Yamaha YZF-R6R Automobile User Manual
Contents
1. 43 80 HP GEARBOX Ret Part Name Gearbox No 184080 1 172 Vented Pipe Plug 131035 2 Seal Input NAK SC 35X60X10 156040 3 1 8 Pipe Plug 131040 4 Endcap Input 129025 5 Gasket Input 124133 6 Bearing Race Input Timken LM603014 155015 7 Bearing Input Timken LM603049 155020 8 Spacer 9 Gear Input 185015 10 Snap Ring 131025 11 Shaft Input 186040 12 Gear Output 185035 18 Bearing Race Output Timken 362A 155037 14 Bearing Output Timken 368 155040 15 Shaft Output 186035 16 Bearing Race Output Timken 362 155036 17 Gasket Output 124134 18 Seal Output TOM 50X68X9TC 156035 19 Endcap Output 129030 20 1 Castle Nutiw Washer amp Cotter Pin 501110 45 HingKutter 1 Limited Warranty King Kutter Inc King Kutter PO Box 1200 Winfield Alabama 35594 warrants to the original retail purchaser Purchaser that the product thatis the subject of this sale is free from defects in material and workmanship atthe time of sale Under this warranty King Kutter wil repairthe defective product free of charge to the Purchaser with either new or used and reconditioned replacement arts Al warranty service willbe performed at service centers designated by King Kutter If King Kutter is unable to repair the product to conform to the warranty after a rea2. Replace any safety sign that is not readable or is missing Location of such safety signs is indicated in this manual Never use alcoholic beverages or drugs that can hinder alertness or coordination while operating this equipment Consult your doctor about operating this machine while taking prescription medications Under no circumstances should children under the age of 18 be allowed to work with this equipment Do not allow persons to operate or assemble this unit until they have read this manual and have developed a thorough understanding of the safety precautions and of how it works Review the safety instructions with all users annually This equipment is dangerous to children and persons unfamiliar with its operation The operator should be a responsible properly trained and physically able person familiar with farm machinery and trained in this equipment s operations If the elderly are assisting with farm work their physical limitations need to be recognized and accom modated Use a tractor equipped with a Roll Over Protective System and seat belts ROPS Never exceed the limits of a piece of machinery If ability to do a job or to do so safely is in question DON T TRY IT Do not modify the equipment in any way Unauthorized modification could result in serious injury or death and may impair the function and life of the equipment In addition to the design and the confirmation of this implement including safety signs
3. 147022 147022 147029 147029 147034 1470341 147034 147034 PTOShaftw Sip Clutch 1471291 147129 147134 147134 147134 147134 9 Lift Arms 310087 310088 310088 310088 310091 310081 310091 310091 10 CAT 1 Lift Pins Pkg of 2 500001 500001 500001 500001 500001 500001 500001 500001 11 LiftArm Support Strap 310071 310071310071 310071 310071 310071 310071 12 Blade Carrier 403030 5 2 13 Stump Jumper 408061 403081 408081 2 403031 403032 14 Blade BoltSet Pko 0f2 501001 501001 501001 501001 501001 501001 501001 501001 15 Mower Blade Soe of2 501118 501118 501124 501124 501127 501127 501130 501130 16 Swivel 501027 501027 so1027 501027 501027 501007 501027 17 WheelWasherKit 501013 s01013 501013 501013 501013 501013 501013 501013 18 Shear Bolt Kit Pkg 5 500101 500101 800101 00101 500101 500101 500101 500101 32 5 Depeniing on he size a rotary mower purchased the Blade carrier can be any of these 2 Types 40 Mower doesn t have a swivel Ret Ne Part Name Part Number Rotary Mower Size 5760 5780hp 1 Tire amp Rim jw Hub 501000 501000 2 Wheel Fork Assembly 403602 403602 3 Wheel Hub Assembly 191200 191200 4 A Frame Assembly 401023 401023 5 A Frame Ht Adj 310081 310081 6 Gear Box 184065 18408
4. PTO set brake shut off the tractor en gine remove the ignition key lower implement to the ground and allow mower blades to come to a complete stop before dismounting tractor Never leave equipment unattended with the tractor running Never place hands or feet under mower with tractor engine running or be fore you are sure all motion has stopped Stay clear of all moving parts Do not reach or place any part of your body under equipment until it is blocked securely Do not allow riders on the rotary mower or tractor at anytime There is no safe place for any riders Do not operate unless all personnel livestock and pets are several hun dred feet away to prevent injury by thrown objects Never operate tractor and rotary mower under trees with low hanging limbs Operators can be knocked off the tractor and then run over by the rotating blades The rotating parts of this machine have been designed and tested for rug ged use However they could fail upon impact with heavy solid objects such as steel guardrails and concrete abutment Such impact could cause the broken objects to be thrown outward at very high velocities To reduce the possibility of property damage serious injury or even death never allow the cutting blades to contact such obstacles Stop mower and tractor immediately upon striking an obstruction Turn gine off remove key inspect and repair any damage before resuming op eration Stay alert for uneven terrain
5. and safety equipment hazard control and accident prevention are dependent upon the awareness concern prudence and proper training of personnel involved in the opera tion transport maintenance and storage of the machine Refer also to safety mes sages and operation instruction in each of the appropriate sections of the tractor and mower manuals Pay close attention to the safety signs affixed to the tractor and the rotary mower 7 ROTARY MOWER ASSEMBLY INSTRUCTIONS STEP 1 Place rotary mower on a flat level surface See Figure A STEP 2 Remove the wired on PTO shaft lift pins and spacers Loosen and re move the 4 bolts on the lift arm brackets that secure the lift arm support straps lift arms and lift arm braces from the shipping positions and set aside See Figure B STEP 3 Install the right lift arm and lift arm support strap using 2 two short bolts and 1 one lift pin See Figure C Note The lift arm support strap has one hole punched larger than the other The larger hole is to be used to fasten with the lift pin The lift arm amp support straps should be fastened to the outside of the lift arm bracket STEP 4 Loosen and remove the 2 nuts and washers for the A frame tailwheel section leaving the bolts in place See Figure D STEP 5 Install both the right and left side lift arm braces by sliding them over the 2 two A frame tailwheel bolts that were loosened in step 4 Start the nuts on the b
6. hitch as described in the Tractor s Operator s Manual TO INSTALL PTO SHAFT WITH SHEAR PIN 1 REMOVE SNAP RING 2 ATTACH PTO SHAFT 3 REPLACE SNAP RING 4 INSTALL SHEAR PIN SNAP ewe SHEAR PIN WARNING A Failure to install retaining clip on gearbox input shaft would allow driveline to swing freely if bolt is sheared causing possible injury or death STEP 2 Determine if the PTO shaft needs to be shortened NOTE Due to the many variations in the tractor hitch points and distances between equipment gearbox input shaft and tractor PTO out put shafts some combinations may require PTO shafts to be shortened as described by the following steps STEP 3 Raise and lower rotary mower in order to locate the shortest distance be tween equipment gearbox input shaft and tractor PTO output shaft With the rotary mower in the shortest distance position shut down the tractor and SE CURELY BLOCK ROTARY MOWER IN POSITION STEP 4 Pull apart PTO shaft and attach outer section to tractor PTO output shaft NOTE Be sure to pull on PTO shaft section to ensure yoke has locked into place 17 ATTACHING TO TRACTOR continued STEP 5 Place and hold inner PTO shaft section next to outer section and check if PTO shaft is too long Each section should end approximately 3 inches short of reaching u joint shield on the opposite section If the shaft is too long mea sure 3 inches back from each u join
7. lift arm Finally insert bolt nut and washer to lower section of lift arm support strap to lift arm bracket See Figure J STEP 8 Tighten all nuts and bolts Figure A Figure Figure D A Figure E Figure F Figure G Figure H y Figure I BEFORE PUTTING ROTARY MOWER INTO SERVICE IMPORTANT INSTRUCTIONS PRIOR TO START UP SHIPPED WITHOUT OIL IN GEAR BOX AND WITHOUT GREASE IN GREASE FITTINGS UNIT MUST BE SERVICED BEFORE USING Fill Gearbox using Multi Purpose Gear I E S A E 80w 90 or S A E 85w 140 Multi purpose gear oil For all Grease Fittings use TYPE grade II tube grease STEP 1 Place rotary mower so that the deck is secure and level STEP 2 Remove 1 2 Pipe Plug Located at top of gearbox and 1 8 Pipe Plug located at lower 1 3 of gearbox STEP 3 Fill gearbox using multi purpose gear oil through top 1 2 fill hole until gear oil is level with lower 1 8 hole STEP 4 Replace both the 1 2 pipe plug located at top of gear box and 1 8 pipe plug located at lower 1 3 of gear box and clean away any excess oil STEP 5 Grease with a grade II type tube grease The following zerks wheel wheel fork See Figure M 1 page 23 wheel fork See Figure M 1 page 23 Both U Joints on the PTO shaft See Figure M 2 page 23 STEP 6 Inspect all guards to insure they are in good working order If not re place before using STE
8. or hidden objects your mower should be set to the highest position that will give the desired cutting height By setting your mower up this way you reduce blade wear and stress to the mower Mowing at regular intervals will yeild far better results than periodic mowings i e less wind rowing To adjust cutting heights follow these steps STEP 1 Raise rotary mower off the ground with the tractor and SECURELY BLOCK IN POSITION Remove 5 8 bolt from adjusting bracket See Figure K STEP 2 Move the A frame tailwheel up or down to desired cutting height Re install 5 8 bolt and tighten to secure in position See Figure L Note may be necessary to loosen the A frame tailwheel attachment bolts See Figure D page 9 Figure K Figure L 20 Note For best results in heavier cutting conditions adjust the deck so the rear of the mower is approximately 2 higher than the front This method requires less horsepower and ground speeds of approximately 3 5mph If finer shredding results are desired adjust the deck to level or slightly lower in the rear This method will keep foilage under the deck longer resulting in finer pieces The down side of this method is if it takes alot more horsepower and very slow ground speed This method is not reccommended unless a PTO speed of 540 RPM can be maintained ROTARY MOWER OPERATION STEP 1 Before each use perform the maintenance described in maintenance section page 22 STEP2
9. safety and movement of farm machinery on public roads The use of flashing amber lights is acceptable in most localities However some localities prohibit their use Local laws should be checked for all lighting and marking requirements At all times when driving the tractor and equipment on the road or highway under 20mph 32kph use flashing amber warning lights and a slow moving vehicle SMV identification emblem Do not exceed 20 mph 32 kph Re duce speed on rough roads and surfaces Plan your route to avoid heavy traffic Always install transport locks pins or brackets before transporting Do not drink and drive Be a safe and courteous driver Always yield to oncoming traffic in all situa tions including narrow bridges intersections etc Watch for traffic when operating near or crossing roadways Turn curves or go up or down hills only at a low speed and at a gradual steering angle Make certain that a least 20 of the tractor s weight is on the front wheels to maintain safe steerage Slow down on rough or uneven surface Always check tractor manual for proper use on slopes Use extreme care and maintain minimum ground and when operating close to ditches or fences Be careful when turning sharp corners Never allow riders on either tractor or mower ATTACHING TO TRACTOR A WARNING Never stand between tractor and rotary mower while backing up tractor to the hitch STEP 1 Attach to tractor s category 1 three point
10. 0 7 Lift Arm Brace 310080 310080 8 PTO Shaft 147134 147134 9 Lift Arm Assembly 403656 403656 10 2 Lift Pins Pkg of 2 500002 500002 11 Swivel Yoke Assembly 403455 403455 12 Blade Carrier 403041 403041 13 Blade Bolt Set Pkg of 2 501002 501002 14 Mower Blade Set Pkg of 2 501224 501224 Lift Pin Plate 310974 310974 33 HEAVY DUTY LIFT 6 8 7 MOWER Ret Part Name Part Number No Rotary Mower Size 6760hp 6780np 7 60hp 7 80np 7 Tire amp Rim w Hub 501000 501000 501000 501000 2 Wheel Fork Assembly 403602 403602 403602 403602 3 Wheel Hub Assembly 191200 191200 191200 191200 4 Gross Axle Assembly 403600 403600 403601 403601 5 Gear Box 184065 184080 184065 184080 6 Lift Arm Brace 310619 310619 310609 310609 PTO Shaft 147134 147134 147248 147248 8 Lif Arm Assembly 403658 403658 403658 403658 E Swivel Yoke Assembly 403402 403402 403402 403402 10 CAT 2 Lift Pins Pkg of 2 500002 500002 500002 500002 11 Rachet Jack 195170 195170 195170 195170 12 Blade Carrier 403041 403041 403033 403033 13 Blade Bolt Set Pkg of 2 501002 501002 501002 501002 14 Mower Blade Set Pkg of 2 501230 501230 501230 501230 34 ROTARY MOWER PULL Ref Part Name Part Number No Rotary Mower
11. 0 170110 170110 10 Safety Shield BYPY 124310 124315 124315 10 Safety Shield Eurocardan 124311 124316 124816 E S SLIP CLUTCH ASSEMBLY Rei Part Name Part Number No im 8 1 Clutch Spring with Compression Bolts amp Nuts Pkg 8 500140 500140 2 Flanged Yoke 196006 196011 3 Sleeve 196005 196005 a Clutch Plate 196008 196003 5 Friction Hub 196004 196007 6 Slip Clutch Lock Bott 147350 147350 7 Slip Clutch Liner Plate 196002 195998 8 Pressure Plate 196001 196015 31 Rei Part Name Part Number No Rotary Mower Size 40 40hp 4 40hp 5 40hp 5 spe 5 1 2 donpf5 t amp ohq 6 40 6 me 1 Rim wHub 403001 408001 403001 403001 403001 403001 403001 403001 2 Wheel Fork Assembly 409019 403019 403019 409019 403019 403019 403019 403019 3 Wheel Hub Assembly 191100 191100 191100 191100 191100 191100 191100 191100 4 AFrameAssembly 401022 401018 401019 401019 401017 401017 401020 401020 5 A FrameHLAd 810081 310081 310081 310081 310081 310081 310081 310081 6 GearBoxSlick 184000 184000 184005 184060 184005 184060 184005 184060 6 Gear Box Splined 184010 184065 184010 1840651 184010 184065 7 UfAmBrace 310075 310078 310074 310074 310079 310079 310073 310073 8 PTOShaftwShearPin
12. 2 501002 12 Mower Blade Set Pkg of 2 501230 501230 PTO SHAFTS COVER REMOVAL Pictures are on next page BONDIOLI BYPY 1 2 There are 3 white tabs around the cover as shown in FIG 1 Take screwdriver and press against the tabs one at a time with downward an gular pressure toward the end of shaft marked B in FIG 2 As you are pressing tab grasp cover at point marked in FIG 2 and apply pres sure against cover in the direction of arrow do this for each tab Some times the other tabs may relock if they do you must repeat unlock proce dure You will feel it click when the tab releases after all 3 tabs are re leased you can slide the cover down the shaft in direction of C in FIG 2 To put cover back into place slide cover back toward end until all the tabs relock You may have to tap lightly with screwdriver or hammer handle NOTE Cover may be longer on some models but they will come off the same as above EUROCARDAN SERIES 4 1 2 3 First you must locate the black tab D in FIG 3 put flat screwdriver in slot in end of tab and turn until the flat side is pointing towards center of shaft Once you do this take the thin flat screwdriver and put into slot labeled in FIG 3 pry tab all the way out as shown in FIG 3 There are 3 white tabs around the cover as shown in G in FIG 4 You must line up cover slots and tabs as shown in FIG 4 F amp G Take a screwdriver an
13. 55010 155010 11 Housing 129010 129010 129010 12 Output Shaft 185005 185006 185006 73 Spacer 131045 131045 14 Output Seal NAK40X54X7 156005 156005 156005 15 Bottom Cap Gasket 124131 124131 124181 16 Botlom Cap 129005 129005 129005 17 T Castle Washer amp Cotter Pin 501110 501110 501110 78 1 2 Pipe Plug 131035 131035 131035 19 1 8 Pipe Plug 131040 131040 131040 20 3 8 x 1 Bolt 8 Lockwasher 41 60 HP GEARBOX Ref Part Name Gearbox No 184060 184065 1 Seal Input NAK SC 35X60X10 156040 156040 2 Endcap Input 129025 129025 3 Gasket Input 124133 124133 4 Bearing Race Input Timken LM603014 155015 155015 5 Bearing Input Timken LM603049 155020 155020 6 Spacer 1 4 131050 131050 7 Input Gear 185015 185026 8 Input Shaft 186020 186015 9 Housing 129020 129020 10 Gear Output 185035 185035 11 Bearing Race Output Timken 363 155035 155035 12 Bearing Output Timken 368 155040 155040 13 Output Shaft 186022 186022 14 Gasket Output 124134 124134 15 Seal Output TCM 50X68X9TC 156035 156035 16 Endcap Output 129030 129030 7 1 Castle Nut w Washer amp Cotter Pin 501110 501110 18 1 2 Pipe Plug 131035 131035 19 1 8 Pipe Plug 181040 131040 20 3 8 x 1 Bolt amp Lockwasher
14. ERIES 5 1 2 There 2 black tabs around the cover as shown in FIG 1 Take flat screwdriver and pry under the tabs one at a time at point B in FIG 2 lifting tab over on top of e shaped lock After both tabs are released you can slide the locking ring down the shaft in direction of C in FIG 3 Then you will see a metal e ring E in FIG 4 at point D in FIG 4 you must pry under ring and remove it it will just slide down shaft unless you take PTO apart then apply pressure against cover A in FIG 1 in the direction of arrow and slide cover down shaft To put cover back into place slide cover back toward end making sure cover and locking mechanism in FIG 4 line up Replace metal e ring slide the locking ring back into place be sure the tabs lock securely over locks NOTE Cover may be longer on some models but they will come off the same as above 39 40 HP GEARBOX Ret Part Name Gearbox No 184000 184005 184010 1 Snap Ring 106138 106138 106138 2 Input Seal NAK35X54X10 156010 156010 156010 3 Front Cap 129015 129015 129015 4 Front Cap Gasket 124130 124130 124130 5 Snap Ring 131081 131081 6 Snap Ring 131030 131030 131030 7 Bearing Hoover 208 155005 155005 155005 8 Input Gear 185007 185010 185010 9 Input Shaft 186010 186010 186010 10 Bearing NSK6207 155010 1
