Woods Equipment BW2400XQ, BW1620XQ, BW2400X, BW1620X User Manual

BW2400X, BW2400XQ BW1620X, BW1620XQ

BW1620XQREV

MAN0764

(Rev. 10/25/2010)

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. Please contact your dealer to complete this form. 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. 3/5/2010)

TABLE OF CONTENTS

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

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

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

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

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

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

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

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

TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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

ASSEMBLY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

DEALER CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

INDEX TO PARTS LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

BOLT TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

BOLT SIZE CHART & ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 79

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

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

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

MAN0764 (11/5/2008)

Introduction 3

SPECIFICATIONS

WARNING

BW1620X, BW1620XQ

BW2400X, BW2400XQ

Cutting Height (Varies with tire selection) . . . . . . . . . . . . . . . . . . . . . . . 2" - 15" 2" - 15"

Cutting Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240" (20’) 162" (13.5’)

Overall Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249" 171"

Transport Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123" 99"

Tractor HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 - 250 75 - 250

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

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

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

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (BW1620XQREV has CW Rotation on Center Spindle)

Input Driveline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cat 5 Heavy Cat 5 Heavy

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

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

BW1620XQREV

Weight (approximate lbs. with 8 large aircraft tires,

single chain shielding & CV drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7740 7300

Wheel Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15" Rims; 24" Aircraft, 29" Aircraft, 22" Solid

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

BW2400X, BW1620X BW2400XQ, BW1620XQ, BW1620XQREV

Tractor PTO rpm 540 1000

Blade Speed (Feet per minute) 15,450 16,700

GENERAL INFORMATION

operating conditions. However, through experience and these instructions, you should be able to develop procedures suitable to your particular situation.

 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

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.

4 Introduction

MAN0764 (11/5/2008)

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

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)

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-

BW2400X/1620X SR (11/14/2008)

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

(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.

 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.

 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.

 The offset model is unstable without adequate counterweight. Use counterweight box loaded with 1300 lbs (591 kg) of steel.

 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 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.

8 Safety

BW2400X/1620X SR (11/14/2008)

• If this machine is not equipped with full chain

SAFETY RULES

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

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 protec-

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).

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

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

It is possible for objects to ricochet

 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

 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.

 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.

 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 the ground, raise cutter, and engage transport lock-up in the locked position. Attach parking jack and lower to the ground. Securely block all four corners of the 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.

(Safety Rules continued on next page)

BW2400X/1620X SR (11/14/2008)

Safety 9

(Safety Rules continued from previous page)



SAFETY RULES

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

 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.

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

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

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

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

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

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

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

 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.

 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

 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.



Make sure shields and guards are properly

installed and in good condition. Replace if damaged.

10 Safety

 Keep children and bystanders away from storage area.

BW2400X/1620X SR (11/14/2008)

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

2 - FRONT AMBER REFLECTOR

(PN 1002940)

3 - REAR RED REFLECTOR

(PN 57123)

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.

17 - PN 1004114

PN 1006348 (located on split rim wheels)

(Safety Decals continued on next page)

1 - SERIAL NUMBER PLATE

WARNING

RELEASE ALL AIR PRESSURE BEFORE LOOSENING BOLTS.

FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY OR DEATH.

MAX. SPEED: 20 MPH, MAX. WEIGHT: 4000 LBS., MAX. AIR PRESSURE: 40 PSI.

1006348

EXPLOSION

HAZARD

MODEL NO. SER IAL NO.

SAFETY & INSTRUCTIONAL DECALS

Replace Immediately If Damaged!

Woods Equipment Company

Oregon, Illinois, U.S.A.

MAN0764 (11/5/2008)

DO NOT OPERATE - PUT SHIELD ON

DANGER

SHIELD MISSING

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

Safety 11

18869-B

1004114

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

ROTATING BLADES AND

THROWN OBJECTS

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

engine is running.

 Before mowing, clear area of objects that may be

thrown by blade.

 Keep bystanders away.

 Keep guards in place and in good condition.

BLADE CONTACT OR THROWN OBJECTS CAN

CAUSE SERIOUS INJURY OR DEATH.

DANGER

15503-C

DO NOT EXCEED PTO SPEED OF

540 RPM

PTO speeds higher than 540 RPM can cause

equipment failure and personal injury.

WARNING

18866-D

6 - PN 18866

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

(Safety Decals continued from previous page)

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

12 Safety

18864-C

MAN0764 (11/5/2008)

SAFETY & INSTRUCTIONAL DECALS

12 - PN 1004991

ds.

sta

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!

Cutt

hydraulic system failures, or mechanical component failures.

1004991

 Be extremely careful handling various parts of

 Operate tractor controls from tractor seat only.  Do not stand between tractor and implement

 Make sure parking brake is engaged before

 Stand clear of machine while in operation or

WARNING

RAISED CUTTER CAN DROP AND CRUSH

rs must be equipped with transport lock

ansport components must be functional, kept in goodAll t

FAILURE TO FOLLOW INSTRUCTIONS CAN

RESULT IN SERIOUS INJURY OR DEATH.

WARNING

CRUSHING AND PINCHING HAZARD

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

when tractor is in gear.

going between tractor and implement.

when it is being raised or lowered.

FAILURE TO FOLLOW THESE

INSTRUCTIONS COULD RESULT IN

SERIOUS INJURY OR DEATH.

1003751-A

TRANSPORT LOCK

AND CYLINDER

REQUIREMENTS

SINGLE-ACTING FULL

EXTENSION

28-1/4"

TRANSPORT LOCK

WARNING

TO AVOID SERIOUS

INJURY OR DEATH:

 Read Operator's Manual (available

from dealer) and follow all safety precautions.

 Keep all shields in place and in good

condition.

 Operate mower from tractor seat only.

 Lower mower, stop engine and remove

key before dismounting tractor.

 Allow no children or untrained persons

to operate equipment.

 Do not transport towed or

semi-mounted units over 20 mph.

FAILURE TO OPERATE SAFELY

CAN RESULT IN

INJURY OR DEATH.

18877-C

MAN0764 (11/5/2008)

Safety 13

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 models BW2400X and BW1620X (1000 rpm on models BW2400XQ, BW1620XQ and BW1620XQREV).

 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).

It is possible for objects to ricochet

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 the 540 rpm cutter and 16" for the 1000 rpm cutter. Tractors with 1-3/4 20-spline PTO shaft should be set to 20". This will minimize joint knock and damage to drive components.

 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 sturdy, rough-soled work shoes and protective

14 Operation

Figure 1. Cutter to Tractor Connection

1. Check tongue clevis to make sure it is adjusted to

match your tractor PTO speed. See Figure 26, page 36.

2. Position tongue clevis (A) up or down based on tractor drawbar height.

(Rev. 1/30/2009)

MAN0764 (11/5/2008)

3. Attach cutter using a 1-1/8" clevis pin (1) and clip.

WARNING

4. Attach safety tow chain (2) to drawbar support. Leave enough slack for turning.

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

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

NOTE: CV driveline does not require a tether chain.

7. Remove parking jack (3) from the tongue and attach it to the storage post on the front of the left wing.

NOTE:

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

Equal Angle Drive Only:

With cutting height

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.

Cutting Height Adjustment

8. Adjust nuts (4) so tongue clevis (A) is parallel with

the tractor drawbar.

9. Place driveline in storage position on the hose holder (5) when not in use.

Hydraulic Connection

1. Inspect hydraulic hoses to ensure they are in good

condition.

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

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

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 2" 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.

3. Use the hydraulic cylinder or ratchet jack to raise or

lower the center section to obtain a distance of 5" from bottom edge of skid shoe to the ground.

NOTICE

 You must not exceed a turning angle of 80 degrees at the head of the Constant Velocity driveline or damage will occur.

(Rev. 1/30/2009) MAN0764 (11/5/2008)

4. Place jackstands under the four corners of the center section. See chart on page 20. Lower center section to relieve pressure on attitude rod nuts.

5. Loosen outer jam nut on the attitude rods.

Operation 15

6. Adjust inner nuts in or out until the rear of the cutter

WARNING

is approximately 1/2" higher than the front. (See Attitude Rod Adjustment, page 16.)

TRACTOR OPERATION

7. Raise cutter, remove jackstands and check deck

height. 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.

4. Make sure jam nuts are tightened once wing is leveled.

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.

Attitude Rod Adjustment (Figure 2)

Use the following chart as a starting point for adjusting the attitude rod, based on different tongue height and wheel options.

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

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. 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 a 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.

Figure 2. Attitude Rod Adjustment

16 Operation

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.

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.

(Rev. 1/30/2009)

MAN0764 (11/5/2008)

Mowing Tips

WARNING

CAUTION

WARNING

CAUTION

Pin Storage Position

DP2/4-1

Wing Lock Position

TRANSPORTING

 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.

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.).

 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.

 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. Place equipment on a level surface before raising wings.

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. (See Attitude Rod Adjustment, page 16.)

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.

(Rev. 1/30/2009) MAN0764 (11/5/2008)

Figure 3. Transport Lock-Up;

Wing and Center Section Shown

Operation 17

Wing Lock-Up (Figure 3)

DP8A

1. Remove safety pin and lock-up pin from storage position.

2. Raise wing and align wing transport lock with slotted holes in the cylinder lugs.

3. Insert lock-up pin above cylinder pin and secure with klik pin

4. Repeat steps 1 to 3 for opposite wing.

5. Relieve hydraulic pressure from wing cylinders and

lower the wing against the wing transport lock.

Center Section Lock-Up (Figure 3)

1. Raise cutter with hydraulic cylinder to maximum

height.

2. Rotate transport lock into position over cylinder rod.

3. Lower cutter against transport lock.

4. To lower the cutter for operation, extend hydraulic

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

5. Lower the cutter to cutting height. Use cylinder stops (stroke control kit) to set desired cutting height.

Figure 4. Transport Lock in Operation Position

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.

3. Lower wings to ground.

4. Raise cutter center section and rotate transport

lock into position over cylinder. Relieve hydraulic pressure.

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 on each wing to prevent wheel rotation.

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

8. Remove hydraulic hoses after tractor is off.

9. Remove safety tow chain.

10. Remove retainer 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.

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

___ Set tractor PTO at correct rpm for your equip-

ment.

___ 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. ___ Check that blades are sharp and secure and cut-

ting edge is positioned to lead with correct rota-

tion. ___ 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 dam-

aged. ___ Before starting engine, operator must be in trac-

tor seat with seat belt fastened. Place transmis-

sion 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. ___ 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. ___ Check the tire pressure for pneumatic tires. The

maximum pressure allowed is 40 psi.

18 Operation

(Rev. 1/30/2009)

MAN0764 (11/5/2008)

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 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.

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.

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.

 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.

MAN0764 (11/5/2008)

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.

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

Owner Service 19

Ref Description Frequency

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. Splitter gearbox Daily (bottom of side hole)

11. Tailwheel spindle 20 Hours

12. Turnbuckle 40 Hours

X = JACKSTAND PLACEMENT

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.

Figure 5. Jackstand Placement and Lubrication Points

Gearbox Lubrication

For gearboxes, use a high quality gear oil with a viscosity index of 80W or 90W and an API service rating of GL-4 or -5. Check gearboxes daily for evidence of

20 Owner Service

leakage, and contact your dealer if leakage occurs. Splitter Gearbox: Fill gearbox until oil runs out the side plug on gearbox. Wing and Center Gearboxes: Fill gearbox until oil is between lowest ring and end of dipstick.

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.

(Rev. 11/9/2009) MAN0764 (11/5/2008)

Seasonal Lubrication

WARNING

7. Blade pin

8. Crossbar assembly

9. Shim, 18 ga

10. Shim, 20 ga

11. Keyhole plate

12. Blade lock clip

50. 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.

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)

lock clip (12), keyhole plate (11), and shims (9 &

10). Carefully drive blade pin (7) out of crossbar.

4. Rotate crossbar and repeat for opposite blade.

NOTICE

 If blade pin (7) 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.

NOTICE

 Crossbar rotation has clockwise rotation on left gearbox and counterclockwise rotation on the right gearbox when looking down on cutter. The center gearbox has counterclockwise rotation on all models except BW1620XQREV, which has clockwise. Be sure to install blade cutting edge to lead in the correct rotation.

