King Kutter Rotary Mower Users Manual Kutter_manual

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2015-02-09

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PO Box 1200
305 Commerce Drive
Winfield, Alabama 35594

ROTARY MOWER
OPERATION AND PARTS
MANUAL

Part No 999998

www.kingkutter.com

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 dependable 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….
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Read and understand the information contained in this
manual.

Operate, lubricate, assemble and maintain the equipment in accordance with all instructions and safety procedures in this manual.

Inspect the equipment and replace or repair any parts
that are damaged or worn which under continued operation 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 service
or replacement of defective parts that are covered by
warranty. (The King Kutter Factory may inspect equipment or parts before warranty claims are honored.)

Payment of all costs incurred by the dealer for traveling
to or transporting the equipment for warranty inspection and or claims.

CONTENTS
ITEM

PAGE

Safety ......................................................................... 6
Assembly Instructions ................................................ 8
Before Putting Into Service ...................................... 11
Safety Training ......................................................... 12
Operational Safety ................................................... 14
Transportation Safety ............................................... 16
Attaching To Tractor ................................................. 17
Sizing PTO ............................................................... 19
Operating Instructions.............................................. 20
Maintenance ............................................................. 22
Maintenance Safety ................................................. 23
Safety Decal's And Locations................................... 24
PTO Shaft Parts ....................................................... 29
Replacement Parts................................................... 32
PTO Shaft Cover Removal......................................37
Gearbox Parts .......................................................... 40
Warranty ................................................................... 46

SAFETY
READ AND FOLLOW THE INSTRUCTIONS IN THIS MANUAL AND ESPECIALLY IN THE SAFETY SECTION. FAILURE TO DO SO CAN RESULT IN SERIOUS INJURY OR DEATH.
TAKE NOTE! THIS SAFETY ALERT SYMBOL FOUND THROUGHOUT THIS
MANUAL IS USED TO CALL YOUR ATTENTION TO INSTRUCTIONS INVOLVING YOUR PERSONAL SAFETY AND
THE SAFETY OF OTHERS.

THIS SYMBOL MEANS
ATTENTION!
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 situations typically for machine components that, for functional purposes, cannot be guarded.
WARNING: Indicates a potentially hazardous situation that, if not avoided,
could result in serious injury or death, and includes hazards that are exposed 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
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EQUIPMENT SAFETY GUIDELINES
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Safety of the operator and by standards is one of the main concerns 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 equipment. You, the operator, can avoid many accidents by observing the following precautions 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 necessary for repairs, replace the shield prior to use.

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 accommodated.

Use a tractor equipped with a Roll Over Protective System and seat belts. (ROPS)

Never exceed the limits of a piece of machinery. If its 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
and safety equipment, hazard control and accident prevention are dependent upon the
awareness, concern, prudence, and proper training of personnel involved in the operation, transport, maintenance, and storage of the machine. Refer also to safety messages 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.

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 remove 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 & 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 bolts, 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 & H) Note: You may have to move the assembly around to start the
nut & 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
& washer. Install the swivel (U-Shaped piece) put mounting bolt through
upper hole in left lift arm, the spacer & 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.
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STEP 7
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) Install washer and nut. Place the lift pin in the larger of the (2) holes on the lift arm
brace and loosley attach the 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 C

Figure B

Figure D
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Figure E

Figure F

Figure G

Figure H

Figure I
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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.
•
•

STEP 1
STEP 2
STEP 3
STEP 4
STEP 5

STEP 6
STEP 7

Fill Gearbox using Multi-Purpose Gear Oil (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.
Place rotary mower so that the deck is secure and level.
Remove 1/2” Pipe Plug (Located at top of gearbox) and 1/8” Pipe
Plug (located at lower 1/3 of gearbox.
Fill gearbox using multi-purpose gear oil through top 1/2” fill hole until
gear oil is level with lower 1/8" hole.
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.
Grease (with a grade II type tube grease)
The following zerks:
*Tail wheel wheel fork (See Figure M-1, page 23).
*Tail wheel fork (See Figure M-1, page 23).
*Both U-Joints on the PTO shaft (See Figure M-2, page 23).
Inspect all guards to insure they are in good working order. If not replace before using.
Check all bolts and nuts to insure they are tight and secure.

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 warranty.
11

SAFETY TRAINING
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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, maintenance 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 responsibility to make certain that owner's manual be available to the operator prior
to operating:
1- Reads and understands the operator’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 workers. Be certain only a properly trained and physically able person will operate 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
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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, maintenance, 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 basis 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
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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-running 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 at idle speed. Once engaged
and ready to start cutting, raise PTO speed to 540 RPM and maintain throughout cutting
operation.

OPERATIONAL SAFETY

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The use of this equipment is subject to certain hazards that cannot be protected against by the mechanical means or product design. All operators of
this equipment must read and understand this entire manual, paying particular 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 helpers 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 driveline, injury of
bystanders by the objects thrown by the rotating blades, and operators being 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 familiar 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 entangled 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 mowing. Remove any like objects from the site.

OPERATIONAL SAFETY continued...
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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 PTO, set brake, shut off the tractor engine, 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 before 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 hundred 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 rugged 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 engine off, remove key, inspect and repair any damage before resuming operation.
Stay alert for uneven terrain, holes, rocks, and roots and other hidden hazards. 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.

OPERATIONAL SAFETY continued...
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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, causing 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
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Comply with state and local laws governing highway 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). Reduce 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 situations, 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
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 hitch as described in the
Tractor's Operator’s Manual.

WARNING
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 between equipment gearbox input shaft and tractor PTO output shaft. With the
rotary mower in the shortest distance position shut down the tractor and SECURELY 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.
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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 measure 3 inches back from each u-joint 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 #500101)
WARNING - 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 9
Pull on tractor side of PTO 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.
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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 a vice and cut
off shield where marked. (Figure
1-A & 1-B)

Figure 1-A

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-B

Figure 2
19

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 tractor's lIft control stop at a position that will prevent the PTO shaft from coming in contact
with the front edge fo the mower when it is at full lift. Consult your tractor manual for instructions.
CUTTING HEIGHT ADJUSTMENT
To prevent mower blades from striking the ground 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: It may be necessary to loosen the A-frame tailwheel attachment bolts.
(See Figure D, page 9)

Figure K
20

Figure L

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
Read, understand, and follow the information on safety training, preparation, starting and
stopping safety, operational safety, transport safety warning 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 controlled 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 worn parts and replace
before next use. Store rotary mower in a dry environment.

MAINTENANCE

1).

Periodically check and maintain proper gear oil level.

2). Every 8 hours, wheel fork(s), wheel hub(s), PTO shaft universal
joints (2), and PTO telescoping surface. (See Figures M-1 & M-2)
NOTE: Use only a grade Type II tube grease.
3). Before each use check to make sure all safety features are installed 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
(grease points at arrows)

Figure M-2
(U-joints)

MAINTENANCE SAFETY
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Good maintenance is your responsibility. Poor maintenance is an invitation
to trouble.
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Follow good shop practices.
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Keep service area clean and dry
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Be sure electrical outlets and tools are properly grounded
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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 protectors, when performing any service or maintenance.
Frequently check mower blades. They should be balanced, sharp, free of
nicks and cracks and securely fastened.
Periodically 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 servicing, genuine factory replacement parts must be used to restore your equipment 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.

z
z
z
z
z
z
z
z
z
z
z
z

STORAGE SAFETY
z
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.
z
Store the unit in an area away from human activity.
z
Do not park equipment where it can be exposed to direct contact to livestock for long periods of time. Damage and livestock injury could result.
z
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 illustration below. Good safety requires that 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

3
26

5
27

8
28

SHEAR PIN PTO SHAFT
3
2
8
6

4
5
9

Ref.
No.
1
2
3
4
5
6
7
8
9
10
10

Part Name
Roll Pin Kit
Male Tube End Yoke
Implement End Yoke
Female Tube End Yoke
Tractor End Yoke
Inner Tube
Outter Tube
Cross Kit #4
Quick Disconnect Pin
Safety Shield BYPY
Safety Shield Eurocardan
**Must specify name brand of PTO.

147022
500131
151045
151040
151050
151035
151090
151091
170015
170110
124310
124311

Part Number
147029
500131
151045
151040
151050
151035
151090
151091
170015
170110
124310
124311

147034
500133
151065
151060
151070
151055
151092
151093
170020
170110
124315
124316

SLIP CLUTCH PTO SHAFT
5

6
10
4

2
7

Ref.
No.
1
2
3
4
5
6
7
8
9
10
10

Part Name
Cross Kit
Roll Pin
Female Tube End Yoke
Inner Tube
Slip Clutch Assembly
Male Tube End Yoke
Outer Tube
Tractor End Yoke
Quick Disconnect Pin
Safety Shield BYPY
Safety Shield Eurocardan

147129
170015
170120
151050
151090
151045
151091
151035
170110
124310
124311

Part Number
147134
170020
170120
151070
151092
151065
151093
151055
170110
124315
124316

147248
170020
170120
151070
151092
151065
151093
151055
170110
124315
124316

SLIP CLUTCH ASSEMBLY

6
4
5
3
2
1
1

Ref.
No.
1
2
3
4
5
6
7
8

Part Name
Clutch Spring with Compression Bolts & Nuts (Pkg 8)
Flanged Yoke
Sleeve
Clutch Plate
Friction Hub
Slip Clutch Lock Bolt
Slip Clutch Liner Plate
Pressure Plate

Part Number
7"
8"
500140
500140
196006
196011
196005
196005
196008
196003
196004
196007
147350
147350
196002
195998
196001
196015

ROTARY MOWER - LIFT

Ref.
No.
1
2
3
4
5
6
6
7
8
8
9
10
11
12
13
14
15
16
17
18

Part Name
Rotary Mower Size
Tire & Rim /w Hub
Wheel Fork Assembly
Wheel Hub Assembly
A-Frame Assembly
A-Frame Ht. Adj.
Gear Box Slick
Gear Box Splined
Lift Arm Brace
PTO Shaft w/ Shear Pin
PTO Shaft w/ Slip Clutch
Lift Arms
CAT. 1 Lift Pins (Pkg. of 2)

Lift Arm Support Strap
Blade Carrier*
Stump Jumper*
Blade Bolt Set (Pkg. of 2)

Part Number
40"- 40hp
403001
403019
191100

4'- 40hp 5'- 40hp
403001 403001
403019 403019
191100 191100

5'- 60hp 5-1/2'- 40hp 5-1/2'- 60hp 6'- 40hp 6'- 60hp
403001 403001 403001 403001 403001
403019 403019 403019 403019 403019

191100 191100 191100 191100 191100
401022 401018 401019 401019 401017 401017 401020 401020
310081 310081 310081 310081 310081 310081 310081 310081
184000 184000 184005 184060 184005 184060 184005 184060
184010 184065 184010 184065 184010 184065
310075 310076 310074 310074 310079 310079 310073 310073
147022 147022 147029 147029 147034 147034 147034 147034
147129 147129 147134 147134 147134 147134
310087 310088 310088 310088 310091 310091 310091 310091
500001 500001 500001 500001 500001 500001
310071 310071 310071 310071 310071
403030
403031 403031 403032 403031 403032
501001 501001 501001 501001 501001 501001

Mower Blade Set(Pkg. of 2) 501118 501118 501124 501124

Swivel Kit**

501027 501027 501027
501013 501013 501013 501013
Wheel Washer Kit
Shear Bolt Kit (Pkg. 5) 500101 500101 500101 500101

501127

500001 500001
310071 310071
403031 403032
501001 501001

501127 501130 501130

501027 501027 501027 501027
501013 501013 501013 501013
500101 500101 500101 500101

on the size of rotary mower purchased, the blade carrier can be any of these 2 types.
32 *** Depending
40" Mower doesn't have a swivel.

HEAVY DUTY LIFT 5' MOWER

Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14

Part Name
Rotary Mower Size
Tire & Rim /w Hub
Wheel Fork Assembly
Wheel Hub Assembly
A-Frame Assembly
A-Frame Ht. Adj.
Gear Box
Lift Arm Brace
PTO Shaft
Lift Arm Assembly
CAT. 2 Lift Pins (Pkg. of 2)
Swivel Yoke Assembly
Blade Carrier
Blade Bolt Set (Pkg. of 2)
Mower Blade Set(Pkg. of 2)
Lift Pin Plate

Part Number
5'/60hp
501000
403602
191200
401023
310081
184065
310080
147134
403656
500002
403455
403041
501002
501224

5'/80hp
501000
403602
191200
401023
310081
184080
310080
147134
403656
500002
403455
403041
501002
501224

310974

HEAVY DUTY LIFT 6' & 7' MOWER

Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14

Part Name
Rotary Mower Size
Tire & Rim /w Hub
Wheel Fork Assembly
Wheel Hub Assembly
Cross Axle Assembly
Gear Box
Lift Arm Brace
PTO Shaft
Lift Arm Assembly
Swivel Yoke Assembly
CAT. 2 Lift Pins (Pkg. of 2)
Rachet Jack
Blade Carrier
Blade Bolt Set (Pkg. of 2)
Mower Blade Set(Pkg. of 2)

6'/60hp
501000
403602
191200
403600
184065
310619
147134
403658
403402
500002
195170
403041
501002
501230

Part Number
6'/80hp 7'/60hp
501000 501000
403602 403602
191200 191200
403600 403601
184080 184065
310619 310609
147134 147248
403658 403658
403402 403402
500002 500002
195170 195170
403041 403033
501002 501002
501230 501230

7'/80hp
501000
403602
191200
403601
184080
310609
147248
403658
403402
500002
195170
403033
501002
501230

ROTARY MOWER - PULL

Ref.
No.
1
2
3
4
5
6
7
8
9
10
11

Part Name
Rotary Mower Size
Tire & Rim /w Hub
Cross Axle Assembly
Wheel Hub Assembly
Top Link CAT. 1
Gear Box
PTO Shaft
Pull Tongue Assembly
Axle Cuff
Stump Jumper
Blade Bolt Set (Pkg. of 2)
Mower Blade Set(Pkg. of 2)

4'
403001
403548
191100
195166
184005
147029
403648
320160
403031
501001
501118

5'/40hp
403001
403560
191100
195166
184005
147148
403648
320160
403031
501001
501124

Shear Bolt Kit (Pkg. 5)

500101

Part Number
5'/60hp 6'/40hp
403001 403001
403560 403564
191100 191100
195166 195166
184060 184005
147148 147148
403648 403648
320160 320160
403032 403031
501001 501001
501124 501130
500101

6'/60hp
403001
403564
191100
195166
184060
147148
403648
320160
403032
501001
501130

6'/80hp
403001
403564
191100
195166
184080
147248
403648
320160
403032
501001
501130

500101 500101 500101

7' PULL MOWER

Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12

Part Name
Rotary Mower Size
Tire & Rim /w Hub
Cross Axle Assembly
Wheel Hub Assembly
Rachet Jack
Gear Box
PTO Shaft
Pull Arm (Fits Left or Right Side)
Axle Cuff
Swivel Yoke Assembly
Blade Carrier
Blade Bolt Set (Pkg. of 2)
Mower Blade Set (Pkg. of 2)

Part Number
7'/60hp
7'/80hp
501000
501000
403568
403568
191100
191100
195170
195170
184065
184080
147248
147248
403658
403658
320160
320160
403403
403403
403033
403033
501002
501002
501230
501230

PTO SHAFTS COVER REMOVAL (Pictures are on next page)
BONDIOLI- (BYPY)
1). There are 3 white tabs around the cover as shown in (A in FIG. 1). Take a
screwdriver and press against the tabs one at a time with downward angular pressure toward the end of shaft marked (B in FIG. 2). As you are
pressing tab grasp cover at point marked (B in FIG. 2) and apply pressure against cover in the direction of arrow, 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 (C in FIG. 2).
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)
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 (E
in FIG. 3) pry tab all the way out as shown in (FIG. 3)
2). 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 & G) Take a
screwdriver and press against the tabs one at a time with downward angular 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).
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)
There are 3 black tabs around the cover (K in FIG. 5). Take a 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.
2)
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

FIGURE- 5

PTO SHAFTS COVER REMOVAL
EUROCARDAN SERIES 5
1). There are 2 black tabs around the cover as shown in (B in FIG. 1). Take a
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.
2)
To put cover back into place slide cover back toward end, making sure
cover and locking mechanism (F 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.

FIGURE- 1

FIGURE- 2

FIGURE-3

FIGURE-4
39

40 HP GEARBOX

Ref.
No.

Part Name

1
2
3

Snap Ring

4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

Input Seal (NAK35X54X10)
Front Cap
Front Cap Gasket
Snap Ring
Snap Ring
Bearing (Hoover 208)
Input Gear
Input Shaft
Bearing (NSK6207)
Housing
Output Shaft
Spacer
Output Seal (NAK40X54X7)
Bottom Cap Gasket
Bottom Cap
1" Castle Nut/w Washer & Cotter Pin
1/2" Pipe Plug
1/8" Pipe Plug
3/8" x 1" Bolt & Lockwasher

Gearbox
184000

184005

184010

106138
156010
129015
124130

106138
156010
129015
124130
131031
131030
155005
185010
186010
155010
129010
185006
131045
156005
124131
129005
501110
131035
131040
-

131030
155005
185007
186010
155010
129010
185005
156005
124131
129005
501110
131035
131040
-

60 HP GEARBOX

Ref.
No.

Part Name

1
2
3

Seal Input (NAK SC 35X60X10)

4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

Endcap Input
Gasket Input
Bearing Race Input (Timken LM603014)
Bearing Input (Timken LM603049)
Spacer 1/4"
Input Gear
Input Shaft
Housing
Gear Output
Bearing Race Output (Timken 363)
Bearing Output (Timken 368)
Output Shaft
Gasket Output
Seal Output (TCM 50X68X9TC)
Endcap Output
1" Castle Nut/w Washer & Cotter Pin
1/2" Pipe Plug
1/8" Pipe Plug
3/8" x 1" Bolt & Lockwasher

Gearbox
184060
184065
156040
129025
124133
155015
155020
131050
185015
186020
129020
185035
155035
155040
186022
124134
156035
129030
501110
131035
131040
-

156040
129025
124133
155015
155020
131050
185026
186015
129020
185035
155035
155040
186022
124134
156035
129030
501110
131035
131040
-

80 HP GEARBOX
8
9

7
5

6
6
7

17
18
12

19
13
14
15
20
14
16

Ref.
No.

Part Name

Gearbox
184080

1
2
3

1/2" Vented Pipe Plug

131035
156040
131040
129025
124133
155015
155020
185015
131025
186040
185035
155037
155040
186035
155036
124134
156035
129030
501110

4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

Seal Input (NAK SC 35X60X10)
1/8" Pipe Plug
Endcap Input
Gasket Input
Bearing Race Input (Timken LM603014)
Bearing Input (Timken LM603049)
Spacer
Gear Input
Snap Ring
Shaft Input
Gear Output
Bearing Race Output (Timken 362A)
Bearing Output (Timken 368)
Shaft Output
Bearing Race Output (Timken 362)
Gasket Output
Seal Output (TCM 50X68X9TC)
Endcap Output
1" Castle Nut/w Washer & Cotter Pin

1. Limited Warranty.
King Kutter, Inc. (“King Kutter”), P.O. Box 1200, Winfield, Alabama 35594, warrants to the original retail purchaser
(“Purchaser”) that the product that is the subject of this sale is free from defects in material and workmanship at the
time of sale.
Under this warranty, King Kutter will repair the defective product free of charge to the Purchaser, with either new or
used and reconditioned replacement parts. All warranty service will be performed at service centers designated by
King Kutter. If King Kutter is unable to repair the product to conform to the warranty after a reasonable 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 of the 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 liability, 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, facilities or services, down time, the
claims of third parties including customers, and injury to property. These limitations also apply, to the extent allowed
by law, to personal injury.
The purchaser must notify the Seller in writing of any defect in material or workmanship within one (1) year following
the date of purchase. If the equipment is used for commercial purposes, the Purchaser must notify the Seller in
writing of any defect in material or workmanship within ninety (90) days following the date of purchase. In no event will
King Kutter be liable under this warranty unless written notice is received by the Seller within one (1) year from the
date of original retail sale.
2. Warranty of Title.
King Kutter warrants that it transfers a good title to the product free of any encumbrances, and free of the rightful claim
of any third party for infringement of patent or copyright.
3. What is Not Covered by This Limited Warranty.
King Kutter will not be responsible for damage to or failure in the 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 it was designed.
4. No Other Warranties.
Unless modified in writing and signed by both parties, this agreement is understood to be the complete and exclusive agreement and warranty between King Kutter and Purchaser, superseding all prior agreements, oral and
written, and all other communication between King Kutter and Purchaser related to the subject matter of this agreement.
THIS LIMITED WARRANTY IS IN 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 made in 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 its terms.

Source Exif Data:

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PDF Version                     : 1.4
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Page Count                      : 46
XMP Toolkit                     : XMP toolkit 2.9.1-13, framework 1.6
About                           : uuid:192ca966-0dc6-47d9-a6d8-611e79e08f70
Producer                        : Acrobat Distiller 6.0 (Windows)
Keywords                        : 
Creator Tool                    : Adobe PageMaker 7.0
Modify Date                     : 2007:06:18 13:01:59-05:00
Create Date                     : 2007:06:13 09:17:11-05:00
Metadata Date                   : 2007:06:18 13:01:59-05:00
Document ID                     : uuid:b8d59ca9-3761-4223-abb3-baf5aaae2044
Format                          : application/pdf
Title                           : Kutter_manual
Creator                         : Doug
Description                     : Kutter_manual
Author                          : Doug
Subject                         : Kutter_manual

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