15. ES Winfield Alabama 35594 PO Box 1200 305 Commerce Drive tter gnutte ROTARY MOWER OPERATION AND PARTS MANUAL TO THE PURCHASER This manual contains valuable information about your new King Kutter Mower It has been carefully prepared to give you helpful suggestions for operating adjusting servicing and ordering repair parts Keep this manual in a convenient place for quick and easy reference Study it carefully You have purchased a depend able and sturdy mower but only by proper care and operation can you expect to receive the service and long life designed and built into it Sometime in the future your mower may need new parts to replace those that are worn or broken If so go to your dealer and provide him with the model and part number Customer Information Name Purchased From Date Purchased Model No Serial No It is the purchaser and or operator s responsibility to Read and understand the information contained in this manual Operate lubricate assemble and maintain the equip ment in accordance with all instructions and safety pro cedures in this manual Inspect the equipment and replace or repair any parts that are damaged or worn which under continued opera tion would cause damage wear to other parts or cause a safety hazard Return the equipment or parts to the authorized King Kutter dealer from where it was purchased for
16. O shaft yoke to be sure it has locked in place Make certain PTO shaft shielding is in place and good working condition STEP 10 The PTO shaft shield is a non rotating design and must be secured prior to equipment use Using the chain on each yoke shield attach to a fixed object on the tractor and equipment ends that will not allow the PTO shaft shield to rotate during operation SIZING PTO SHAFT STEP 1 Cutting the PTO shaft to length NOTE Be sure to cut equal lengths of each PTO shaft section Clamp end of PTO shaft in vice and cut Figure 1 A off shield where marked Figure 1 A amp 1 B STEP 2 Using cut section of the shield as a guide cut shaft off the same amount Figure 2 STEP 3 Repeat steps 1 and 2 for other PTO shaft section STEP 4 Use a file to deburr PTO shafts Clean up all chips burrs and filings from both ends of the PTO shaft Figure 1 8 Figure 2 OPERATING INSTRUCTIONS This mower was designed to CUT PASTURE GRASS AND ROUGH AREAS UP TO 1 IN DIAMETER Use of your rotary mower to cut any material larger than 1 in diameter may damage the mower and void your warranty PRE OPERATIONAL ADJUSTMENTS Set tractors control stop at a position that will prevent the PTO shaft from coming in contact with the front edge fo the mower when itis at full Consult your tractor manual for instructions CUTTING HEIGHT ADJUSTMENT To prevent mower blades from striking the ground
17. P 7 Check all bolts and nuts to insure they are tight and secure pen ESCH dh Lo CAUTION DO NOT over fill gearbox This could cause damage to oil seals and can cause permanent damage to the gearbox This issue will not be covered under war ranty SAFETY TRAINING 12 Safety is a primary concern in the design and manufacture of our product Unfortunately our efforts to provide safe equipment can be wiped out by a single careless act of an operator or bystander In addition to the design and configuration of equipment hazard control and accident prevention are dependent upon the awareness concern prudence and proper training of personnel involved in the operation transport mainte nance and storage of this equipment It has been said The best safety device is an informed careful operator We ask you to be that kind of operator It is the operator s responsibility to read and understand all safety and operating instructions in the manual and to follow them Accidents can be avoided Working with unfamiliar equipment can lead to careless injuries Read this manual and the manual for your tractor before assembly or operating to acquaint yourself with the machines If this machine is used by any person other than you or is loaned or rented it is the rotary mower owner s respon sibility to make certain that owner s manual be available to the operator prior to operating 1 Reads and understands the opera
18. Read understand and follow the information on safety training preparation starting and stopping safety operational safety transport safety warming sections of this manual pages 11 thru 16 STEP 3 With tractor running lower rotary mower into working position STEP 4 With the tractor at idle RPM engage PTO and slowly advance throttle to 540 PTO RPM NOTE Rotary mower designed to run at 540 PTO RPM only STEP 5 Select a low gear for the tractor and begin to mow Tractor ground speed is to be con trolled by gear selection only and not engine speed Tractor ground speed should allow rotary mower to maintain 540 PTO RPM and thus maximum blade tip speed NOTE Do not allow the tractor engine or rotary mower to bog down or stall This causes undue wear and tear on the mower and tractor If this continues to happen reduce ground speed and raise cutting height of rotary mower until the 540 PTO RPM is able to be maintained Never attempt to clean out a plugged discharge chute until the tractor has been shut down and the mower blades have completely stopped STEP 6 After each use clean all debris from the top and bottom of the rotary mower Replace any missing or illegible safety decals Inspect for any damaged or wom parts and replace before next use Store rotary mower in a dry environment 21 MAINTENANCE 1 Periodically check and maintain proper gear oil level 2 Every 8 hours wheel fork s wheel hub s PTO sh
19. Size 5740 5760hp 6740hp 6760 6780np 7 Tire amp Rim w Hub 403001 403001 403001 403001 403001 403001 2 Cross Axle Assembly 403548 403560 403560 403564 403564 403564 3 Wheel Hub Assembly 191100 191100 191100 191100 191100 191100 4 Top Link 1 195166 195166 195166 195166 195166 195166 5 Gear Box 184005 184005 184060 184005 184060 184080 6 PTO Shaft 147029 147148 147148 147148 147148 147248 7 Pull Tongue Assembly 403648 403648 403648 403648 403648 403648 8 Axle Cuff 320160 320160 320160 320160 320160 320160 9 Stump Jumper 403031 403031 403032 403031 403032 403032 10 Blade Bolt Set Pkg of 2 501001 501001 501001 501001 501001 501001 11 Mower Blade Set Pkg of 2 501118 501124 501124 501130 501130 501130 12 ShearBoltkit Pkg 5 500101 500101 500101 500101 500101 500101 35 7 PULL MOWER Ref Part Name Part Number No Rotary Mower Size 7 60 7 80hp 1 Tire amp Rim w Hub 501000 501000 2 Gross Axle Assembly 403568 403558 3 Wheel Hub Assembly 191100 191100 4 Rachet Jack 195170 195170 5 Gear Box 184065 184080 6 PTO Shaft 147248 147248 7 Pull Arm Fits Left or Right Side 403658 403658 8 Axle Cuff 320160 320180 9 Swivel Yoke Assembly 403403 403403 10 Blade Carrier 403033 403033 1 Blade Bolt Set Pkg of 2 50100
20. aft universal joints 2 and PTO telescoping surface See Figures M 1 amp M 2 NOTE Use only a grade Type Il tube grease 3 Before each use check to make sure all safety features are in stalled and working properly 4 Keep blades sharp and balanced at all times When replacing blades replace all blades and blade bolts at the same time 5 Periodically check all nuts and bolts to insure they are tight and secure Figure M 1 Figure M 2 grease points at arrows U joints MAINTENANCE SAFETY A Good maintenance is your responsibility Poor maintenance is an invitation to trouble Follow good shop practices Keep service area clean and dry Be sure electrical outlets and tools are properly grounded Use adequate light for the job at hand Make sure there is plenty ventilation Never operate the engine of the tractor in a closed building The exhaust fumes may cause asphyxiation Before working on this machine disengage the PTO shut off the engine set the brakes and remove the ignition keys Be certain all moving parts on attachments have come to a complete stop before attempting to perform maintenance Never work under equipment unless it is blocked securely Always use personal protection devices such as eye hand and hearing pro tectors when performing any service or maintenance Frequently check mower blades They should be balanced sharp free of nicks and cracks and securely fastened Pe
21. d press against the tabs one at a time with downward an gular pressure toward the end of shaft As you are pressing tab grasp cover and apply pressure against cover in the direction of arrow H in FIG 3 do this for each tab Sometimes the other tabs may relock if they do you must repeat unlock procedure You will feel it click when the tab releases after all 3 tabs are released you can slide the cover down the shaft in direction of H in FIG 3 To put cover back into place slide cover back toward end be sure tabs and slots line up until all the tabs relock You may have to tap lightly with screwdriver or hammer handle Once they have relocked replace black tab that was removed with flat side toward shaft center then turn flat side up to lock in place LA MAGDALENA 1 2 There are 3 black tabs around the cover in FIG 5 Take screwdriver and press against the tabs one at a time with downward angular pressure toward the end of shaft marked J in FIG 5 As you are pressing tab grasp cover at point marked J in FIG 5 and apply pressure against cover in the direction of arrow do this for each tab To replace slide cover back toward end and line up black tabs with the holes and lock in place 37 BONDIOLI COVER REMOVAL FIGURE 1 FIGURE 2 EUROCARDAN SERIES 4 COVER REMOVAL FIGURE 3 FIGURE 4 LA MAGDALENA COVER REMOVAL J FIGURE 5 38 PTO SHAFTS COVER REMOVAL EUROCARDAN S
22. ee ofthe rightful of any third party for infringement of patent or copyright 3 What is Not Covered by This Limited Warranty King Kutter wil not be responsible for damage to or failure inthe product which results from accident misuse abuse neglect installation of attachments not provided by King Kutter modifications to the product or damage caused by use of the product for purposes other than those for which itwas designed 4 No Other Warranties Unless modifiedin writing and signed by both parties this agreements understood to be the complete and exclu sive agreement and warranty between King Kutter and Purchaser superseding prior agreements oral and written and all other communication between King Kutter and Purchaser related to the subject matter ofthis agree ment THIS LIMITED WARRANTY ISIN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTY OF MERCHANTABILITY AND THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE No employee of King Kutter nor anyone else is authorized to make any warranty or representation in addition to or different from those madein this agreement 5 Allocation of Risk This agreement allocates the risk of product failure between King Kutter and the Purchaser This Allocation is recognized by both parties as reflected in the price of the goods The Purchaser acknowledges that he or she has read this agreement understands it and is bound by
23. een tractor and mower Be careful on uneven terrain Decrease speed when turning Do not exceed a safe transport speed 25 26 A DANGER Boo EN ROTATING BLADES KEEP AWAY To prevent serious injury or death when the engine is running and the blades are rotating Never allow riders especially children on tractor or mower Do not operate with bystanders in mowing area Do not operate with deflectors guards removed Do not place hands or feet under deck Do not stand on or near implement at any time Do not stand between tractor and implements lt Operate only with tractor equipped ROPS and seatbelts ADANGER THROWN OBJECT HAZARD To prevent serious injury or death Do not operate unless guards are installed and in good condition Stop blade rotation if bystanders come within several hundred feet A DANGER ROTATING DRIVELINE HAZARD KEEP AWAY To prevent serious injury or death from rotating driveline Keep all guards in place when operating Operate only at 540 RPM Keep hands feet clothing and hair away from moving parts Do not operate without driveline securely attached at both ends Do not operate without driveline shields that turn freely on driveline A WARNING TO PREVENT SERIOUS INJURY OR DEATH Keep hands and body out of hitch area when attaching mower to tractor Keep body clear of crush point between tractor and
24. g PTO clutch may change the length of the PTO driveline required Pay extra attention to the instructions on the PTO driveline Installation Be sure that the driveline system guarding is adequate Mower operating power is supplied from tractor PTO Refer to your tractor manual for PTO engagement and disengagement instructions Know how to stop tractor and mower quickly in case of an emergency When engaging PTO the engine RPM should always be atidle speed Once engaged and ready to start cutting raise PTO speed to 540 RPM and maintain throughout cutting operation 13 OPERATIONAL SAFETY 14 The use of this equipment is subject to certain hazards that cannot be pro tected against by the mechanical means or product design All operators of this equipment must read and understand this entire manual paying particu lar attention to safety and operating instructions prior to using If there is something in this manual you do not understand ask your supervisor or your dealer to explain it to you Most accidents occur because of neglect or carelessness Keep all help ers and bystanders at least several hundred feet from an operating rotary mower Only properly trained people should operate this machine When machine is operated in populated areas where thrown objects could injure persons or property operation must be stopped when anyone comes within several hundred feet The majority of the accidents involve entanglement on the driveli
25. hat you familiarize yourself with the various safety signs the type of warning and the area or particular function related to that area that requires your SAFETY AWARENESS REMEMBER If safety signs have been damaged removed become illegible or parts have been replaced without signs new safety signs must be applied New safety signs are available from your authorized dealer distributor or factory 24 A WARNING To prevent serious injury or death Si no lee ingles pida ayuda a alguien que si lo lea para que le traduzca las medidas de seguridad Read and understand Operator s Manual before using Review annually Do not permit riders on the tractor or mower including children Do not allow children to operate mower Operate only with guards installed and in good working condition lt Keep away from moving parts Operate only with tractor equipped with ROPS and seatbelts Before mowing clear debris from mowing Do not operate in the raised position Stop engine lower mower set brake and wait for all moving parts to stop before dismounting Support mower securely before working beneath unit Transport with clean reflectors SMV and working tights as required by federal state and local laws Keep yourself others and clothing away from the rotating PTO Keep others away from area to be mowed to avold injury from flying objects Do not stand betw
26. holes rocks and roots and other hidden haz ards Keep away from drop offs and hazards that could cause roll over Use extreme care and maintain minimum ground speed when transporting or operating on hillsides over rough ground and when operating close to ditches or fences Be careful and slow down when turning sharp corners and changing direction on slopes Do not start or stop suddenly on slopes Avoid operation on steep slopes In extremely uneven terrain rear wheels weights front tractor weight and or tire ballast should be used to improve stability 15 OPERATIONAL SAFETY continue A Pass rotary mower diagonally through sharp dips and avoid sharp drops to prevent hanging up tractor and rotary mower Practice will improve your skills in maneuvering on rough terrain Always cut down slopes never across the face Always check tractor manual for proper use on slopes When using a unit a minimum 20 of tractor and equipment weight must be on tractor front wheels Without this weight the tractor could tip over caus ing personal injury or death The weight may be attained with a front end loader front wheel weights ballast in the tires or front tractor weights When attaining a minimum 20 of tractor and equipment weight on the front wheels you must not exceed the ROPS weight certification Weigh the tractor and equipment Do not guess or estimate TRANSPORT SAFETY 16 Comply with state and local laws governing highway
27. ions typically for machine components that for func tional purposes cannot be guarded WARNING Indicates potentially hazardous situation that if not avoided could result in serious injury or death and includes hazards that are ex posed when guards are removed It may also be used to alert against unsafe practices CAUTION Indicates a potentially hazardous situation that if not avoided may result in minor or moderate injury It may also be used to alert against unsafe practices If you have any questions not answered in this manual or require additional copies or the manual is damaged please contact your dealer or King Kutter Inc P O Box 1200 Winfield AL 35594 205 487 3202 or www kingkutter com 6 EQUIPMENT SAFETY GUIDELINES A Safety of the operator and by standards is one of the main concems in designing and developing a mower However every year accidents occur which could have been avoided by a few seconds of thought and a more careful approach to handling equip ment You the operator can avoid many accidents by observing the following precau tions and insist those working with you or for you follow them In order to provide a better view certain photographs or illustrations in this manual may show an assembly with a safety shield removed However equipment should never be operated in this condition Keep all shields in place If shield removal becomes neces sary for repairs replace the shield prior to use
28. is if the noise in the operator s position exceeds 80 db Noise over 80 db on a long term basis can cause severe hearing loss Noise over 90 db adjacent to the operator over a long term basis may cause permanent total hearing loss NOTE Hearing loss from loud noise from tractors chain saws radios and other such sources close to the ear is cumulative over a lifetime without hope of natural recovery Operate the mower only with a tractor equipped with an approved Roll Over Protective System ROPS Always wear your seat belt Serious injury of even death could result from falling off the tractor particularly during a turnover when the operator could be pinned under the ROPS or the tractor Clear area to be cut of stones branches or other debris that might be thrown causing injury or damage Operate only in daylight or good artificial light Ensure mower is properly mounted adjusted and in good operating condition Ensure that all safety shielding and safety signs are properly installed and in good condition STARTING AND STOPPING SAFETY A Check the tractor master shield over the PTO stub shaft Make sure it is in good condition and fastened securely to the tractor Purchase a new shield if old shield is damaged or missing All tractors that are not equipped with a live power takeoff PTO need to be equipped with an over running PTO clutch These are available through most farm equipment stores NOTE The addition of an over runnin
29. mower 27 SHIPPED WITHOUT OIL IN GEAR BOX AND WITHOUT GREASE IN GREASE FITTINGS CONSULT OWNERS MANUAL FOR LUBRICATING AND OPERATING INSTRUCTIONS Operators Manuals are available from your dealer or King Kutter INC P O Box 1200 Winfield AL 35594 205 487 3202 www kingkutter com MODEL NO DESCRIPTION SN XXXXXXXXXX 28 SHEAR PIN PTO SHAFT Ref Part Name Part Number No 147022 147029 147034 1 Roll Pin Kit 500131 500131 500133 2 Male Tube End Yoke 151045 151045 151065 3 Implement End Yoke 151040 151040 151060 4 Female Tube End Yoke 151050 151050 151070 5 Tractor End Yoke 151035 151085 151055 6 Inner Tube 151090 151090 151092 7 Outter Tube 151091 151091 151093 8 Cross Kit 4 170015 170015 170020 9 Quick Disconnect Pin 170110 170110 170110 10 Safety Shield BYPY 124310 124310 124315 10 Safety Shield Eurocardan 124311 124311 124316 Must specify name brand of PTO 29 SLIP CLUTCH PTO SHAFT Ref Part Name Part Number No 147129 147134 147248 1 Cross Kit 170015 170020 170020 2 Roll Pin 170120 170120 170120 3 Female Tube End Yoke 151050 151070 151070 4 Inner Tube 151090 151092 151092 5 Slip Clutch Assembly 6 Male Tube End Yoke 151045 151065 151065 7 Outer Tube 151091 151093 151093 8 Tractor End Yoke 151085 151055 151055 9 Quick Disconnect Pin 17011
30. ne injury of bystanders by the objects thrown by the rotating blades and operators be ing knocked off the tractor by low hanging limbs and then being run over by the mower Accidents are most likely to occur with machines that are loaned or rented to someone who has not read the owner s manual and is not famil iar with a rotary mower The rotary mower is designed for use only on tractors with 540 RPM power take off Install and secure all guards and shields before starting or operating The flaps driveline guards and tractor shields should be used and maintained in good working condition They should be inspected carefully at least daily for missing or broken chain links shields or guards Worn items must be replaced at once to reduce possibility of injury Disengage power takeoff PTO and place transmission in neutral before attempting to start engine Many varied objects such as wire cable rope or chains can become en tangled in the operating parts of the mower These items could then swing outside the housing at greater velocities than the blades Such a situation is extremely hazardous Inspect the cutting area for such objects before mow ing Remove any like objects from the site OPERATIONAL SAFETY continued Never allow the cutting blade to contact such items Cut material higher at first allowing rotary mower to clear hidden objects Never assume an area is clear Always Check Always stop the tractor disengage
31. olts but at this time DO NOT TIGHTEN THEM Allow the lift arm braces to rotate forward and rest against the installed lift arm See Figure E STEP 6 Install the long top mounting bolt by inserting it through the hole in the left side lift arm brace the lower of the 2 two holes in the left side lift arm the spacer the lower of the 2 two holes in the top of the right side lift arm which should not be attached to the lift arm bracket at this time and finally through the right side lift arm brace Install a washer and start the nut on the bolt but do not tighten it at this time See Figure F G amp H Note You may have to move the assembly around to start the nut amp washer If unable to get the nut and washer started a C clamp may be necessary to compress the assembly to be able to start the nut amp washer Install the swivel U Shaped piece put mounting bolt through upper hole in left lift arm the spacer amp swivel making sure the 1 block on swivel is toward the front and rests against front side of the bottom spacer then through top hole of right lift arm install a washer and start the nut on the bolt but do not tighten it at this time STEP7 Using the right side lift arm as a lever pull to the outside of the lift arm bracket and inset bolt through lift arm and lift arm bracket See Figure I In stall washer and nut Place the lift pin in the larger of the 2 holes on the lift arm brace and loosley attach the
32. riodically tighten all bolts nuts and screws and check that all cotter pins are properly installed to ensure unit is in safe condition When completing a maintenance or service function make sure all safety shields and devices are installed before placing unit in service After servicing be sure all tools parts and service equipment are removed from mower Do not allow debris grease or oil to build up on any deck or platform Where replacement parts are necessary for periodic maintenance and ser vicing genuine factory replacement parts must be used to restore your equip ment to original specifications The manufacturer will not be responsible for injuries or damages caused by use of unapproved parts and or accessories A fire extinguisher and a first aid kit should be kept readily accessible while performing maintenance on this equipment STORAGE SAFETY A Following operation or when unhooking the mower stop the tractor set the brakes disengage the PTO shut off the engine and remove the ignition keys Store the unit in an area away from human activity Do not park equipment where it can be exposed to direct contact to live stock for long periods of time Damage and livestock injury could result Make sure all parked machines are on a hard level surface and engage all safety devices 23 SAFETY SIGN LOCATIONS The types of safety signs and locations on the equipment are shown in the illustra tion below Good safety requires t
33. service or replacement of defective parts that are covered by warranty The King Kutter Factory may inspect equip ment or parts before warranty claims are honored Payment of all costs incurred by the dealer for traveling to or transporting the equipment for warranty inspec tion and or claims CONTENTS Assembly Instructions Before Putting Into Service Safety Training Operational Safety Transportation Safety Attaching To Tractor Sizing PTO Operating Instructions Maintenance Maintenance Safety Safety Decal s And Locations PTO Shaft Parts Replacement Parts PTO Shaft Cover Removal Gearbox Parts Warranty SAFETY READ AND FOLLOW THE INSTRUC TIONS IN THIS MANUAL AND ESPE CIALLY IN THE SAFETY SECTION FAIL URE TO DO SO CAN RESULT IN SERI OUS INJURY OR DEATH TAKE NOTE THIS SAFETY ALERT SYM BOL FOUND THROUGHOUT THIS MANUAL IS USED TO CALL YOUR AT TENTION TO INSTRUCTIONS INVOLV THIS SYMBOL MEANS ING YOUR PERSONAL SAFETY AND ATTENTION THE SAFETY OF OTHERS BECOME ALERT YOUR SAFTEY IS INVOLVED SIGNAL WORDS The signal words DANGER WARNING and CAUTION are used with the safety messages in this manual and with each safety signs They are defined as follows DANGER Indicates an immediate hazardous situation that if not avoided could result in serious injury or death This signal word is to be limited to the most extreme situat
34. sonable number of attempts King Kutter will provide at its option one of the following a a replacement for the product or b a full refund ofthe purchase price Repair replacement or refunds are the Purchaser s EXCLUSIVE remedies against King Kutter under this limited warranty King Kutter will not be liable for any special incidental or consequential damages based upon breach or warranty breach of contract negligence strict tort iabilty or any other legal theory Such damages include but are not limited to loss of profits loss of savings or revenue loss of use of the product or any associated equipment cost of capital cost of any substitute equipment facies or services down time the aims of third partes including customers and injury to property These limitations also apply to the extent allowed bylaw to personalinjury The purchaser must notify the Selerin writing of any defectin material or workmanship within one 1 year following the date of purchase Ifthe equipment is used for commercial purposes the Purchaser must natiy the Seller in writing of any defect in material or workmanship within ninety 90 days folowing the date of purchase Inno event will King Kutter be liable under this warranty unless written notice is received by the Seller within one 1 year fromthe date of original retail sale 2 Warranty of Title King Kutter warrants transfers good tite to the product free of any encumbrances and fr
35. t shield and mark the other shaft section Be sure to do this for both PTO shaft halves NOTE Do not cut PTO shaft sections at this time STEP 6 Raise rotary mower and remove blocking Raise and lower rotary mower in order to locate the longest distance between equipment input shaft and the tractor PTO output shaft With the rotary mower in the longest distance position shut down the tractor and SECURELY BLOCK THE ROTARY MOWER IN POSITION STEP 7 As in step 5 hold PTO shaft sections together and check for a minimum of 6 inches of overlap If PTO shaft has been marked for cutting the overlap is the distance measured between the two marks If the PTO shaft has less than a 6 inch overlap DO NOT USE Contact your authorized King Kutter Dealer NOTE If the PTO shaft length is too long go to SIZING PTO SHAFT page 19 STEP 8 Apply any multi purpose grease to the outside of the male inner PTO shaft section Assemble PTO shaft and install on rotary mower and tractor NOTE If you shear the bolt that attaches the PTO shaft to the gear box replace with a grade 2 bolt only Replacement with another grade of bolt will void your warranty and may cause terminal damage to the PTO shaft gearbox or tractor King Kutter shear pin 5 pack part 4500101 WARNING Failure to install retaining clip on gearbox input shaft would allow driv eline to swing freely if bolt is sheared causing possible injury or death STEP 9 Pull on tractor side of PT
36. tor s manuals 2 Is instructed in safe and proper use Know your controls and how to stop tractor engine and the mower quickly in an emergency Read this manual and the one provided with your tractor Train all new personnel and review instructions frequently with existing work ers Be certain only a properly trained and physically able person will oper ate the machinery A person who has not read and understood all operating and safety instructions is not qualified to operate the machine An untrained operator exposes himself and bystanders to possible serious injury or death If the elderly are assisting with farm work their physical limitations need to be recognized and accommodated PREPARTION A Never operate the tractor and mower until you have read and completely understand this manual the Tractor Operator s Manual and each of the safety messages found on the safety signs on the tractor and mower Personal protection equipment including hardhat safety glasses safety shoes and gloves are recommended during assembly installation operation adjustment mainte nance repairing removal or moving the implement Do not allow long hair loose fitting clothing or jewelry to be around equipment PROLONGED EXPOSURE TO LOUD NOISE MAY CAUSE PERMANENT HEARING LOSS Tractors with or without mowers attached can often be noisy enough to cause permanent partial hearing loss We recommend that you wear hearing protection on a full time bas
37. ts terms
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