NOTE: Always replace or sharpen both blades at the

same time.

1. Inspect blade pin (7) 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 (8) with blade access hole in cutter frame. Apply a liberal coating of Never-Seez equivalent to blade pin and crossbar hole. Make sure blade offset is down away from cutter.

4. Insert blade pin (7) through blade. Push blade pin through crossbar.

5. Install shims (9 & 10) over blade pin.

Figure 6. Blade Assembly

1. Disconnect driveline from tractor PTO.

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

3. Align crossbar (8) with blade access hole in the

cutter frame. Remove cap screw (50), blade pin

MAN0764 (11/5/2008)

NOTE: Only use enough shims to allow keyhole plate (11) to slide into blade pin groove.

6. Install blade clip (12) over keyhole plate and into blade pin groove.

7. Secure into position with cap screw (50). 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

Blade Sharpening (Figure 7)

Follow Original Pattern

Maintain Corner

1/16"

CD1257-2

1. Flange yoke

2. Friction disc

3. Hub, 1-3/4 splined

4. Thrust plate

5. Belleville spring plate

6. Drive plate

7. Drive plate

8. Backup plate

9. Lock assembly

10. M12 x 1.75P x 85 mm Hex head cap screw

11. M12 x 1.75P Hex lock nut

12. M8 x 1.25P Hex nut

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.

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. Tighten four nuts (12) to remove pressure from the

clutch plates (2). Repeat for all three clutches.

3. Start tractor at low throttle and slowly engage PTO and allow clutches to slip for 5 seconds. Disengage PTO and turn off tractor engine.

4. If clutches slip freely, completely loosen nuts (12).

5. If clutch does not slip freely, disassemble and

clean plates (4, 6, 7), flange yoke (1), and clutch hub (3).

6. Reassemble clutch.

7. Tighten Belleville spring (5) with nuts (11) until it is

against the thrust plate (4) of the clutch. Back off each of the four nuts (11) until gap between Belleville spring and thrust plate is .180 or 3/16” as shown in Figure 8.

Figure 7. Blade Sharpening

SLIP CLUTCH ADJUSTMENT (Figure 8)

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

8. If a clutch continues to slip when the spring is compressed to .180 or 3/16” 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".

NOTE: When storing cutter for long periods of time, relieve the pressure on the clutch discs by tightening the four nuts (12) on each clutch. Completely loosen nuts (12) to return to service.

22 Owner Service

Figure 8. Slip Clutch Assembly

MAN0764 (11/5/2008)

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).

It is possible for objects to ricochet

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.

— 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 9. Split Rim Tire Servicing

Repairing Optional Chain Shielding:

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

CLEANING

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.

MAN0764 (11/5/2008)

Owner Service 23

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.

MAN0764 (11/5/2008)

DEALER SERVICE

WARNING

CAUTION

1. Seal

2. Pipe or tube

3. Seal seat

4. Casting

Incorrect Installation

Pipe or tube must press at outer edge of seal.

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

■ Before working underneath, read manual

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

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

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 REPAIR

NOTE: Read this entire section before starting any

repair. Many steps are dependent on each other.

1. Fill gearbox with SAE 80W or 90W gear lube.

2. Inspect gearbox for leakage and bad bearings.

Seal Replacement (Figure 10)

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.

MAN0764 (11/5/2008)

Proper oil level for wing and center gearboxes is between lowest ring and end of dipstick. On splitter gearbox, fill gearbox until oil runs out the side plug on gearbox.

NOTE: Repair to these gearboxes 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.

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.

Aviation 3D Form-A-Gasket or equivalent.

Figure 10. Seal Installation

Vertical Shaft Seal Replacement (Figure 11)

1. Disconnect and remove driveline from the gearbox.

2. Remove dipstick breather assembly (30) and

siphon gear lube from housing through this opening.

3. Remove crossbar (see page 30).

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.

6. Remove and replace any seal damaged in installation.

Dealer Service 25

+ 57 hidden pages

Woods Equipment BW2400XQ, BW1620XQ, BW2400X, BW1620X User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual