Woods Equipment RD6000-2, RD7200-2, RD8400-2 User Manual

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Page 1

Page 2

TO THE DEALER:

CAUTION

IMPORTANT

WARNING

DANGER

NOTE

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

The dealer must complete the Product Registration included with the Operator’s Manual. The customer must sign the registration which certifies that all Dealer Check List items have been completed. The dealer is to return the prepaid postage portion to Woods, give one copy to the customer, and retain one copy. Failure to complete and return this

card 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 IMPORTANT is used to indicate that failure to observe can cause damage to equipment. The terms CAUTION, WARNING, and DANGER are used in conjunction with the Safety-Alert Symbol (a triangle with an exclamation mark) to indicate the degree of hazard for items of personal safety.

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

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

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

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

Indicates that failure to observe can cause damage to equipment.

IMPORTANT

DANGER

WARNING

CAUTION

NOTE

ii Introduction

Indicates helpful information.

Gen’l (Rev. 5/23/2005)

Page 3

TABLE OF CONTENTS

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inside Front Cover

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

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

SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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

OWNER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

DEALER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

DEALER CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

PARTS LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

BOLT TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

BOLT SIZE CHART & ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 42

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

PRODUCT WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

REPLACEMENT PARTS WARRANTY . . . . . . . . . . . . . . . . Inside Back Cover

(Rev. 4/28/2006) MAN0180 (Rev. 1/7/2005)

LEA EL INSTRUCTIVO!

Si no lee Ingles, pida ayuda a

alguien que si lo lea para que le

traduzca las medidas de seguridad.

Introduction 1

Page 4

SPECIFICATIONS

RD6000-2 RD7200-2 RD8400-2

3-Point Hitch Category 1 Category 1 Category 1

Cutting Width 60" 72" 84"

Cutting Height Range 1" - 5-1/2" 1" - 5-1/2" 1" - 4-1/4"

Operating Weight with Chain Shielding 605 lbs 671 lbs 770 lbs

Blade Speed (feet per minute) 16,950 16,800 16,700

Blade Speed (RPM) 3,083 2,570 2,179

2 Introduction

MAN0180 (Rev. 1/7/2005)

Page 5

AFETY RULE

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

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

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

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

TRAINING

 Safety instructions are important! Read all attachment and power unit manuals; follow all safety rules and safety decal information. (Replacement manuals 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.

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

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

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

 Never allow children or untrained persons to operate equipment.

PREPARATION

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

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

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

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

 Make sure driveline shield tether chains are attached to the tractor and equipment as shown in this manual. 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.

 A minimum 25% 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. Weigh the tractor and equipment. Do not estimate.

OPERATION

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

 Full chain shielding, designed to reduce the possibility of thrown objects, 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 several hundred feet.

RD Mower (Rev. 4/28/2006)

Safety 3

Page 6

AFETY RULE

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

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

 Keep bystanders away from equipment.

 Never go underneath equipment (lowered to the

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

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

 Operate only in daylight or good artificial light.

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

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

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

 Never allow riders on power unit or attachment.

 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. Do not exceed.

 Look down and to the rear and make sure area

is clear before operating in reverse.

 Do not operate or transport on steep slopes.

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

denly on slopes.

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

 Watch for hidden hazards on the terrain during operation.

 Stop power unit and implement immediately upon striking an obstruction. Dismount power unit, using proper procedure. Inspect and repair any damage before resuming operation.

 Before dismounting power unit or performing any service or maintenance, follow these steps: disengage power to equipment, lower the 3-point hitch and all raised components to the ground,

operate valve levers to release any hydraulic pressure, set parking brake, stop engine, remove key, and unfasten seat belt.

 Before working underneath, 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.

TRANSPORTATION

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

 Do not operate PTO during transport.

 A minimum 25% 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. Weigh the tractor and equipment. Do not estimate.

 Do not operate or transport on steep slopes.

 Do not operate or transport equipment while

under the influence of alcohol or drugs.

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

 Never allow riders on power unit or attachment.

MAINTENANCE

 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.

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

4 Safety

RD Mower (Rev. 4/28/2006)

Page 7

AFETY RULE

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

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

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

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

 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.

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

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

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

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

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



Make sure shields and guards are properly

installed and in good condition. Replace if damaged.

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

 Use care when installing or removing belt from spring-loaded idler. Springs store energy when extended and, if released suddenly, can cause personal injury.

STORAGE

 Follow manual instructions for storage.

 Keep children and bystanders away from stor-

age area.

RD Mower (Rev. 4/28/2006)



Safety 5

Page 8

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

1 - 15503

SHIELD MISSING

2 - 18867

3 - Serial Number Plate

DANGER

DO NOT OPERATE

PUT SHIELD ON

18867--B

CD4984A

6 Safety

MAN0180 (Rev. 1/7/2005)

Page 9

SAFETY & INSTRUCTIONAL DECALS

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Replace Immediately If Damaged!

WARNING

FALLING OFF CAN RESULT IN BEING RUN OVER.



Tractor must be equipped with ROPS (or ROPS CAB) and seat belt. Keep foldable ROPS systems in “locked up” position at all times.



Buckle Up! Keep seat belt securely fastened.



Allow no riders.

RAISED EQUIPMENT CAN DROP AND CRUSH.



Before working underneath, follow all instructions and safety rules in operator’s manual and securely block up all corners of equipment with jack stands.



Securely blocking prevents equipment 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.

MAN0180 (Rev. 1/7/2005)

DANGER

GUARD MISSING.

DO NOT OPERATE.

DANGER

GUARD MISSING.

DO NOT OPERATE.

33347E

DANGER

Safety 7

Page 10

OPERATION

The operator is responsible for the safe operation of the mower. The operator must be properly trained. Operators should be familiar with the mower, the tractor, and all safety practices before starting operation. Read the safety rules and safety decals on page 3 to 7.

This mower is designed for lawn and grass mowing. It is not designed for rough conditions or heavy weed mowing. It is equipped with suction type blades for best results in lawn mowing.

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

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

DANGER

 Never allow children or untrained persons to operate equipment.

 Keep bystanders away from equipment.

 Make sure spring-activated locking pin or collar

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

 Stop power unit and implement immediately upon striking an obstruction. Dismount power unit, using proper procedure. Inspect and repair any damage before resuming operation.

 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.

TRACTOR STABILITY

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

8 Operation

Figure 1. Tractor Stability

MAN0180 (Rev. 1/7/2005)

Page 11

ATTACHING MOWER TO TRACTOR

CUTTING HEIGHT ADJUSTMENT

WARNING

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

The standard 1-3/8" 6B-spline driveline with a QD yoke is used to connect the mower to the tractor.

1. Attach the mower hitch pins to the lower tractor lift arms and secure.

2. Attach tractor top link (1), Figure 2, to mower top link bracket attachment point A. Connect the driveline to the tractor PTO shaft.

3. Attach tether chain to tractor drawbar (Figure 3).

4. Adjust the tractor lower 3-point arm anti-sway

devices to prevent mower from swinging side to side during transport.

WARNING

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

IMPORTANT

■ Avoid low cutting heights. Striking the ground

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

1. Level mower from side to side. Check by

measuring from mower frame to the ground at each deck rail.

2. Verify that the same amount of spacers are under all caster arms.

3. Loosen cap screws that attach caster arm assembly to deck.

4. Set mower on the ground.

CD3944

1. Tractor top link A. Mower top link attachment point B. Mower hitch pin

Figure 2. Attachment Points

Tether Chain

5. Retighten cap screws. This equalizes the clearance in the bolt holes.

6. Adjust front of mower level with or slightly lower than the rear to obtain best mowing results.

7. Control cutting height by adjusting front and rear caster wheels.

8. To raise rear of mower, move caster adjustment spacers under rear caster arms, Figure 5.

9. To raise front of mower, move spacers under front caster wheel arms.

FORWARD

CD3551B

Figure 3. Attach Mower to Tractor

MAN0180 (Rev. 1/7/2005)

CM906

Figure 4. Cutting Height Adjustment

Remember, measurement at location A (Figure 4) should not be less than location B and should not be over 1/2" greater than location B.

Operation 9

Page 12

Table 1: Cutting Height Chart

SPACERS REQUIRED UNDER

CASTER ARM PIVOT TUBE

Cut

Height

1-1/2" 1

2" 1

2-1/2" 11

3" 2

3-1/2" 12

4" *111

4-1/4" 112

4-1/2" *1 1 1 1

5" *121

5-1/2" *1 1 2 1

1/2"

Spacer

* RD6000 and RD7200 only

3/4"

Spacer

Space

1-1/4" *Spacer (Spring)

Figure 6. Top Link Adjustment

Figure 7. Gauge Wheel Distance

Figure 5. Height Adjustment with Caster Arm Spacers

TRACTOR TOP LINK ADJUSTMENT

When the cutting height is set, adjust tractor top link until mower top link attachment point A is aligned vertically with mower hitch pin B.

Adjust tractor top link so mower is level between caster wheel and ground (dimension C Figure 7). This will allow the mower to follow ground contour.

FRONT CASTER ARM CONFIGURATION

For RD6000-2 & RD7200-2 only

The RD6000-2 and RD7200-2 front casters can be set in two positions using the right and left offset caster arms. Figure 8 shows a right offset assembly.

Check the offset position by looking from mounting hole A to pivot tube B. The pivot tube should be higher than the mounting holes.

Figure 8 shows the two possible configurations for the RD6000-2 and RD7200-2 front caster arms.

● The inner position allows the outside edge of the

mower to be used for trimming under shrubs or fences.

● The outer position provides the most clearance for

rear tractor tire interference.

To change configurations, remove the cap screws and nuts and move the arms from one side of the machine to the other. Secure with hardware.

The rear caster arms should be mounted as shown.

NOTE: The RD8400-2 front caster arms are fixed and cannot be changed.

10 Operation

MAN0180 (Rev. 1/7/2005)

Page 13

wheels in their highest position and provide the lowest

CAUTION

cutting height for the mower.

RIGHT OFFSET

R - Right Offset L - Left Offset A - Mounting Holes B - Pivot Tube

1. Raise mower with tractor hydraulics to 16" at dimension C or maximum height of tractor lift, whichever is less.

2. Pivot both front caster wheels forward and check that there is clearance between caster wheels and tractor tires.

3. If there is interference on models RD6000-2 and RD7200-2, mount front casters in the outer position.

NOTE: On model RD8400-2, caster wheel width is not adjustable; see tractor operator's manual and adjust tractor wheels to narrower spacing.

CD4990

Figure 8. Front Caster Arm Configuration for

RD6000-2 & RD7200-2 Only

FRONT CASTER WHEEL INTERFERENCE CHECK

IMPORTANT

■ Do not operate tractor and mower until this

interference check has been performed. If you change tractors, you must perform the check for that mounting.

Perform this check with all of the spacers and springs above the caster wheel arm. This will place the caster

CD3528C

Figure 9. Front Gauge Wheel Interference Check

FRONT ROLLER (OPTIONAL)

The caster wheels and side skids effectively reduce scalping in most cases. However, you may encounter areas where the caster wheels and/or side skids drop into depressions and allow center of the mower to contact ground and scalp. An optional front roller may be installed to minimize scalping.

OPERATING TECHNIQUE

 Stop power unit and implement immediately upon striking an obstruction. Dismount power unit, using proper procedure. Inspect and repair any damage before resuming operation.

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

MAN0180 (Rev. 1/7/2005)

Operation 11

Page 14

If mower becomes plugged causing belt to slip for over two seconds follow these steps:

1. Maneuver equipment into a previously cut area and allow mower to clear accumulated material.

2. Continue running at least two minutes, allowing pulleys to cool. Stopping the mower in contact with a very hot pulley will bake and ruin belt.

Proper ground speed will depend upon the terrain, the height, and type and density of material to be cut.

12 Operation

MAN0180 (Rev. 1/7/2005)

Page 15

OWNER PRE-OPERATION CHECK LIST

(OWNER'S RESPONSIBILITY)

___ Review and follow all safety rules and safety

decal instructions on pages 3 through 7.

___ Check that all safety decals are installed and in

good condition. Replace if damaged.

___ Check that all shields and guards are properly

installed and in good condition. Replace if damaged.

___ Check that chain shielding is in good condition

and replace any damaged chain links.

___ Check that all hardware and cotter pins are prop-

erly installed and secured.

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

tion, and installed correctly. 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.

___ Make sure the driveline guards and tether chains

are in good condition. Guards must rotate freely on driveline. Fasten tether chains to the tractor and the equipment as instructed.

___ Inspect area and remove stones, branches or

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

___ Do not allow riders.

___ Check all lubrication points and grease as

instructed in “Lubrication Information” on page

14. 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.

___ Make sure tractor ROPS or ROPS cab and seat

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

___ 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.

NOTES

MAN0180 (Rev. 1/7/2005)

Operation 13

Page 16

OWNER SERVICE

CAUTION

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

WARNING

 Never allow children or untrained persons to operate equipment.

 Keep bystanders away from equipment.

 Before working underneath, carefully read Oper-

ator’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.

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

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

BLOCKING METHOD

Do not work underneath mower unless it is properly attached to the tractor and blocked securely. When properly attached, the unit will be anchored to minimize front to rear movement.

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

The only approved blocking device for this mower is a jackstand with a load rating of 1000 pounds or more. One jackstand under each corner of the mower (four total) must be installed before working underneath this unit.

Install jackstands under each corner of the mower.

When blocking, you must consider overall stability of the unit. Just blocking under the unit will not ensure your safety. The working surface must be level and solid to support the loaded weight of the jackstands. Test jackstands stability before working under any portion of the mower.

Figure 11. Blocking Method

LUBRICATION INFORMATION

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

Figure 12 shows the lubrication points. The accompanying chart gives the frequency of lubrication in operating hours, based on normal operating conditions.

Severe or unusual conditions may require more frequent lubrication. Some reference numbers have more than one location; be sure you lubricate all locations.

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

14 Owner Service

MAN0180 (Rev. 1/7/2005)

Page 17

Use SAE 90W gear lube in the gearbox. Fill to plug on side of gearbox.

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

Driveshaft Lubrication

Lubricate the driveshaft slip joint every 8 operating hours. Failure to maintain proper lubrication could result in damage to U-joints, gearbox, and driveshaft.

1. Lower mower to ground.

2. Apply grease at three locations as shown in Figure

12.

Overfilling the gearbox will cause the excess gear lube to blow out vent plug and ruin the belt.

CD4985

3. Raise and lower mower several times to distribute grease.

REF DESCRIPTION FREQUENCY

1 Front U-Joint 8 Hours

(Rev. 4/28/2006)

MAN0180 (Rev. 1/7/2005)

Caster Wheel (Four wheels) 8 Hours

Caster Pivot (Four wheels) 8 Hours

Left Spindle (Access through hole) 24 Hours

Shield Bearings 8 Hours

Rear U-Joint 8 Hours

Gearbox (Fill to center of horizontal shaft with SAE 90W gear lube) Check Daily

Right Spindle (Access through hole) 24 Hours

Center Spindle (Access through hole) 24 Hours

Slip Joints (3 Sides) 8 Hours

Figure 12. Lubrication Points & Chart

Owner Service 15

Page 18

BELT SERVICE

CAUTION

Belt Replacement

One of the major causes of belt failure is improper installation. Before installing a new belt, check the following:

6. Adjust belt guide G to provide 1/16" to 1/8" clearance from belt. Tighten bolt to 85 lb.-ft.

BLADE SERVICE

1. Check pulley shafts and bearings for wear.

2. Check pulley grooves for cleanliness.

3. Make sure spindles turn freely and without wobble.

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

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

WARNING

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

Blade Installation

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

1. Place cap screws (3) through outer holes in blade

and spindle shaft.

Figure 13. Belt Routing

Belt Installation

Refer to Figure 13.

1. Disconnect idler spring from deck lug I.

2. Slide belt under drive pulley A and over idler arm.

Position belt around drive pulley A.

3. Loosen bolt holding belt guide G and swing it away from pulley B. Route belt around pulley B, idler C and pulley D as shown.

4. Make sure belt is on drive pulley A, route around idler F, and connect idler spring to lug I on deck.

5. Grasp belt between spindle pulley E, spring loaded idler F and spindle pulley D. Pull spring loaded idler with belt to obtain enough belt length to route it over pulley E. Make sure spring-loaded idler pivots freely with belt installed.

IMPORTANT

■ Use care when installing or removing belt from

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

2. Make sure blade cutting edge is positioned to lead

in a clockwise rotation, as viewed from top of mower.

3. Place locknuts (4) on screws, torque to 84 lbs-ft.

Figure 14. Blade Assembly

16 Owner Service

MAN0180 (Rev. 1/7/2005)

Page 19

Blade Sharpening

IMPORTANT

■ When sharpening blades, be sure to balance

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

1. Remove blades.

2. Always sharpen both ends at the same time to

maintain balance.

3. Follow original sharpening pattern.

4. Do not sharpen blade to a razor edge. Leave from

1/32" to 1/16" blunt edge.

5. Do not sharpen back side.

Figure 15. Blade Sharpening

CHAIN SHIELDING

DANGER

 Full chain, rubber, curtain, or belt shielding, designed to reduce the possibility of thrown objects, must be installed when operating in populated areas or other areas where thrown objects

could injure people or damage property. If this machine is not equipped with full chain, rubber, curtain, or belt shielding, operation must be stopped when anyone comes within several hundred feet.

Check that chain shielding is in good condition and replace any damaged chain links.

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.

MAN0180 (Rev. 1/7/2005)

Owner Service 17

Page 20

TROUBLE SHOOTING

MOWING CONDITIONS

PROBLEM POSSIBLE CAUSE SOLUTION

Grass cut higher in center of swath than at edge

Grass cut lower in center of swath than at edge

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

Height of mower higher at front than at rear

Loose Blade Check blade hardware.

Height of mower lower at front than at rear

Loose Blade Check blade hardware

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

Dull blades Sharpen or replace blades.

Adjust mower height and attitude so that mower rear and front are within 1/2 inch of same height. See instructions on page 9.

Slow ground speed of tractor but keep engine running at full PTO rpm. Cutting lower will help. Adjust tractor tire spacing if possible.

Material discharges from mower unevenly; bunches of material along swath

Loose Blade Check blade hardware.

Material too high and too much material

Grass wet Allow grass to dry before mowing.

Reduce ground speed but maintain 540 rpm at tractor PTO, or make two passes over material. Raise mower for the first pass and lower for the second and cut 90 degrees to first pass. Raise rear of mower high enough to permit material discharge, but not so high that conditions listed above occur.

Slow ground speed of tractor but keep engine running at full PTO rpm.

18 Owner Service

MAN0180 (Rev. 1/7/2005)

Page 21

TROUBLE SHOOTING

BELT CONDITIONS

PROBLEM POSSIBLE CAUSE SOLUTION

Belt slippage Mower overloading; Material too

tall or heavy

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

Belt hung up or rubbing Check belt position in pulleys and

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

Pulley misaligned Inspect to ensure belt is running in

Reduce tractor ground speed but maintain full PTO rpm. Cut material twice, one high pass and then mow at desired height. Cut 90 degrees to first pass.

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

idlers. Check belt for free travel in pulleys. Check under mower and around blade spindle shaft for wire, rags, or other foreign material. Clean all material from under mower.

rub any other part while running.

center of backside idler. Shim idler as necessary to align.

Belt rollover Pulley misaligned Re-align.

Damaged belt Replace belt*.

Foreign object in pulley groove Inspect all pulley grooves for rust,

paint, or weld spots and remove.

Worn pulley groove Replace pulley.

Damaged belt Rollover, high shock loads or

installation damaged

Belt breakage High shock loads Avoid abusive mowing. Avoid hitting

Belt came off drive Check pulleys for foreign material in

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

Replace belt*.

the ground or large obstructions.

grooves. Avoid hitting solid objects or ground.

MAN0180 (Rev. 1/7/2005)

Owner Service 19

Page 22

DEALER SERVICE

CAUTION

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.

WARNING

 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.

CD4985-1

Figure 16. Blocking Method

BLADE SPINDLE SERVICE

Spindle repair requires special skills and tools. If your shop is not properly equipped or your mechanics are not trained in this type of repair, you may be time and money ahead to use a new spindle assembly.

BLOCKING METHOD

Do not work underneath mower unless it is properly attached to the tractor and blocked securely. When properly attached, the unit will be anchored to minimize front to rear movement.

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

The only approved blocking device for this mower is a jackstand with a load rating of 1000 pounds or more. One jackstands under each corner of the mower (four total) must be installed before working underneath this unit.

Install jackstands under each corner of the mower.

For reference, the grease fitting is in the top of the spindle shaft.

Per matex is recommended as a sealant.

®1

3D Aviation Form-A-Gasket or equivalent

Spindle Removal

1. Remove blade from spindle.

2. Remove belt from pulleys.

3. Remove jam nut (1) and washer (3) from top of

spindle shaft.

4. Disassemble split taper bushing (5) (located on top of pulley) by removing the two bolts (2) and washers (4).

5. Insert bolts (2) into the threaded holes of bushing flange.

6. Tighten bolts alternately to remove split taper bushing.

7. Remove pulley (6).

8. Remove bolts (19) that attach spindle to mower

frame and remove spindle.

9. Remove grease fitting (21) from top of shaft.

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

20 Dealer Service

MAN0180 (Rev. 1/7/2005)

Page 23

1 3

1. 7/8 NF Jam nut

2. 1/4 NC x 1 HHCS GR5

3. .929 x 1.66 Lock washer

4. 1/4 Lock washer

5. Bushing, H 1 straight bore w/ke

Seal Lip

CD5055-1

6. Sheave, H 1 BK

19. 1/2 NF x 1-1/4 HHCS GR5

21.Grease fitting

Figure 17. Sheave and Blade Assembly

Spindle Disassembly

1. Place spindle assembly in press and press shaft

down through housing.

2. Remove seals from housing.

Spindle Assembly

Refer to Figure 18.

Bearing cones and cups are designed to work together. It is important to position them so bearing cone taper mates with cup taper.

1. Lubricate new cups with a light oil. Place them in spindle housing so they will mate with bearing cones. Cups and cones are a press fit to minimize wear.

Seat cups securely with a press or place a large drift in the flat lip and drive them into housing until cup seats against machined shoulder of housing.

Remove bearing cups from housing by placing a punch in the slots provided and driving them out. Alternate punch positions from side to side. Take care to prevent housing damage.

2. Place bottom bearing cone into spindle with taper positioned to mate with cup.

1. Grease fitting

2. Seal, 1.50 x 2.12 x .31

3. Sleeve, 1.14 x 1.50 x .55

4. Bearing, cone

5. Bearing, cup

6. Spindle, housing

7. Shaft, blade spindle

Figure 18. Spindle and Shaft Assembly

Seal Lip

CD5061

IMPORTANT

■ Improper positioning of seals can cause seal

damage. An improperly installed seal will leak and could cause bearing failure.

3. Identify the open side of the seal containing the

spring.

4. Apply a thin coat of Permatex to the area of housing where seals seat.

5. Install bottom seal with spring up toward center of housing.

6. Place seal squarely on housing and select a piece of pipe or tubing with an OD that will set on outside edge of seal. A tubing with an OD that is too small will bow seal cage.

7. Carefully press seal into housing, to prevent distortion to metal seal cage. Bottom seal should seat firmly and squarely against machined shoulder in housing.

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

9. Insert shaft and bearing through bottom of housing.

10. Fill housing cavity with a medium grade grease.

11. Install top bearing on shaft to mate with top cone.

MAN0180 (Rev. 1/7/2005)

Dealer Service 21

Page 24

Refer to Figure 19.

12. Apply a thin coat of Permatex to shaft area where

sleeve will seat.

13. Install sleeve on shaft and press sleeve and bearing into housing until all free play is removed and there is a very light drag on bearings (similar to adjusting front wheel bearings on an automobile). Check by spinning spindle. It should turn freely.

14. Be careful not to overtighten bearings. Proper bearing adjustment is essential to good bearing life.

15. If you overtighten bearings, hold spindle housing and rap spindle shaft with a lead hammer.

16. Carefully press top seal in with spring up. Top seal should be flush with or to within 1/16" above the housing.

17. Rotate housing on spindle shaft, checking for free movement.

18. Install grease fitting in spindle shaft.

2. Install pulley and split taper bushing with integral

key on spindle shaft. Make sure bushing is in contact with sleeve on spindle shaft.

3. Alternately tighten split taper bushing cap screws to 12 lbs-ft.

4. Install toothed lock washer and nut on spindle shaft. Tighten nut until snug. Bend up edge of lock washer against a flat side on nut.

GEARBOX REPAIR

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

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

Repair to this gearbox is limited to replacing bearings, seals, and gaskets. Replacing gears, shafts, and a housing is not cost effective. It is more economical to purchase a complete gearbox if repair to anything other than replacement of bearings, seals or gaskets is required.

Seal Lip

1. Grease fitting

2. Seal, 1.50 x 2.12 x .31

3. Sleeve, 1.14 x 1.50 x .55

4. Bearing, cone

5. Bearing, cup

6. Spindle, housing

7. Shaft, blade spindle

Figure 19. Spindle & Shaft Assembly

Seal Lip

CD5061

Spindle Installation

IMPORTANT

■ Pulley installation sequence is very important

for bearing life. Follow the sequence exactly.

Inspect gearbox for leakage and bad bearings.

Leakage is a very serious problem and must be corrected immediately.

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

Seal Replacement

Recommended sealant for gearbox repair is Perma-

tex

Aviation 3D Form-A-Gasket or equivalent.

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

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.

1. Install spindle through bottom of mower and secure with four mounting bolts.

22 Dealer Service

5. Carefully press seal into housing, avoiding

distortion to the metal seal cage.

MAN0180 (Rev. 1/7/2005)

Page 25

1. Seal

2. Pipe or tube

3. Seal seat

4. Casting

3. Remove gearbox stand from mower deck.

4. Remove gearbox and pulley from gearbox stand.

5. Remove vertical shaft seal (18). Replace with new seal (see Seal Replacement, page 22).

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

CD1094

Pipe or tube must press at outer

Incorrect

CD1092

Installation

Figure 20. Seal Installation

edge of seal

Vertical Shaft Seal Replacement

1. Disconnect and remove the driveline from the

gearbox.

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

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

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

7. Assemble gearbox and pulley to gearbox stand. Attach gearbox stand to mower deck.

Horizontal Shaft Seal Replacement

1. Disconnect and remove the driveline from the

gearbox.

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

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

22).

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

MAN0180 (Rev. 1/7/2005)

Figure 21. Gearbox Assembly

Dealer Service 23

Page 26

Remove Gearbox from Mower

Refer to Figure 22.

1. Disconnect and remove the rear driveline from the

gearbox.

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

3. Remove gearbox stand (20) from mower deck by removing four flanged lock nuts (56).

4. Remove four cap screws (43) and washers (42) and remove shield (22) from gearbox.

5. Remove castle nut and hardware from output shaft of gearbox.

6. Remove sheave (19) from gearbox.

7. Remove four bolts (63) that attach gearbox to

gearbox stand and remove gearbox.

Vent Plug

Castle Nut

19. Sheave, offset 12.4 PD

20. Gearbox stand

22. Shield, counter cone

42. Washer, flat standard 5/16

43. Screw, HHCS 8mm x 1.25P x 16mm

56. Nut, flanged lock 1/2 NC

59. Nut, flanged lock 5/8 NC

63. Screw, Flanged Hex Head 5/8 NC x 1-3/4

Figure 22. Gearbox Stand Assembly

CD4986A-1

Disassemble Gearbox

1. Remove top cover (22) from housing. Turn gearbox

upside down and pour out remaining gear oil from gearbox.

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 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) and cotter pin (25) are already

removed with the drive sheave. Remove the snap ring (21), washer (8), and seal (18).

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

12. Remove output shaft (4) by using a punch and hammer and tap on top to drive down.

13. Remove gear (5) and shim (16) from inside housing.

14. Remove bearing (26) by using a punch and hammer from the top, outside the housing.

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

16. 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.

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

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

Reassemble Gearbox

Refer to Figure 23

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.

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 output bearings (6 & 26) in the housing, using a round tube of the correct diameter and a hand press.

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

26) until it rests against bearing (6).

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

24 Dealer Service

MAN0180 (Rev. 1/7/2005)

Page 27

Figure 23. Gearbox Assembly

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

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

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

8. Insert protective washer (8) by hand. Install snap ring (21) and position it together with dual lip seal (18) by pressing it into position. Verify that snap ring 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 spacer (12) over input shaft (3) and press bearing 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.

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

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

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

MAN0180 (Rev. 1/7/2005)

Dealer Service 25

Page 28

Install Gearbox

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

out mechanical assistance.

1. Set gearbox on gearbox stand and fasten with bolts and nuts. Torque bolts to 175 lbs-ft.

2. Attach drive sheave to output shaft. Secure using castle nut and hardware previously removed.

3. Attach gearbox stand to mower using four flanged lock nuts.

Install Drive Sheave

1. When gear stand is installed on mower, dimension

A (from the top of the mower deck to the center line of the drive pulley) must be 2-7/16" (±1/32"). This is a critical dimension and must be carefully adjusted for proper belt life. Add or subtract shim washers under idler pulley to align with drive pulley.

2. Tighten gear stand hardware.

UNIVERSAL JOINT REPAIR

1. Yoke

2. Cup and bearings

3. Snap ring

4. Journal cross

Figure 25. U-Joint Exploded View

CD1645A

U-Joint Disassembly

1. Remove external snap rings from yokes in four

locations as shown in Figure 26.

3. Fill gearbox half full with SAE 90W gear lube.

4. Check level after waiting five minutes to permit

lube to work through bearings. Add lube, if necessary, until gearbox is half full.

5. Replace driveline shield. Attach driveline to gearbox.

CD4991

3125 4

1. Shim

2. Idler arm

3. Idler pulley

4. Drive sheave

5. Castle nut & cotter pin

6. Gearbox stand

CD1385A

Figure 26

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 27.

CD1386

Figure 24. Drive Sheave Installation

26 Dealer Service

Figure 27

MAN0180 (Rev. 1/7/2005)

Page 29

3. Clamp cup in vise as shown in Figure 28 and tap on yoke to completely remove cup from yoke. Repeat Step 2 and Step 3 for opposite cup.

CD1387

Figure 28

4. Place universal cross in vise as shown in Figure 29

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

U-Joint Assembly

1. Place seals securely on bearing cups. Insert cup

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

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 30. Install snap ring and repeat on opposite cup.

4. Repeat Step 1 & 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.

Figure 29

MAN0180 (Rev. 1/7/2005)

CD1388

CD1389

Figure 30

Dealer Service 27

Page 30

ASSEMBLY INSTRUCTIONS

CAUTION

DEALER SET-UP INSTRUCTIONS

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

Complete Dealer Check Lists on page 32 when you have completed the assembly.

The mower is shipped partially assembled. Assembly will be easier if components are aligned and loosely assembled before tightening hardware. Recommended torque values for hardware are located on page 41.

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

CM824

Figure 31 Uncrate Mower

Install Front Offset Links

1. Loosen lock nuts at lower hitch point and install

offset link as shown.

WARNING

Uncrate Mower

2. Tighten nut securely.

3. Repeat for opposite side.

NOTE: Front link with the PTO storage bracket should

be installed on right side of mower as shown in Figure

32.

Rear Offset Links

Front Offset Link

PTO Storage Bracket

Front Offset Link

1. Remove sides and top of mower shipping crate.

2. Remove lag screws and brackets that secure

mower to crate base.

3. Remove driveshaft wired to mower deck.

28 Assembly

Lock Nuts

CM832

Figure 32. Front Offset Links Installed

MAN0180 (Rev. 1/7/2005)

Page 31

Install Rear Offset Links

1. Loosen nut (56) at rear frame lug and attach offset

link (13) as shown in Figure 33.

2. Repeat for opposite side.

3. Do not tighten at this time.

13. Link, rear offset

56. Nut, flanged lock 1/2 NC

Figure 33. Right Rear Offset Link Installed

CM905

1. Insert cap screw (54) through rear offset links (13), pipe (49), U-bracket (15) and front offset links (14) as shown and tighten securely with nut (56).

2. Tighten hardware on rear frame lug and offset link.

Install Rear Caster Arm

1. Remove rear caster wheel assembly (3) from

shipping position and install as shown in Figure 35 using the same bolts (51) and nuts (56).

2. Repeat for opposite side.

3. Tighten bolts so that caster arm is snug against

deck bracket, but not fully torqued. NOTE: Refer to Front Caster Wheel Interference

Check, page 11 for possible front caster arm positions.

4. Attach front caster arm in desired position and tighten snug against deck bracket.

Install Top Link

Figure 34. Top Link Assembled

Figure 35. Rear Caster Arm Installed

CM757

Torque Caster Arm Hardware

1. Lift mower off shipping pallet and set on a hard level surface. This allows clearance in the caster wheel assemblies to be equalized.

2. Tighten all cap screws and nuts on all four caster wheel arms.

3. Tighten all cap screws and nuts to specifications found in Bolt Torque Chart on page 41.

MAN0180 (Rev. 1/7/2005)

Assembly 29

Page 32

Install Driveline Shield (RD8400-2)

The counter-cone drive shield is factory installed on models RD6000-2 and RD7200-2.

On the RD8400-2 model, attach counter-cone shield (22) to gearbox (21) with cap screws (43) and flat washers (42). Orient chain attachment lug as shown.

Chain Attachment Lug

3. Pour in one pint of gear lube, wait five minutes and add additional gear lube until it just comes out of side hole.

4. Allow an additional five minutes for the lube to flow through bearings, then check to make sure oil level is at bottom of side hole. Replace side plug. Install vent plug.

IMPORTANT

■ Gearbox is not filled at the factory. Prior to

delivery, make sure each gearbox is filled half-full with 80W or 90W API GL-4 or GL-5 gear lube.

Install Chain Shielding (Optional)

CD5064

A. Gearbox input shaft B. QD Yoke C. Shield retainer D. Anti-rotation chain

21. Gearbox

22. Shield, counter cone

23. Driveline

42. Washer, flat standard 5/16

43. Screw, HHCS 8mm x 1.25P x 16mm

Figure 36. Rear Driveshaft Installation

Install Driveshaft

1. Slide QD yoke (B) of driveshaft assembly onto

gearbox shaft (A). Make sure QD yoke pin is seated securely in groove of gearbox shaft.

2. Attach shield anti-rotation chain (D) to drive shield (22) as shown.

Fill Gearbox

CM768

3. Shield, chain plate

14. Bolt, carriage 3/8 NC x 1

15. Nut, flanged lock 3/8 NC

Figure 37. Chain Shield Installed

DANGER

1. Make sure vent plug hole is clear. Fill gearbox half-

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

2. Fill gearbox until oil runs out the side plug on gearbox.

30 Assembly

1. Install chain shielding plate (3) to rear mower frame

as shown.

2. Secure with carriage bolts (14) and flanged lock nuts (15).

3. Inserted carriage bolts from bottom upward as shown.

MAN0180 (Rev. 1/7/2005)

Page 33

Install Quick Hitch Kit (Optional)

NOTE: Figure 38 shows RM660, other models use the

same assembly instructions.

NOTE: This kit allows mower to fit only Cat. 1 standard ASAE quick hitch.

Figure 38. Quick Hitch Kit Installation

1. Attach offset link (1) to mounting pins, using 7/8"

sleeve (8) and flat washer (9). Do not tighten hardware.

2. Attach upper end of offset link to pivot link, using flat washer (5), sleeves (6 & 10), flange lock nut (7), and 1/2" x 4-3/4" cap screw.

MAN0180 (Rev. 1/7/2005)

Assembly 31

Page 34

DEALER CHECK LISTS

DEALER 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.

___ 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.

DEALER DELIVERY CHECK LIST

(DEALER’S RESPONSIBILITY)

___ Show customer how to make adjustments and

select proper PTO speed.

___ Instruct customer how to lubricate and explain

importance of lubrication.

___ Point out the safety decals. Explain their mean-

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

___ Present Operator's Manual and request that

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

___ 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.

___ Show customer the safe, proper procedures to

be used when mounting, dismounting, and storing equipment.

___ Check all bolts to be sure they are properly

torqued.

___ Check that all cotter pins and safety pins are

properly installed. Replace if damaged.

___ Check and grease all lubrication points as iden-

tified in “Lubrication Information” on page 14.”

___ Gearboxes are not filled at the factory. Prior to

delivery, fill as specified in the "Service, lubrication information" on page 14 and check to see that there are no leaking seals.

___ Check that blades have been properly installed.

___ 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 "Service, blocking methods" section of the operators manual. Explain that blocking up prevents equipment dropping from hydraulic leak down, hydraulic system failures or mechanical component failures.

___ For mounted units, add wheel weights, ballast in

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

___ Make customer aware of optional equipment

available so that customer can make proper choices as required.

___ Point out all guards and shields. Explain their

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

32 Dealer Check Lists

MAN0180 (Rev. 1/7/2005)

Page 35

PARTS INDEX

Rear Discharge Mowers: RD6000-2 RD7200-2 RD8400-2

MAIN FRAME ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 - 35

GEARBOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

DRIVESHAFT ASSEMBLY (WALTERSCHEID TWO-LOBE) . . . . . . . . 37

BLADE & SPINDLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

REAR CHAIN SHIELDING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 39

FRONT ROLLER ASSEMBLY (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . 39

QUICK HITCH (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

MAN0180 (Rev. 1/7/2005)

Parts 33

Page 36

RD6000-2, RD7200-2 & RD8400-2 MAIN FRAME ASSEMBLY

34 Parts

MAN0180 (Rev. 1/7/2005)

Page 37

RD6000-2, RD7200-2 & RD8400-2 MAIN FRAME ASSEMBLY

REF PART QTY REF

9 – – –– – CW Spindle Assembly (see page 38)

10 1001244 1 V-Belt W99 (used on RD6000-2 only)

or-

10 18879 1 V-Belt W112 (used on RD7200-2 only)

-or-

10 53418 1 V-Belt W157 (used on RD8400-2 only)

11 53567 1 Guide, Belt 8 GA Formed

12 64555 1 Idler, Flat 5.5 Dia.

13 55331 2 Link, Rear Offset (for RD6000-2 only) -

or-

13 19578 Link, Rear Offset (for RD7200-2 only) -

or-

13 52873 2 Link, Rear Offset (for RD8400-2 only)

14 19579 2 Link, Front Offset

15 19605 1 Link, U-Bracket

16 52893 1 Bracket, PTO Hanger

17A 55340 1 Shield, Belt RD6000-2 -or-

17A 53539 1 Shield, Belt RD7200-2 -or-

17A 52874 1 Shield, Belt Right RD8400-2

17B 55340 1 Shield, Belt RD6000-2 -or-

17B 53539 1 Shield, Belt RD7200-2 -or-

17B 52875 1 Shield, Belt Left RD8400-2

18 29792 * 1 Key, 1/4 x 1/4 x 1-1/4

19 65197 1 Sheave, Offset 12.4 PD

20 53534 1 Gearbox Stand

21 1002499 1 Gearbox 1:1.92

22 51849 1 Shield, Counter Cone

23 40551 1 Drive, Cmpl 1240, 29.9 x 41.8

24 67131 1 Spring, Ext .177 x 1.22 x 9.88

25 53595 1 Idler, Flat 5.0 Dia.

RD6000-2 & RD7200-2

25 64555 1 Idler, Flat 5.5 Dia. RD8400-2

26 58989 1 Idler Arm

27 55344 1 Complete Decal Set (RD6000-2) -or-

27 53589 1 Complete Decal Set (RD7200-2) -or-

27 52889 1 Complete Decal Set (RD8400-2)

28 53590 1 French Safety Decal Set

29 53591 1 English Safety Decal Set

30 18824 2 Bracket, Htch Pin

40 35141 Ring, Retaining

41 12296 * Grease Fitting 1/4-28, 15/32 Long

42 4378 * Washer, Flat Standard 5/16

43 39254 Screw, HHCS 8mm x 1.25P x 16mm

44 62153 Bolt, Flanged Whiz 3/8 NC x 1

REF PART QTY DESCRIPTION

45 855 * Washer, Lock 1/2

46 24537 Washer, Flat .50 x 1.38 x .38 (used on

RD6000-2 & RD7200-2) -or-

46 22166 Washer, Flat .50 x 1.00 x .25

(used on RD8400-2)

47 33677 Washer, Flat .50 x 1.56 x 10 GA

48 31983 Washer, Shim .50 x .88 x 18 GA

49 64814 Sleeve .62 x .84 x 2.75

50 6100 * Screw, HHCS 1/2 NC x 1-1/4 GR5

51 24576 * Screw, HHCS 1/2 NC x 1-3/4 GR5

52 1517 Washer, Flat .63 x 1.38 x 7 GA

53 639 * Screw, HHCS 1/2 NC x 2-1/2 GR5

54 29561 * Screw, HHCS 1/2 NC x 4-3/4 GR5

55 23479 * Screw, HHCS 1/2 x 5 GR5

56 11900 * Nut, Flanged Lock 1/2 NC

57 29368 Sleeve .50 x .75 x 3.38 (HD tires) -or-

57 19749 Sleeve, .50 x .75 x 4.0625

(pneumatic tires)

58 52877 Sleeve, .504 x .625 x .64 (RD8400-2)

59 19025 Nut, Flanged Lock 5/8 NC

60 22060 Seal, Felt .63 x 1.00 x .25

61 484 Sleeve, HT .63 x 1.00 x .44

62 1791 Sleeve, HT .63 x 1.00 x .56

63 19024 Screw, Flngd Hex Head

5/8 NC x 1-3/4

64 34473 * Screw, HHCS 5/8 NC x 3 GR5

65 302178 Nut, Castle 5/8 NF

66 35193 Bearing

67 30007 * Nut, Hex 7/8 NF

68 30008 * Washer, Lock 7/8

69 33647 Sleeve 1.05 x 1.31 x .75 (used on

RD6000-2 & RD7200-2) -or-

69 52854 Sleeve 1.28 x 1.66 x .75 (RD8400-2)

70 65129 Sleeve 1.05 x 1.31 x .50 (used on

RD6000-2 & RD7200-2) -or-

70 52853 Sleeve 1.28 x 1.66 x .50 (RD8400-2)

71 65130 Sleeve 1.05 x 1.31 x 1.00 (used on

RD6000-2 & RD7200-2) -or-

71 52855 Sleeve 1.28 x 1.66 x 1.00 (RD8400-2)

72 1266 * 1 Pin, Cotter 3/16 x 1-1/2

73 1003828 1 Manual Tube

74 6697 * 2 Bolt, Carriage 3/8 NC x 1 GR5

75 14350 2 Nut, Flanged Lock 3/8 NC

76 53543 1 Idler post

* Obtain locally

(Rev. 4/28/2006)

MAN0180 (Rev. 1/7/2005)

Parts 35

Page 38

RD6000-2, RD7200-2 & RD8400-2 GEARBOX ASSEMBLY

36 Parts

MAN0180 (Rev. 1/7/2005)

Page 39

RD6000-2, RD7200-2 & RD8400-2 DRIVESHAFT

WALTERSCHEID (TWO-LOBE SHAFT)

REF PART QTY DESCRIPTION

40551 1 Complete Drive Shaft

1 40571 2 Yoke, 1-3/8-6 Spline Q

2 154 2 U-Joint Repair Kit L14R

3 40775 2 Pin, Spring 10mm x 65mm

4 40572 1 Yoke, Inner Profile

5 40583 1 Drive Tube, Inner Profile

6 40584 1 Drive Tube, Outer Profile

7 40573 1 Yoke, Outer Profile

12 40776 2 Bearing Ring, Guard

13 40777 2 Chain, Guard Anti-Rotation

CD5556

REF PART QTY DESCRIPTION

14 40778 2 Screw, Guard Retainer

17 40779 1 Grease Zerk, Drive Line

18 40780 1 Bearing, Guard Support

20 40589 2 Slide Lock Collar Repair Kit

(without yoke)

21 40585 1 Guard, Outer Half

(also includes items 12, 13 and 14)

22 40586 1 Guard, Inner Half

(also includes items 12, 13, 14 and 18)

23 40581 1 Drive, Inner Half Complete

24 40582 1 Drive, Outer Half Complete

MAN0180 (Rev. 1/7/2005)

Parts 37

Page 40

RD6000-2, RD7200-2 & RD8400-2 BLADE & SPINDLE ASSEMBLY

REF PART QTY DESCRIPTION

1 37009 Nut, Jam 7/8 NF

2 10378 * Screw HHCS 1/4 NC x 1 GR5

3 52898 Washer, Lock .929 x 1.66

4 1985 * Washer, Lock 1/4

5 34440 Bushing, H 1 Straight bore w/key

6 66694 Sheave, H 1 BK 4.17 PD (RD6000-2)

-or-

6 12622 Sheave, H 1 BK 5.0 PD (RD7200-2)

-or-

6 53419 Sheave, H 1 BK 5.9 PD (RD8400-2)

7 52881 Spindle Assembly Complete

8 52949 Seal 1.50 x 2.12 x .31

9 52872 Sleeve 1.14 x 1.50 x .55

10 29899 Bearing, Cone

11 52882 Spindle, Housing with Cups

12 29898 Bearing, Cup

14 52852 Shaft, Blade Spindle

16 1001513KT Blade Kit, High Suction 21 In

(set of 3) (RD6000-2)

16 1008199KT Blade Kit, High Suction 25 In

(set of 3) (RD7200-2)

16 53417KT Blade Kit, High Suction 29.33 In

(set of 3) (RD8400-2)

16 1001510KT Blade Kit, Low Suction 21 In

(set of 3) (RD6000-2)

16 1001511KT Blade Kit, Low Suction 25 In

(set of 3) (RD7200-2)

16 1001512KT Blade Kit, Low Suction 29.33 Im

(set of 3) (RD8400-2)

19 4358 Screw, HHCS 1/2 NF x 1-1/4 GR5

21 1972 Grease Fitting, 1/4-28 tapered thread

22 3379 Screw, HHCS 1/2 NC x 1-1/2 GR5

23 11900 Nut, Flanged Lock 1/2 NC

SEAL LIP

CD5055

* Standard Hardware - Obtain Locally

38 Parts

MAN0180 (Rev. 1/7/2005)

Page 41

RD6000-2, RD7200-2 & RD8400-2

REAR CHAIN SHIELDING ASSEMBLY (OPTIONAL)

RD6000-2, RD7200-2 & RD8400-2 FRONT ROLLER ASSEMBLY (OPTIONAL)

MAN0180 (Rev. 1/7/2005)

Parts 39

Page 42

QUICK HITCH KIT (OPTIONAL)

1/2 x 4-3/4 HHCS

REF PART QTY DESCRIPTION

1 1003692 2 Link, Offset .38 x 2.0 x 15

2 1005401 2 Chain 3/8 Proof Coil 38 Link

3 38214 2 Sleeve, .91 x 1.44 x 1.25

4 13563 1 Screw, HHCS 1/2 NC x 6 GR5

5 * 6 Washer, Flat 1/2 ZP

6 29368 1 Sleeve, .50 x .75 x 3.38

7 11900 1 Nut, Flange Lock 1/2 NC

8 29281 2 Sleeve, 7/8 x 1-1/8 x 19/32 HT

9 * 2 Washer, Flat 7/8

10 1003614 1 Sleeve, .81 x 1.25 x 1.81

CD6080A

40 Parts

* Standard Hardware, Obtain Locally

MAN0180 (Rev. 1/7/2005)

Page 43

BOLT TORQUE CHART

(

)

(

)

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

SAE SERIES

Diameter

(Inches)

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

5/16"1/2"121719262737

3/8"9/16"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

TORQUE CHART

Wrench

Size

SAE Grade 2

(No Dashes)

SAE 2 SAE 5 SAE 8

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

METRIC SERIES

TORQUE CHART

Diameter &

Thread Pitch

(Millimeters)

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

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

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

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

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

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

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

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

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

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

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

Wrench

Size

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

COARSE THREAD FINE THREAD

MARKING ON HEAD MARKING ON HEAD

Metric 8.8 Metric 10.9 Metric 8.8 Metric 10.9

SAE Bolt Head

Identification

8.8

Metric

Grade 8.8

SAE Grade 5

3 Radial Dashes

MARKING ON HEAD

Metric Bolt Head

Identification

SAE Grade 8

6 Radial Dashes

10.9

Metric

Grade 10.9

Diameter &

Thread Pitch

(Millimeters)

Typical Washer Installations

Lock Washer

Bolt

Nut

Bolt Torque & Size Charts (Rev. 8/14/02)

Flat Washer

8/9/00

Appendix 41

Page 44

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

42 Appendix

Bolt Torque & Size Charts (Rev. 8/14/2002)

Page 45

INDEX

ASSEMBLY

Dealer Set-Up Instructions 28

DEALER CHECK LISTS

Delivery (Dealer’s Responsibility) 32 Pre-Delivery (Dealer’s Responsibility) 32

DEALER SERVICE

Blade Spindle

Assembly 21 Disassembly 21 Installation 22 Removal 20

Service 20 Blocking Method 20 Drive Sheave Installation 26 Gearbox

Disassembly 24

Horizontal Shaft Seal Reoplacement 23

Installation 26

Reassembly 24

Removal 24

Repair 22

Seal Installation 22

Seal Replacement 22

Vertical Shaft Seal Replacement 23 Universal Joint

Assembly 27

Disassembly 26

Repair 26

GENERAL

Abbreviations 42 Bolt Size Chart 42 Bolt Torque Chart 41 General Information 2 Introduction, Inside Front Cover Obtaining Replacement Manuals,

Inside Front Cover Specifications 2 Warranty

Product 44 Replacement Parts 45

OPERATION

Adjustment

Cutting Height 9 Cutting Height Chart 10 Tractor Top Link 10

Attaching Mower to Tractor 9

Front Caster Arm Configuration 10

Front Caster Wheel Interference Check 11

Front Roller 11

Operating

On Uneven Terrain 12 Technique 11 Tips 12

Pre-Operation Check List (Owners Responsibility)

Removing Mower from Tractor 12

Storage 12

Tractor Stability 8

OWNER SERVICE

Belt

Installation 16 Replacement 16

Blade

Install 16 Service 16 Sharpening 17

Blocking Method 14

Chain Shielding 17

Cleaning 17

Lubrication

Driveshaft 15 Information 14 Points 15

PARTS

Parts Index 33

SAFETY

Blocking Method 14, 20

Dealer Check Lists

Delivery (Dealer’s Responsibility) 32 Pre-Delivery (Dealer’s Responsibility) 32

Owner Pre-Operation (Owners Responsibility) 13

Safety & Instructional Decals 6, 7

Safety Rules 3, 4, 5

Safety Symbols explained, Inside Front Cover

TROUBLE SHOOTING

Belt Conditions 19

Mowing Conditions , Inside Front Cover

MAN0180 (Rev. 1/7/2005)

Index 43

Page 46

WARRANTY

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

Please Enter Information Below and Save for Future Reference.

Date Purchased: __________________________ From (Dealer): ________________________________________

Model Number: __________________________ Serial Number:________________________________________

Woods Equipment Company

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

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

F-3079 (Rev. 4/10/2006)

Page 47

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.

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 cover normal wear or tear, or normal maintenance items.

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

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

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

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

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

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

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

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

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

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

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

Page 48

PART NO.

MAN0180

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

© 2002 Woods Equipment Company. All rights reserved. WOODS, the Woods logo, and "Tested. Proven. Unbeatable." 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.