Shaft 29

Vertical Shaft Repair 29

Gearbox Repair - (Style B) 30

Gearbox Assembly 30 Gearbox Disassembly 30 Gearbox Installation 31 Gearbox Removal 30

Splitter Gearbox Repair - (Style A) 32

Gearbox Assembly 32 Gearbox Disassembly 32 Gearbox Inspection 33 Gearbox Installation 33 Gearbox Removal 32

Splitter Gearbox Repair - (Style B) 34

Gearbox Assembly 34 Gearbox Disassembly 34 Gearbox Inspection 34 Gearbox Installation 35 Gearbox Removal 34

Universal Joint

Assembly 38 Disassembly 37 Repair 37

GENERAL

Abbreviations

Bolt Size Chart 83

INDEX

OPERATION

OWNER SERVICE

PARTS

SAFETY

TROUBLESHOOTING 24

Bolt Torque Chart 82 General Information 4 Introduction 2 Obtaining Replacement Manuals 2 Product Registration 2 Specifications 4 Table of Contents 3 Warranty

Product 85 Replacement Parts 86

Connecting Cutter to Tractor

Cutting Height Adjustment 15 CV Driveline Turning Limits 15 Hydraulic Connection 15 Interference Check 15

Cutter Operation 16

Mowing Tips 16 Shredding 16

Pre-Operation Check List (Owner’s Responsibility)

Storage 18 Tractor Operation 16 Transporting 17

Lock-Up 17

Center Section 17 Wing 17

Adjusting Slip Clutch Blades

Installation 21 Removal 21 Sharpening 22

Blocking Method 19 Lubrication

Driveline 20 Gearbox 20 Lubrication Points 20 Seasonal 21

Shielding Repair 23 Slip Clutch Adjustment 22

Parts Index

Blocking Method Check Lists

Delivery Check List (Dealer’s Responsibility) 51 Pre-Delivery Check List (Dealer’s Responsibility) 51 Pre-Operation Check List (Owner’s Responsibility) 18

Free Mower Safety Video Order Form 6 Safety & Instructional Decals 11, 12, 13 Safety Rules 7, 8, 9, 10 Safety Symbols Explained 2

84 Index

MAN0963 (2/16/2012)

Page 85

WARRANTY

All Models Except Mow’n MachineTM Zero-Turn Mowers

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.

All current model loaders and backhoes 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

Gearbox

Seals

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:

All units listed below 2 years

BW1260, BW1620, BW1800, BW2400 8 years

BW240HD, BW180HD, BW180HB, BW126HB 7 years

BB48X, BB60X, BB72X, BB84X, BB600X, BB720X, BB840X, BB6000X, BB7200X, BB8400X, DS1260, DSO1260, DS1440, TS1680, BW126-3, BW180-3, BW240

PHD25, PHD35, PHD65, PHD95, DS96, DS120, RCC42, RD990X, PRD6000, PRD7200, PRD8400, S15CD, S20CD, S22CD, S25CD, S27CD, S30CD BW15LH, TC/R74, TC/R68, TC/R60, TBW144, TBW180, TBW204, HC48, HC54, HC60, HC72

RDC54, RD60, RD72, TBW150C, TS/R60, TS/R52, TS/R44

RD990X, PRD6000, PRD7200, PRD8400, TBW144, TBW180, TBW204 3 years

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

Model Number

Duration (from date of delivery to the original

purchaser)

6 years

5 years

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

10 years

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

F-3079 (Rev. 1/3/2012)

Page 86

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.

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.

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:

©2008 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.

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

Woods Equipment BW180XHDQ, BW180XHD, BW126XHD, BW126XHDQ User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual