Flail Cutter 6903303 EnUS Sm 11-08

Flail Cutter FC155 - FC175 (Europe Only)

FC200

Service Manual (FC155 Europe Only) S/N A01P00101 & Above (FC175 Europe Only) S/N 467500101 & Above (FC200) S/N 467300101 & Above

6903303 (11-08) 1 of 110

Printed in U.S.A.

© Bobcat Company 2008

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ALPHABETICAL INDEX BRUSH DEFLECTOR (EARLIER MODELS) . . . . . . . . . . . . . 30-40-1 DAILY DAILY INSPECTION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1 DELIVERY DELIVERY REPORT. REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III DRIVE BEL BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1 DRIVE BEL BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-100-1 30-100-1 DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1 FLAIL KNIVES. KNIVES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1 HYDRAULIC HYDRAULIC MOTOR MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1 HYDRAULIC CONTROL VALVE VALVE (S/N A01P00143 A01P001 43 & BELOW, S/N 467500163 & BELOW, S/N 467300196 & BELOW) . . . . . . . . 20-20-1 HYDRAULIC CONTROL VALVE VALVE (S/N A01P00144 A01P001 44 & ABOVE, S/N 467500154 & ABOVE, S/N 467300197 & ABOVE). . . . . . . . . 20-21-1 HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1 IDENTIFICATION AND MACHINE SIGNS (DECALS) . . . . . . . . . . .IV . IV LINKAGE. LINKAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-1 LUBRICA LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1 MANUAL STORAGE STORAGE LOCA LOCATION TION . . . . . . . . . . . . . . . . . . . . . . . . . . . III REAR HATCH HATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ROLLER ASSEMBLY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RUBBER SKIRT SKIRT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RUBBER STOP. STOP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-40-1 30-20-1 30-30-1 30-70-1

SERIAL NUMBER NUMBER LOCA LOCATION TION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III SKID SHOE. SHOE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1

e l a s e R r o f t o N y p o C r e l ALPHABETICAL a e INDEX D

TROUBLESHOO TROUBLESHOOTING TING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1 WEAR STRIP STRIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-90-1

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Flail Cutter Service Manual 4 of 110

SAFETY AND MAINTENANCE

CONTENTS SERIAL NUMBER NUMBER LOCA LOCATION TION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III Attachment Attachment Serial Number. Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III MANUAL STORAGE STORAGE LOCA LOCATION TION . . . . . . . . . . . . . . . . . . . . . . . . . . . III

HYDRAULIC SYSTEM

DELIVERY DELIVERY REPORT. REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III IDENTIFICATION AND MACHINE SIGNS (DECALS) . . . . . . . . . . .IV . IV SAFETY AND AND MAINTENANCE. MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01 HYDRAULIC HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01

MAIN FRAME SPECIFICATION AND SCHEMATICS

MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01 SPECIFICATIONS SPECIFICATIONS AND SCHEMATICS SCHEMATICS . . . . . . . . . . . . . . . . SPEC-01


CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State State of California Cali fornia to cause cancer, birth defects and other reproductive harm.

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Flail Cutter Service Manual


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SERIAL NUMBER LOCATION

Figure 3

Attachment Serial Number Figure 1

1

Later Models

P-60854

The Operation & Maintenance Manual and Safety Manual are stored in a container (Item 1) [Figure 2] & [Figure 3] located on the flail cutter.

P-57630

Always use the serial number of the flail cutter when requesting service information or when ordering parts. Early or later models (identification made by serial number) may use different parts, or it may be necessary to use a different procedure in doing a specific service operation [Figure 1].

DELIVERY REPORT e l a s e R r o f t o N y p o C r e l a e D

Figure 4

MANUAL STORAGE LOCATION Read and understand the Operation & Maintenance Manual before operating the flail cutter. Figure 2

1 P-20022

The delivery report must be filled out by the dealer and signed by the owner or operator when the flail cutter is delivered. An explanation of the form must be given to the owner. Make sure it is filled out completely [Figure 4].

Earlier Models

P-57633

III 7 of 110


IDENTIFICATION AND MACHINE SIGNS (DECALS)

HYDRAULIC MOTOR

HYDRAULIC CONTROL VALVE ROLLBACK HOOK STEPS 7106129 (1)

68156993 (3)

68156993 (3)

7100705 (1)

REAR

7100706 (1)

RUBBER SKIRT

SKID SHOE

SIDE

FRONT

RUBBER SKIRT

RUBBER SKIRT

7107788 (2)

P-57631

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IDENTIFICATION AND MACHINE SIGNS (DECALS) (CONT’D) MANUAL STORAGE CONTAINER DRIVE PULLEY SHIELD

EARLIER MODELS

LATER MODELS

MOUNTING FRAME

HYDRAULIC QUICK COUPLERS 7107788 (2)

68156993 (3)

6734443 (2)

Drive Pulley Shield has been removed for picture clarity.

P-57633

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VI 10 of 110


SAFETY AND MAINTENANCE DRIVE BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1 DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Attachment Mounting Frame . . . . . . . . . . . . . . . . . . . . . . . Bob-Tach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Mechanical Linkage For Rotor Shut-Off Device. Checking The Rotor Shut-Off Device. . . . . . . . . . . . . . . . . Rollback Hook Inspection . . . . . . . . . . . . . . . . . . . . . . . . .

SAFETY AND MAINTENANCE

10-20-1 10-20-1 10-20-2 10-20-7 10-20-4 10-20-4

LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1 REAR HATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1 Rear Hatch Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-2 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1 Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1 e l a s e R r o f t o N y p o C r e l a e D

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TROUBLESHOOTING Chart

WARNING AVOID INJURY OR DEATH Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death.

If the attachment is not working correctly, check the hydraulic system of the machine thoroughly before making any repairs on the attachment. Attachment problems can be affected by a hydraulic system that is not operating to specifications or such problems as a plugged fuel filter or hydraulic filter in the machine. Connect a flow meter to the machine to check the hydraulic pump output, relief valve setting and tubelines to check flow and pressure. (See the machine Service Manual for the correct procedure to connect the flow meter).

W-2003-0807

PROBLEM Abnormal machine vibrations.

CAUSE The knife rotor is out of balance.

CORRECTION Rebalance the rotor.

One or more of the knives are broken. Replace broken knives. Poor Cutting.

Machine absorbs too much power.

The roller does not turn.

Casing is punctured.

Loss of a counterweight.

Replace counterweight.

The rotor does not reach the correct working speed.

Check belt tension.

Machine adjustment does not comply with the instructions.

Check transmission rpm.

Forward speed is too fast.

Adjust forward speed.

Worn knives or parts.

Replace knives or sharpen uniformly. DO NOT change their weight and position on the rotor.

Hatch or roller out of adjustment.

Adjust the hatch and/or roller.

Too much material and low machine power.

Adjust power and forward speed.

Dry roller.

Lubricate roller.

Material is fouling the guards.

Clean the guards.

Roller is bent.

Replace roller.

Sandy soil.

Fit roller with larger roller diameter.

Worn sheet metal.

Replace the casing or scrap the attachment. Repair the casing if the rotor is still operational.

Bearings break frequently.

Casing is bent by excessive side loads. Replace casing. No lubrication.

Lubricate bearings.

Attachment overloaded.

Adjust power and forward speed.

Rotor installed wrong.

Reinstall rotor.

Rotor out of adjustment.

Adjust rotor.

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10-10-2 14 of 110


DAILY INSPECTION Attachment Mounting Frame Figure 10-20-5

2 1

P-57632

Inspect the Bob-Tach wedge mounts (Item 1), mounting flange (Item 2) [Figure 10-20-5] and all welds on the flail cutter for wear and damage each time the flail cutter is removed from the loader.


Frequently inspect the flail cutter to ensure that all components are secure and that all bolts and nuts are thoroughly tightened. Figure 10-20-6

1

2

P-57674

Periodically inspect the flail knife bolts (Item 1) and nuts (Item 2) [Figure 10-20-6] for tightness. They must be secured thoroughly as loosening could damage the rotor.

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DAILY INSPECTION (CONT’D)

Figure 10-20-8

Bob-Tach Hand Lever Bob-Tach

WARNING AVOID INJURY OR DEATH The Bob-Tach wedges must extend through the holes in the attachment mounting frame. Levers must be fully down and locked. Failure to secure wedges can allow attachment to come off.

P-79780

W-2715-0208

The wedges must extend through the holes in the attachment mounting frame, securely fastening the attachment to the Bob-Tach [Figure 10-20-8].

Figure 10-20-7

NOTE: If the wedge does not contact the lower edge of the hole, the attachment will be loose and can come off the Bob-Tach. Inspect the mounting frame on the attachment. (See the machine's Operation and Maintenance Manual for inspecting the Bob-Tach). Replace any parts that are damaged, bent or missing. Keep all fasteners tight. Look for cracked welds. Contact your Bobcat dealer for repair or replacement parts. P-41502A

Lubricate the wedges. (See the machine’s Operation & Maintenance Manual for the correct procedure.)

Push down on the Bob-Tach levers until they are fully engaged in the locked position [Figure 10-20-7] (wedges fully extended through the attachment mounting frame holes). The levers and wedges must move freely [Figure 10-207].

10-20-2 16 of 110




Figure 10-20-11

Bob-Tach (Cont’d) Power Bob-Tach

WARNING AVOID INJURY OR DEATH The Bob-Tach wedges must extend through the holes in the attachment mounting frame. Levers must be fully down and locked. Failure to secure wedges can allow attachment to come off. W-2715-0208

Figure 10-20-9 Loader Switch 1

P-41500A

Push and hold the BOB-TACH “WEDGES DOWN” switch (Item 2) [Figure 10-20-9] and [Figure 10-20-10] until the levers are fully engaged in the locked position [Figure 10-20-11] (wedges fully extended through the attachment mounting frame holes). Figure 10-20-12

2

B-15993A

Figure 10-20-10 P-79780

Work Machine Switch The wedges must extend through the holes in the attachment mounting frame, securely fastening the attachment to the Bob-Tach [Figure 10-20-12]. 1

2

NOTE: If the wedge does not contact the lower edge of the hole, the attachment will be loose and can come off the Bob-Tach.

P-88124

Inspect the mounting frame on the attachment. (See the machine's Operation and Maintenance Manual for inspecting the Bob-Tach). Replace any parts that are damaged, bent or missing. Keep all fasteners tight. Look for cracked welds. Contact your Bobcat dealer for repair or replacement parts. Lubricate the wedges. (See the machine’s Operation & Maintenance Manual for the correct procedure.)

10-20-3 17 of 110




Figure 10-20-14

Rollback Hook Inspection A rollback hook is provided to prevent the cutter deck from contacting the frame if the attachment is raised and fully rolled back on some machines. NOTE: The rollback hook must swing freely. Figure 10-20-13

P-70383

Place the flail cutter flat on the ground, fully lower the lift arm(s) [Figure 10-20-14]. Engage the auxiliary hydraulics. (See the Machine Operation & Maintenance Manual for the correct procedure.) The rotor should rotate.

1

Figure 10-20-15

P-60268

Inspect the rollback hook (Item 1) [Figure 10-20-13]. The rollback hook must swing freely. Inspect for cracks, loose hardware or damage. Replace any parts that are damaged bent or missing.

2

P-70370

Checking The Rotor Shut-Off Device 1

WARNING • •

P-70387

Never operate without rotor shut-off device. Never modify the rotor shut-off device and check that it is operating properly. W-2628-0405

Use the following procedures to check the rotor shut-off device.

Procedure 1 Enter the machine. (See the Flail Cutter Operation & Maintenance Manual for the correct procedure.)

Raise the lift arm(s), when the lower cross member of the attachment mounting frame (Item 1) comes in contact with the shut-off lever (Item 2) [Figure 10-20-15], the rotor must come to a complete stop within 7 seconds. Lower the lift arm(s) fully to check that the rotor does not restart. NOTE: If the rotor does not come to a complete stop within seven seconds or begins rotating again after the lift arms are fully lowered during an y of the above procedures, see your Bobcat dealer for service.

While in the operator seat, seat belt fastened and seat bar lowered, start the engine.

10-20-4 18 of 110




Procedure 3

Checking The Rotor Shut-Off Device (Cont’d)

Figure 10-20-18

Procedure 2 Figure 10-20-16

P-70383

Place the flail cutter flat on the ground, fully lower the lift arm(s) [Figure 10-20-18].

P-70383

Place the flail cutter flat on the ground, fully lower the lift arm(s) [Figure 10-20-16]. Engage the auxiliary hydraulics. (See the Machine Operation & Maintenance Manual for the correct procedure.) The rotor should rotate.

Engage the auxiliary hydraulics. (See the Machine Operation & Maintenance Manual for the correct e procedure.) The rotor should rotate. l Figure 10-20-19

2

Figure 10-20-17

P-70370

2 1 P-70370

1

P-70385

Raise the lift arm(s) and tilt the Bob-Tach forward, when the mounting frame (Item 1) comes in contact with the shut-off lever (Item 2) [Figure 10-20-19], the rotor must come to a complete stop within 7 seconds.

P-70382

Tilt the Bob-Tach back, when the mounting frame (Item 1) comes in contact with the shut-off lever (Item 2) [Figure 10-20-17], the rotor must come to a complete stop within 7 seconds. Lower the lift arm(s) fully to check that the rotor does not restart. NOTE: If the rotor does not come to a complete stop within seven seconds or begins rotating again after the lift arms are fully lowered during any of the above procedures, see your Bobcat dealer for service.

Lower the lift arm(s) fully to check that the rotor does not restart. NOTE: If the rotor does not come to a complete stop within seven seconds or begins rotating again after the lift arms are fully lowered during any of the above procedures, see your Bobcat dealer for service.

10-20-5 19 of 110


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DAILY INSPECTION (CONT’D) Checking The Rotor Shut-Off Device (Cont’d) Restart Rotor Rotation Disengage the auxiliary hydraulics by taking it out of detent, re-engage the auxiliary hydraulics into detent. The rotor should start rotating. NOTE: Shut-off valve WILL NOT reset unless the auxiliary hydraulics are cycled off first.


10-20-6 20 of 110


DAILY INSPECTION (CONT’D) Checking Mechanical Linkage For Rotor Shut-Off Device

WARNING

WARNING • •


AVOID BURNS Hydraulic fluid, tubes, fittings and quick couplers can get hot when running machine and attachments. Be careful when connecting and disconnecting quick couplers. W-2220-0396

Figure 10-20-21

WARNING AVOID INJURY OR DEATH Wear safety glasses to prevent eye injury when any of the following conditions exist: • When fluids are under pressure. • Flying debris or loose material is present. • Engine is running. • Tools are being used. W-2019-0907

Stop the engine and exit the loader. (See the Flail Cutter Operation & Maintenance Manual for the correct procedure.)

P-57706

Check for loose or missing bolts mounting the control valve [Figure 10-20-21] to the frame. Check hydraulic hoses for loose connections. Repair or replace as needed.

Figure 10-20-20

Figure 10-20-22 2 3

1

1

P-57690 P-57707

Remove the four bolts (Item 1), then remove cover (Item 2) [Figure 10-20-20]. Check if the pivot bolt (Item 3) [Figure 10-20-20] in the shut-off lever is loose or missing.

Check the condition of the connector link (Item 1) [Figure 10-20-22].

10-20-7 21 of 110




Figure 10-20-23

Follow the flail cutter service schedule for routine maintenance. It is located on top of the attachment, just right of the hydraulic control valve. Check the following items every 8 hours of operation: •

Check rotor shut-off device and rollback hook for proper function. Rollback hook must swing freely.

•

Check the knives and mounting hardware for cracks or damage. Replace if necessary.

•

Check deck, shields and roller. Replace or repair if damaged.

•

Check for damaged or missing decals. Replace if necessary.

•

Check for damaged or leaking hydraulic hoses or fittings. Replace if necessary.

•

Lubricate all grease points.

Check the following every 50 hours of operation: •

Check belt tension and adjust if required.

WARNING

7100706

AVOID INJURY OR DEATH Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes, causing serious injury or death. Fluid leaks under pressure may not be visible. Use a piece of cardboard or wood to find leaks. Do not use your bare hand. Wear safety goggles. If fluid enters skin or eyes, get immediate medical attention from a physician familiar with this injury.

Service schedule decal [Figure 10-20-23].

W-2072-0807

WARNING • •


10-20-8 22 of 110



LUBRICATION

Figure 10-30-4

Lubricate the following locations after every 8 hours of operation. NOTE Always use a good quality lithium based grease when lubricating the attachment. 1

Figure 10-30-1

1

1 P-57678

Lubricate fittings (Item 1) [Figure 10-30-4] on both side link arms of the Flail Cutter.

P-57637

Lubricate fitting (Item 1) [Figure 10-30-1]

Figure 10-30-5

Figure 10-30-2 1

1

1

3

2

P-57687

P-57636

Remove bolts (Item 1), then remove cover plate (Item 2) [Figure 10-30-2].

P-57682

NOTE: The drive pulley shield has been removed (right frame) [Figure 10-30-2] for picture clarity.

Lubricate fittings (Item 1) [Figure 10-30-5] on the center pivot arm.

Lubricate fitting (Item 3) [Figure 10-30-2] on the left side of the mower. Replace cover plate and bolts.

Figure 10-30-6

Figure 10-30-3

1 1

P-57650 P-57688

Lubricate fitting (Item 1) [Figure 10-30-3] on the left side of the drum.

Lubricate fitting (Item 1) [Figure 10-30-6] on both ends of the roller.

10-30-1 23 of 110




10-30-2 24 of 110


REAR HATCH

Figure 10-40-1

Adjustment NOTE: As the rear hatch is progressively opened to one of the seven available positions less hydraulic power is required. Power requirements are also affected by the roller height adjustment. The degree of mulching is also reduced as the rear hatch is opened further.

1

Stop the engine and exit the machine. P-60552

WARNING Before you leave the operator’s seat: • Lower the lift arms, put the attachment flat on the ground. • Stop the engine. • Engage the parking brake. • Raise seat bar. • (Foot Pedal Controls) Move pedals until both lock. • (Advanced Control System-ACS) Move the hydraulic controls to the NEUTRAL POSITION to make sure that both lift and tilt functions are deactivated. The seat bar system must deactivate the lift and tilt control functions when the seat bar is up. Service the system if hand controls do not deactivate. • (Selectable Joystick Controls-SJC) Move the joysticks to the NEUTRAL POSITION to make sure that travel and hydraulic functions are deactivated. The seat bar system must deactivate these functions when the seat bar is up. Service the system if controls do not deactivate. W-2463-0603

Loosen rear hatch pivot bolts (Item 1) [Figure 10-40-1] on both sides of the flail cutter. Figure 10-40-2

e l a s e R r o f t o N y 1 p o P-60545 C r e l Remove bolts (Item 1) [Figure 10-40-2] and nuts from a e both sides of the flail cutter, move the rear hatch to the D

desired position.

NOTE: When installing the bolts (Item 1) [Figure 1040-2] that hold the rear hatch in position, install them from the inside towards the outside. Placing the nut on the outside of the flail cutter. Re-install the bolts securing the rear hatch in position. Tighten bolts (Item 1) [Figure 10-40-2] on both sides of the flail cutter to 65-70 ft.-lb. (88-94 N•m) torque.

WARNING AVOID INJURY OR DEATH Wear safety glasses to prevent eye injury when any of the following conditions exist: • When fluids are under pressure. • Flying debris or loose material is present. • Engine is running. • Tools are being used.

Tighten rear hatch pivot bolts (Item 1) [Figure 10-40-1] to 65-70 ft.-lb. (88-94 N•m) torque.

W-2019-0907

10-40-1 25 of 110


REAR HATCH (CONT’D)

Figure 10-40-5

Rear Hatch Positions Fully Open Position NOTE: When operating the flail cutter in any of the following positions it is important that the rotor speed of 2200 rpm is maintained during operation. Figure 10-40-3 Fully Closed Position P-60539

The fully open position enables a more efficient cut at high forward speeds, reduces fuel consumption and minimizes the hydraulic power required. When the rear hatch is in the fully open position, the cut material exits the flail cutter over the roller [Figure 10-405].

P-60540

The fully closed position is generally used to mulch prunings and when a fine homogeneous mulch is desired.

NOTE: Cutting wet grass is difficult and absorbs a lot of hydraulic power. Adjust travel speed as needed.

When the rear hatch is in the fully closed position, the material being mulched will circulate between the rotor and the roller [Figure 10-40-3]. Figure 10-40-4 Intermediate Positions

P-60541

The intermediate positions allow the operator to adjust the degree of mulching required and discharge the mulched material over the roller [Figure 10-40-4].

10-40-2 26 of 110



DRIVE BELTS

Figure 10-50-3

Adjustment

1 1

NOTE: Check belt tension every 50 hours of use.


P-57637

P-57638

Loosen the four bolts (Item 1) [Figure 10-50-3] supporting the gear box and extension. Installation: Tighten bolts to 65-70 ft.-lb. (88-95 N•m) torque.

Figure 10-50-1 Figure 10-50-4 1 2

1

1

2

P-57634

P-57639

Remove bolts (Item 1) [Figure 10-50-1]. Remove brush guard (Item 2) [Figure 10-50-1]. Installation: Tighten bolts to 65-70 ft.-lb. (88-95 N•m) torque. Figure 10-50-2

Loosen jam nut (Item 1), then turn the tension bolt (Item 2) [Figure 10-50-4] counterclockwise to increase belt tension. Turn the tension bolt clockwise to decrease belt tension.

2 1

P-57635

Remove bolts (Item 1) and drive pulley shield (Item 2) [Figure 10-50-2]. Installation: Tighten bolts to 25-28 ft.-lb. (34-38 N•m) torque. 10-50-1 27 of 110



DRIVE BELTS (CONT’D) Adjustment (Cont’d) Figure 10-50-5

BELT TENSION

Check belt tension by pressing forcefully on the belt. Depending on model and the distance between pulleys, the belt should move between 0.2-0.4 in. (5-10 mm) [Figure 10-50-5].


Once the desired belt tension is obtained, tighten jam nut (Item 1) [Figure 10-50-4]. Install drive pulley shield and brush guard.

10-50-2 28 of 110


HYDRAULIC SYSTEM HYDRAULIC MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . .

20-10-1 20-10-3 20-10-2 20-10-1

HYDRAULIC SYSTEM

HYDRAULIC CONTROL VALVE (S/N A01P00143 & BELOW, S/N 467500163 & BELOW, S/N 467300196 & BELOW) . . . . . . . . 20-20-1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-11 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-4 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-3 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1 HYDRAULIC CONTROL VALVE (S/N A01P00144 & ABOVE, S/N 467500154 & ABOVE, S/N 467300197 & ABOVE). . . . . . . . . 20-21-1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-11 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-4 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-3 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1 e l a s e R r o f t o N y p o C r e l a e D

20-01 29 of 110



20-02 30 of 110


HYDRAULIC MOTOR

Figure 20-10-3

Removal and Installation

IMPORTANT When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

1

I-2003-0888 P-57714

Figure 20-10-1 Remove the bolts (Item 1) [Figure 20-10-3]. Installation: Tighten the bolts to 90-100 ft.-lb. (125-140 N•m) torque. 1

Remove the hydraulic motor from the shaft housing. e l a s e R r o f t o N y p o C r e l a e D

1 1

P-57928

Mark and remove the hydraulic hoses (Item 1) [Figure 20-10-1]. Figure 20-10-2

1

P-57714

Cap hydraulic fittings (Item 1) [Figure 20-10-2].

20-10-1 31 of 110


HYDRAULIC MOTOR (CONT’D) Parts Identification

1. Shaft and Bearing 2.

Housing

3. Cam Plate and Bronze Bushings 4. Rotating Group 5. Manual Control 6.

Valve Plate

7.

Distributor 4

5

3

7 6


2

1

20-10-2 32 of 110


HYDRAULIC MOTOR (CONT’D)

Figure 20-10-6

Disassembly and Assembly

IMPORTANT 1

When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. I-2003-0888

P-57694

Figure 20-10-4

Remove roll pin (Item 1) [Figure 20-10-6]. Figure 20-10-7 2

1

1

1

P-57692

Clean the outside of the hydraulic motor. NOTE: Place marks (Item 1) [Figure 20-10-4] on the housing before beginning disassembly. Figure 20-10-5

Remove bolts (Item 1) and plate (Item 2) 7] from the end housing.

e l a s e R r o f t o N y p o C r P-57695 e l a e [Figure 20-10- D

Installation: Tighten the bolts to 180-200 in.-lb. (21-23 N•m) torque.

1

P-57693

Remove the bolt (Item 1) [Figure 20-10-5].

20-10-3 33 of 110



Figure 20-10-10

Disassembly and Assembly (Cont’d) Figure 20-10-8

1

P-57700

1

Remove the valve plate (Item 1) [Figure 20-10-10]. Figure 20-10-11

P-57696

Remove gasket from cap (Item 1) [Figure 20-10-8]. Figure 20-10-9 1

2

1 P-57728

Remove pistons (Item 1) and plate (Item 2) [Figure 2010-11].

P-57697

Installation: Control bar (Item 1) [Figure 20-10-9] should be in this position during assembly before installing cap.

NOTE: It is recommended that the pistons be kept with their original bores during assembly.

20-10-4 34 of 110




Figure 20-10-14


1

1

P-57719

Remove divider plate (Item 1) from piston assembly [Figure 20-10-14].

P-57729

Figure 20-10-15 Remove pivot bushing (Item 1) [Figure 20-10-12]. Figure 20-10-13 1

2 1

P-57732

Compress washer and spring with a threaded rod and nut. The remove snap ring (Item 1) [Figure 20-10-15].

P-57727

Remove three needle bearings (Item 1) and nylon lock ring (Item 2) [Figure 20-10-13].

20-10-5 35 of 110




Figure 20-10-18


1

P-57720

Remove snap ring (Item 1) and remove shaft [Figure 2010-18].

P-57733

Figure 20-10-19 Remove the spring by backing off the nut on the threaded rod [Figure 20-10-16]. Figure 20-10-17

2

P-57721

1 Press bearing off shaft [Figure 20-10-19]. P-57735A

Remove O-ring (Item 1) and oil seal (Item 2) [Figure 2010-17].

20-10-6 36 of 110




Figure 20-10-22


1

1

1

P-57737

P-57723

Installation: When installing the plate on the end housing, align pegs (Item 1) [Figure 20-10-22] and put into position.

Remove washer (Item 1) [Figure 20-10-20].

Clean all parts in solvent and dry with compressed air.

Figure 20-10-21

Inspect all parts for wear or damage. Replace any worn l e a or damaged parts. s Always install new seals and O-rings. Lubricate all seals and O-rings with clean hydraulic fluid before installation.

1

P-57724

Remove snap ring (Item 1) [Figure 20-10-21].

20-10-7 37 of 110


e R r o f t o N y p o C r e l a e D


20-10-8 38 of 110


HYDRAULIC CONTROL VALVE (S/N A01P00143 & BELOW, S/N 467500163 & BELOW, S/N 467300196 & BELOW)

Figure 20-20-2

Removal And Installation

1

IMPORTANT 1

When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

P-57691

I-2003-0888

Mark all hoses for correct installation. Remove the hoses (Item 1) [Figure 20-20-2].

IMPORTANT Contain and dispose of any oil leakage in an environmentally safe manner. I-2066-0395

Installation: When installing hoses, inspect the O-ring(s) on the fitting(s). Replace the O-ring if damaged. Figure 20-20-3

Figure 20-20-1

1 1

1

P-57707

2

Remove the retaining clip and side link (Item 1) [Figure 20-20-3].

P-57690

Remove the two bolts (Item 1) from both sides of cover, then remove cover (Item 2) [Figure 20-20-1].

20-20-1 39 of 110



HYDRAULIC CONTROL VALVE (S/N A01P00143 & BELOW, S/N 467500163 & BELOW, S/N 467300196 & BELOW) (CONT’D) Removal And Installation (Cont’d) Figure 20-20-4

1 P-57757

Remove the three nuts (Item 1) [Figure 20-20-4] and bolts.


Installation: Tighten bolts to 180-200 in.-lb. (21-23 N•m) torque. Remove the control valve. Figure 20-20-5

1

P-57758

Installation: Inspect nylon spacer (Item 1) [Figure 2020-5] and replace if damaged.

20-20-2 40 of 110


HYDRAULIC CONTROL VALVE (S/N A01P00143 & BELOW, S/N 467500163 & BELOW, S/N 467300196 & BELOW) (CONT’D) Parts Identification 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

Boot Spool Screw Retainer O-Ring Relief Valve Backup Ring Housing Seat Spring Load Check Valve Ball Plug Orifice Washer Block Spool Cover Cap

1

2 3

3

4

6

4 5

5

5


5

7

9

10

5

11

8

12 5 2 13

14 5

10

5

13

13

15 5 13

5 16

10

3

17

18

3

PE2421S

20-20-3 41 of 110


HYDRAULIC CONTROL VALVE (S/N A01P00143 & BELOW, S/N 467500163 & BELOW, S/N 467300196 & BELOW) (CONT’D)

Figure 20-20-8

Disassembly

1

Clean the outside of the valve before disassembly. Figure 20-20-6

1

1 P-56678

Remove the screws (Item 1) [Figure 20-20-8]. Figure 20-20-9

P-56677

Remove the relief valve (Item 1) [Figure 20-20-6].

1

2

Figure 20-20-7

2

P-56679

Remove the boot (Item 1) and retainer (Item 2) [Figure 20-20-9]. 1 N-17086

Remove the O-rings (Item 1) and back-up ring (Item 2) [Figure 20-20-7] from the relief valve.

20-20-4 42 of 110




Figure 20-20-12

Disassembly (Cont'd) Figure 20-20-10

1

1

1

P-56682

1

Remove the O-rings (Item 1) [Figure 20-20-12] from the retainer. P-56680

Figure 20-20-13

Remove the screws (Item 1) [Figure 20-20-10]. Figure 20-20-11 1

1

P-56683

Remove the cap (Item 1) [Figure 20-20-13]. P-56681

Remove the retainer (Item 1) [Figure 20-20-11].

20-20-5 43 of 110




Figure 20-20-16

Disassembly (Cont'd)

1

Figure 20-20-14

1 1

P-56686

1 2

Remove the screws (Item 1) [Figure 20-20-16]. Figure 20-20-17 P-56684

Remove the screws (Item 1) and spool cover (Item 2) [Figure 20-20-14] from the spool.

1

NOTE: The spool cover is under spring pressure. Figure 20-20-15

1

P-56687

Remove the block and spool assembly (Item 1) [Figure 20-20-17].

P-56685

Remove the spring (Item 1) [Figure 20-20-15].

20-20-6 44 of 110




Figure 20-20-20

Disassembly (Cont'd) 2

Figure 20-20-18

1

P-56709

Remove the plug (Item 1) and washer (Item 2) [Figure 20-20-20]. NOTE: Do Not use anything other than hardwood blocks to grip the spool, or the spool will be damaged.

P-56688

Separate the spool assembly [Figure 20-20-18].

Figure 20-20-21

Figure 20-20-19 Cut

3.50”

1.125”

1

3.0” 1.50”

P-56689

B-14674

To remove the plug from the spool a holding fixture will have to be made from a 1.50 inch thick x 3.50 inch wide x 3.0 inch long (38 mm thick x 89 mm wide x 76 mm long) piece of hardwood. Drill a 1.125 inch (28.575 mm) hole in the center of the hardwood block. Cut the block lengthwise [Figure 20-20-19].

Remove the block (Item 1) [Figure 20-20-21].

Clamp the spool in the blocks.

20-20-7 45 of 110




Figure 20-20-24

Disassembly (Cont'd)

1

2

Figure 20-20-22

1

P-56692

1

Remove the spring (Item 1) and seat (Item 2) [Figure 2020-24]. Figure 20-20-25

P-56690

Remove the O-rings (Item 1) [Figure 20-20-22] from the block. Figure 20-20-23

1 1

P-56693

Remove the O-ring (Item 1) [Figure 20-20-25].

P-56691

Turn the valve over and remove the load check valve (Item 1) [Figure 20-20-23].

20-20-8 46 of 110




Figure 20-20-28


Figure 20-20-26

1

N-17085

Remove the O-ring (Item 1) [Figure 20-20-28] from the plug. P-56694

Figure 20-20-29

Remove the plug (Item 1) [Figure 20-20-26]. 1

Figure 20-20-27 1 1

2 1

P-56696

Remove the plugs (Item 1) [Figure 20-20-29]. P-56695

Remove the spring (Item 1) and check ball (Item 2) [Figure 20-20-27].

20-20-9 47 of 110



HYDRAULIC CONTROL VALVE (S/N A01P00143 & BELOW, S/N 467500163 & BELOW, S/N 467300196 & BELOW) (CONT’D) Disassembly (Cont'd) Figure 20-20-30

1

N-17084

Remove the O-ring (Item 1) [Figure 20-20-30] from the plugs.


Figure 20-20-31

1

P-56697

Remove the orifice (Item 1) [Figure 20-20-31].

20-20-10 48 of 110



Figure 20-20-34

2

Assembly Clean all parts in solvent and dry with compressed air.

1

Inspect all parts for wear or damage. Replace any worn or damaged parts. Always install new seals and O-rings. Lubricate all seals and O-rings with clean hydraulic fluid before installation.

2

Figure 20-20-32 P-56696

Install the plug (Item 1) [Figure 20-20-34]. Tighten the plug to 198 in.-lb. (22,4 N•m) torque.

1

Install the plugs (Item 2) [Figure 20-20-34]. Tighten the plugs to 120 in.-lb. (13,6 N•m) torque. e l a s e R r o f t o N y p o C r e l a e D

Figure 20-20-35

1

P-56697

Apply thread lock adhesive (Loctite 242) to the threads of the orifice (Item 1) [Figure 20-20-32]. Install the orifice and tighten to 120 in.-lb. (13.5 N•m) torque. Figure 20-20-33

N-17085

1 Install the O-ring (Item 1) [Figure 20-20-35] on the plug.

N-17084

Install the O-ring (Item 1) [Figure 20-20-33] on the plugs.

20-20-11 49 of 110



Figure 20-20-38

Assembly (Cont'd)

1

Figure 20-20-36

2

1

P-56693

Install the O-ring (Item 1) [Figure 20-20-38] on the plug. Figure 20-20-39 P-56695

Install the check ball (Item 1) and spring (Item 2) [Figure 20-20-36].

2

1

Figure 20-20-37

1 P-56692

Install the seat (Item 1) and spring (Item 2) [Figure 2020-39].

P-56694

Install the plug (Item 1) [Figure 20-20-37]. Tighten the plug to 41 ft.-lb. (56 N•m) torque.

20-20-12 50 of 110




Figure 20-20-42 1

Assembly (Cont'd) Figure 20-20-40

1 2

P-56689

Place the spool in the hard wood blocks. Clamp the blocks (Item 1) [Figure 20-20-42] in the vise. Install the block (Item 2) [Figure 20-20-42] on the spool.

P-56691

NOTE: Do Not use anything other than hard wood e blocks to grip the spool, or the spool will be l a s damaged.

Install the load check valve (Item 1) [Figure 20-20-40]. Figure 20-20-41

e R r o f t o N y p o C r e l a e D

Figure 20-20-43

1 1

1 2 P-56690 P-56709

Install the O-rings (Item 1) [Figure 20-20-41] on the block.

Install the washer (Item 1) and plug (Item 2) [Figure 2020-43]. Tighten the plug to 198 in.-lb. (22.4 N•m) torque. Remove the spool and wood blocks from the vise.

20-20-13 51 of 110



Figure 20-20-46

Assembly (Cont'd)

1

Figure 20-20-44

1

P-56686

Apply the thread lock adhesive (Loctite 242) to the screw threads. Install the screws (Item 1) [Figure 20-20-46]. Tighten the screws to 108 in.-lb. (12.2 N•m) torque. P-56688

Figure 20-20-47 Assemble the spool [Figure 20-20-44].


Figure 20-20-45 2 1

1

P-56685

Install the spring (Item 1) [Figure 20-20-47]. P-56687

Install the spool assembly (Item 1) in the housing (Item 2) [Figure 20-20-45].

20-20-14 52 of 110



Figure 20-20-50

Assembly (Cont'd) 1 Apply thread lock adhesive (Loctite 242) to the threads of the screws. Figure 20-20-48

1 2 P-56682

Install the O-rings (Item 1) [Figure 20-20-50] on the retainer.

2

Figure 20-20-51

1

P-56684

1

Install the spool cover (Item 1) and screws (Item 2) [Figure 20-20-48]. Tighten the screws to 108 in.-lb. (12,2 N•m) torque. Figure 20-20-49

1

P-56681

Install the retainer (Item 1) [Figure 20-20-51].

P-56683

Install the cap (Item 1) [Figure 20-20-49].

20-20-15 53 of 110




Figure 20-20-54

Assembly (Cont'd)

1

Apply thread lock adhesive (Loctite 242) to the threads of the screws. Figure 20-20-52

1 1 P-56678

Install the screws (Item 1) [Figure 20-20-54]. Tighten the screws to 108 in.-lb. (12.2 N•m) torque. 1

Figure 20-20-55

P-56680

2

Install the screws (Item 1) [Figure 20-20-52]. Tighten the screws to 108 in.-lb. (12.2 N•m) torque. Figure 20-20-53

2

1

1

N-17086

Install the O-rings (Item 1) and backup ring (Item 2) [Figure 20-20-55] on the relief valve.

P-56679

Install the retainer (Item 1) and boot (Item 2) [Figure 2020-53]. Apply thread lock adhesive (Loctite 242) to the threads of the screws.

20-20-16 54 of 110



HYDRAULIC CONTROL VALVE (S/N A01P00143 & BELOW, S/N 467500163 & BELOW, S/N 467300196 & BELOW) (CONT’D) Assembly (Cont'd) Figure 20-20-56

1

P-56677

Install the relief valve (Item 1) [Figure 20-20-56]. Tighten the valve to 25 ft.-lb. (34 N•m) torque.

20-20-17 55 of 110




20-20-18 56 of 110


HYDRAULIC CONTROL VALVE (S/N A01P00144 & ABOVE, S/N 467500154 & ABOVE, S/N 467300197 & ABOVE)

Figure 20-21-2

Removal And Installation

1

IMPORTANT 1

When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

P-57691

I-2003-0888

Mark all hoses for correct installation. Remove the hoses (Item 1) [Figure 20-21-2].

IMPORTANT Contain and dispose of any oil leakage in an environmentally safe manner. I-2066-0395

Installation: When installing hoses, inspect the O-ring(s) on the fitting(s). Replace the O-ring if damaged. Figure 20-21-3

Figure 20-21-1

1 1

1

P-57707

2

Remove the retaining clip and side link (Item 1) [Figure 20-21-3].

P-57690

Remove the two bolts (Item 1) from both sides of cover, then remove cover (Item 2) [Figure 20-21-1].

20-21-1 57 of 110



HYDRAULIC CONTROL VALVE (S/N A01P00144 & ABOVE, S/N 467500154 & ABOVE, S/N 467300197 & ABOVE) (CONT’D) Removal And Installation (Cont’d) Figure 20-21-4

1 P-57757

Remove the three nuts (Item 1) [Figure 20-21-4] and bolts.


Installation: Tighten bolts to 180-200 in.-lb. (21-23 N•m) torque. Remove the control valve. Figure 20-21-5

1

P-57758

Installation: Inspect nylon spacer (Item 1) [Figure 2021-5] and replace if damaged.

20-21-2 58 of 110


HYDRAULIC CONTROL VALVE (S/N A01P00144 & ABOVE, S/N 467500154 & ABOVE, S/N 467300197 & ABOVE) (CONT’D) Parts Identification 1. Cap 2. Spool Cover 3. Bolt 4. Spring 5. Spring Guide 6. O-ring 7. Lower Cap 8. Spool 9. Housing 10. Plug 11. Poppet 12. Check Valve Body 13. Seal 14. Orifice 15. Back-up Ring 16. Relief Valve 17. Compensator 18. Orifice Disc 19. Snap Ring

1 3 2

4

5 6

3

7


6

8

19 18 10 6

17

6

9

4

10

6

6 10 10

6

6

15 14

10

16

6 6

6 6

10 10

20-21-3

4

12

10 6

13

59 of 110

6

11

MS2208S


HYDRAULIC CONTROL VALVE (S/N A01P00144 & ABOVE, S/N 467500154 & ABOVE, S/N 467300197 & ABOVE) (CONT’D)

Figure 20-21-8

Disassembly Clean the outside of the valve before disassembly.

1

Figure 20-21-6

1

P-71092

Remove the plug (Item 1) [Figure 20-21-8] from the control valve. Figure 20-21-9 P-71090

Remove the relief valve (Item 1) [Figure 20-21-6]. Figure 20-21-7

2

1 P-71093

Remove the O-ring (Item 1) [Figure 20-21-9] from the plug. 1 P-71091

Remove the O-rings (Item 1) and back-up ring (Item 2) [Figure 20-21-7] from the relief valve.

20-21-4 60 of 110




Figure 20-21-12


Figure 20-21-10

1

2

3 P-71096

Remove the O-ring (Item 1) [Figure 20-21-12] from both plugs. Figure 20-21-13

P-71094

Remove the compensator compression spring (Item 1) and the compensator (Item 2) from the port (Item 3) [Figure 20-21-10].

2

Figure 20-21-11

1

1

P-71097

Remove the orifice (Item 1) from the port (Item 2) [Figure 20-21-13].

P-71095

Remove the 2 plugs (Item 1) [Figure 20-21-11] from the control valve.

20-21-5 61 of 110




Figure 20-21-16


Figure 20-21-14

2

1 P-7100

Remove the check valve compression spring (Item 1) and poppet (Item 2) from the port (Item 3) [Figure 20-2116].

1 P-71098

Figure 20-21-17 Remove the check valve body (Item 1) [Figure 20-21-14] from the control valve. Figure 20-21-15


1

1

P-71101

Remove the 3 plugs (Item 1) [Figure 20-21-17] from the control valve. P-71099

Remove the O-ring (Item 1) [Figure 20-21-15] from the check valve body.

20-21-6 62 of 110



Figure 20-21-20


Figure 20-21-18

2 P-71103

Remove the 2 bolts (Item 1) and spool cover (Item 2) [Figure 20-21-20]. 1 NOTE: The spool cover is under spring pressure.

P-71096

Remove the O-ring (Item 1) [Figure 20-21-18] from the three plugs.

Figure 20-21-21 3

Figure 20-21-19

1 2

1

P-71104

Remove the spool compression spring (Item 1) and the spring guide (Item 2) from the lower cap (Item 3) [Figure 20-21-21].

P-71102

Remove the plastic spool cover cap (Item 1) [Figure 2021-19].

20-21-7 63 of 110




Figure 20-21-24

Disassembly (Cont'd) Figure 20-21-22

1

2

1 P-71118

Remove the mower spool (Item 1) [Figure 20-21-24] from the control valve. Figure 20-21-25

P-71105

Remove the 4 bolts (Item 1) and the lower cap (Item 2) [Figure 20-21-22] from the control valve.

3

Figure 20-21-23

1 1 2

1

P-71112

Remove the wiper seal (Item 1) and O-ring (Item 2) from the spool port (Item 3) [Figure 20-21-25]. P-71106

Remove the 2 O-rings (Item 1) [Figure 20-21-23] from the lower cap.

20-21-8 64 of 110




Figure 20-21-28


Figure 20-21-26

1 P-71109

Remove the plug (Item 1) [Figure 20-21-28] from the control valve. Figure 20-21-29

P-71114

Remove the 3 plugs (Item 1) [Figure 20-21-26] from the load control valve. Figure 20-21-27

1 P-71096

Remove the O-ring (Item 1) [Figure 20-21-29] from the plug. 1 P-71096

Remove the O-ring (Item 1) [Figure 20-21-27] from the 3 plugs.

20-21-9 65 of 110



HYDRAULIC CONTROL VALVE (S/N A01P00144 & ABOVE, S/N 467500154 & ABOVE, S/N 467300197 & ABOVE) (CONT’D) Disassembly (Cont'd) Figure 20-21-30

1

2

P-71111

Remove the snap ring (Item 1) and orifice disc (Item 2) [Figure 20-21-30] from port “A” of the control valve.

20-21-10 66 of 110




Figure 20-21-33

Assembly 1

Clean all parts in solvent and dry with compressed air. Inspect all parts for wear or damage. Replace any worn or damaged parts. Always install new seals and O-rings. Lubricate all seals and O-rings with clean hydraulic fluid before installation. Figure 20-21-31

P-71109



2 1

P-71111

Install the orifice disc (Item 1) and snap ring (Item 2) [Figure 20-21-31] into port “A”. Figure 20-21-32

1 P-71093

Install the O-ring (Item 1) [Figure 20-21-32] on the plug.

20-21-11 67 of 110



Figure 20-21-36

3


2 1

P-71112

Install the O-ring (Item 1) into the second groove of the spool port (Item 3) [Figure 20-21-36] in the control valve.

1

Install the wiper seal (Item 2) into the top groove of the spool port (Item 3) [Figure 20-21-36] of the control valve.

P-71093

Install the O-ring (Item 1) [Figure 20-21-34] on the 3 plugs.


Figure 20-21-37

Figure 20-21-35 2 1 1

P-71118

Install the mower spool (Item 1) [Figure 20-21-37] into the control valve.

P-71114

Install the 2 plugs (Item 1) [Figure 20-21-35]. Tighten the plugs to 25 ft.-lb. (34 N•m) torque. Install the plug (Item 2) [Figure 20-21-35]. Tighten the plug to 20 ft.-lb. (27 N•m) torque.

20-21-12 68 of 110



Figure 20-21-40

3


2

1

1 P-71104

1

Install the spring guide (Item 1) and spool compression spring (Item 2) into the lower cap (Item 3) [Figure 20-2140]. P-71106

Figure 20-21-41 Install the O-rings (Item 1) [Figure 20-21-38] into the lower cap.


Figure 20-21-39 2

1

2

1 P-71103

Install the spool cover (Item 1) and 2 bolts (Item 2) [Figure 20-21-41]. Tighten the 2 bolts to 9 ft.-lb. (12 N•m) torque.

P-71105

Install the lower cap (Item 1) and 4 bolts (Item 2) [Figure 20-21-39]. Tighten the bolts to 9 ft.-lb. (12 N•m) torque.

20-21-13 69 of 110



Figure 20-21-44

Assembly (Cont'd) 1

Figure 20-21-42

2 P-71101

1 Install the 2 plugs (Item 1) [Figure 20-21-44]. Tighten the plugs to 25 ft.-lb. (34 N•m) torque. Install the plug (Item 2) [Figure 20-21-44]. Tighten the plug to 20 ft.-lb. (27 N•m) torque.

P-71102

Install the plastic spool cover cap (Item 1) [Figure 20-2142].


Figure 20-21-45

Figure 20-21-43

1 1

P-71099

Install the O-ring (Item 1) [Figure 20-21-45] onto the check valve body.

P-71093

Install the O-ring (Item 1) [Figure 20-21-43] on the 3 plugs.

20-21-14 70 of 110



Figure 20-21-48

Assembly (Cont'd) 2

Figure 20-21-46

3 1 P-71097

2

Install the orifice (Item 1) into the port (Item 2) [Figure 20-21-48].

1

Figure 20-21-49

P-71100

Install the poppet (Item 1) and compression spring (Item 2) into the port (Item 3) [Figure 20-21-46]. Figure 20-21-47

1 P-71096

Install the O-ring (Item 1) [Figure 20-21-49] on the 2 plugs. 1 P-71098

Install the check valve body (Item 1) [Figure 20-21-47]. Tighten the check valve to 35 ft.-lb. (48 N•m) torque.

20-21-15 71 of 110




Figure 20-21-52


1 1 P-71093

2

Install the O-ring (Item 1) [Figure 20-21-52] on the plug. Figure 20-21-53 P-71095

Install the plug (Item 1) [Figure 20-21-50] into the control valve. Tighten the plug to 25 ft.-lb. (34 N•m) torque. 1

Install the plug (Item 2) [Figure 20-21-50] into the control valve. Tighten the plug to 20 ft.-lb. (27 N•m) torque. Figure 20-21-51

2

1

P-71092


3

P-71094

Install the compensator (Item 1) and the compression spring (Item 2) into the port (Item 3) [Figure 20-21-51].

20-21-16 72 of 110



HYDRAULIC CONTROL VALVE (S/N A01P00144 & ABOVE, S/N 467500154 & ABOVE, S/N 467300197 & ABOVE) (CONT’D) Assembly (Cont'd) Figure 20-21-54

2

1 P-71091

Install the O-rings (Item 1) and back-up ring (Item 2) [Figure 20-21-54] on the relief valve.


Figure 20-21-55

1

P-71090

Install the relief valve (Item 1) [Figure 20-21-55]. Tighten the relief valve to 25 ft.-lb. (34 N•m) torque.

20-21-17 73 of 110



20-21-18 74 of 110


MAIN FRAME BRUSH DEFLECTOR (EARLIER MODELS) . . . . . . . . . . . . . 30-40-1 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1 DRIVE BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-100-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 30-100-1 DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1 FLAIL KNIVES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1

MAIN FRAME

LINKAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-1 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-1 RUBBER SKIRT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1 ROLLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1


RUBBER STOP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1 SKID SHOE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1 WEAR STRIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-90-1 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-90-1

30-01 75 of 110



30-02 76 of 110


SKID SHOE Removal and Installation


Figure 30-10-1

1


1

1

2

P-57648

Remove nuts and washers (Item 1) [Figure 30-10-1]. Remove skid shoe (Item 2) [Figure 30-10-1]. Figure 30-10-2

1

P-57649

Remove remaining bolts (Item 1) [Figure 30-10-2]. Installation: Tighten the bolts to 25-28 ft.-lb. (34-38 N•m) torque.

30-10-1 77 of 110



30-10-2 78 of 110


ROLLER ASSEMBLY

Figure 30-20-2

Removal and Installation Remove skid shoe (See Removal and Installation on Page 30-10-1.)

WARNING

1

AVOID INJURY OR DEATH Wear safety glasses to prevent eye injury when any of the following conditions exist: • When fluids are under pressure. • Flying debris or loose material is present. • Engine is running. • Tools are being used. W-2019-0907

P-57650

Remove bolt (Item 1) [Figure 30-20-2] from both sides of the roller. Installation: Tighten the bolts to 25-28 ft.-lb. (34-38 N•m) torque. Figure 30-20-3

Figure 30-20-1

2

1

Remove bolts (Item 1) and the plate (Item 2) 20-3] on both sides of the roller.

e l a s e R r o f t o N y p o C r e P-57653 l a e [Figure 30- D

Installation: Tighten the bolts to 25-28 ft.-lb. (34-38 N•m) torque. Figure 30-20-4 P-57651

Chain and lift front until roller is flat on the ground [Figure 30-20-1].

1 P-57654

Remove bearing spacer (Item 1) [Figure 30-20-4].

30-20-1 79 of 110


ROLLER ASSEMBLY (CONT’D)

Figure 30-20-7

Removal and Installation (Cont’d)

1

Figure 30-20-5

1

P-57657

Remove dust cap (Item 1) [Figure 30-20-7]. Figure 30-20-8

P-57655

Remove bearing bolts (Item 1) [Figure 30-20-5].

1

Installation: Tighten the bolts to 80-90 in.-lb. (9-10 N•m) torque. Figure 30-20-6

1

P-57658

Remove pinion nut (Item 1) [Figure 30-20-8] and bearing.

P-57656

Installation: Set pinion bearing preload to 15 in.-lb. (17 N•m) rotating torque with used bearings, and 25 in.-lb. (28 N•m) with new bearings. Once preload is set, install the seal and loctite pinion nut.

Remove bearing (Item 1) [Figure 30-20-6].

30-20-2 80 of 110



RUBBER SKIRT

Front Rubber Skirt


Figure 30-30-2


1

W-2019-0907

2 P-57659

Rear Rubber Skirt NOTE: Mounting frame removed for picture clarity.

Remove bolts (Item 1), then remove the rubber skirt (Item 2) [Figure 30-30-2] and flat bar.

Figure 30-30-1 Installation: Tighten bolts to 25-28 ft.-lb. (34-38 N•m) torque. e l

a s e R r o f t o N y p o C r e l a e D

Side Rubber Skirt Figure 30-30-3

1

1 2 P-57686

Remove bolts (Item 1), then remove the rubber skirt (Item 2) [Figure 30-30-1] and flat bar. 2

Installation: Tighten bolts to 25-28 ft.-lb. (34-38 N•m) torque.

P-57659

Remove bolts (Item 1), then remove the rubber skirt (Item 2) [Figure 30-30-3] and flat bar. NOTE: The flat bar on the side skirts is mounted on the inside. Installation: Tighten bolts to 25-28 ft.-lb. (34-38 N•m) torque.

30-30-1 81 of 110



30-30-2 82 of 110


BRUSH DEFLECTOR (EARLIER MODELS)

Figure 30-40-2

Removal and Installation NOTE: This section only affects early model Flail Cutters. Late model Flail Cutters are equipped with a weld-on front rubber skirt mount and are not equipped with metal brush deflectors. Rubber guard removed for clarity. 1

WARNING

P-57662

AVOID INJURY OR DEATH Wear safety glasses to prevent eye injury when any of the following conditions exist: • When fluids are under pressure. • Flying debris or loose material is present. • Engine is running. • Tools are being used.

Remove bolt (Item 1) [Figure 30-40-2]. Installation: Tighten bolts to 65-70 ft.-lb. (88-95 N•m) torque. Figure 30-40-3

W-2019-0907

Figure 30-40-1

2 1

1 P-57663 P-57661

Remove bolts (Item 1) on both sides of the flail cutter, then remove front rubber skirt mount (Item 2) [Figure 3040-1].

Move the brush deflector mount (Item 1) [Figure 30-403] away from the flail cutter.


30-40-1 83 of 110



BRUSH DEFLECTOR (EARLIER MODELS) (CONT’D) Removal And Installation (Cont’d) Figure 30-40-4

1 P-57664

Slide the brush deflectors (Item 1) [Figure 30-40-4] until they are free from the deflector mount. e l a s e R r o f t o N y p o C r e l a e D

Figure 30-40-5

1

P-57662

Remove and replace damaged brush deflectors, then align the brush deflector mount with the flail cutter frame and install bolt (Item 1) [Figure 30-40-5]. Installation: Tighten bolt to 65-70 ft.-lb. (88-95 N•m) torque.

30-40-2 84 of 110


DRUM

Figure 30-50-3

Removal and Installation Place attachment flat on the ground.


Figure 30-50-1

P-57666

Raise the front of the attachment to remove the drum [Figure 30-50-3]. Figure 30-50-4

1

1 2 P-57665

Remove bolts and lock washers (Item 1) [Figure 30-501].

P-57667

Remove bolt and lock washer (Item 1) to remove alignment plate (Item 2) [Figure 30-50-4].

Repeat for other side. Installation: Tighten the bolts to 25-28 ft.-lb. (34-38 N•m) torque.

Repeat for other side. Installation: Tighten the bolts to 25-28 ft.-lb. (34-38 N•m) torque.

Figure 30-50-2

1

P-57651

Install chain to the attachment (Item 1) [Figure 30-50-2].

30-50-1 85 of 110



DRUM (CONT’D)

Figure 30-50-8

Removal and Installation (Cont’d) 1

Figure 30-50-5

1

P-57670

Remove snap ring (Item 1) [Figure 30-50-8]. P-57675

Figure 30-50-9

Remove grease seal (Item 1) [Figure 30-50-5]. Figure 30-50-6

1

1

P-57671

P-57668

Remove bearing spacer (Item 1) [Figure 30-50-9].

Remove snap ring (Item 1) [Figure 30-50-6]. Figure 30-50-7 1

P-57669

Remove flange plate (Item 1) [Figure 30-50-7].

30-50-2 86 of 110



DRUM (CONT’D) Removal and Installation (Cont’d) Figure 30-50-10


P-57672

Remove bearing with a press [Figure 30-50-10]. Installation: Assembly drum in reverse order. Block drum up and lower attachment over drum assembly. Use alignment plates to slide into place. Install bolts and lock washers.

30-50-3 87 of 110



30-50-4 88 of 110


FLAIL KNIVES

WARNING

Removal And Installation Replacing Individual Flail Knives (Broken): When replacing individual broken flail knives to maintain rotor balance, it is best to replace them with worn flail knives that are similar shape and weight to the others not being replaced. NOTE: This reduces abnormal vibrations and can prevent damage to the flail cutter.

AVOID INJURY OR DEATH Wear safety glasses to prevent eye injury when any of the following conditions exist: • When fluids are under pressure. • Flying debris or loose material is present. • Engine is running. • Tools are being used. W-2019-0907

NOTE: Keep a series of worn flail knives on hand. Figure 30-60-2 Replacing Multiple Flail Knives (Broken):

4 1

When replacing multiple flail knives, it is recommended that all the flail knives be replaced.

2

NOTE: The life of the flail knives depends on the type use and the type of land being worked. NOTE: When flail knives are broken, worn or damaged they will cause abnormal vibrations in the rotor. It is recommended that the flail knives be replaced an average of every 200300 hours of operation. NOTE: When installing the flail knives, pay close attention to the direction in which they are installed. If the knives are installed backwards, they do not cut. Figure 30-60-1 1

e l a s e 3 R P-57674 r o f t Remove nut (Item 1), then slide bolt (Item 2) out of the o mount until the knife (Item 3) [Figure 30-60-2] is free. N NOTE: When the knife has been removed, check the y flail supports for wear, rounded or oval p o shaped holes. C r e Installation: Tighten nuts against flail supports (Item 4) l a [Figure 30-60-2]. The knife should move freely. e D

Figure 30-60-3

1 P-57748

Install chains (Item 1) [Figure 30-60-1] to the side arm linkage on both sides of the flail cutter. NOTE: Use chains that are in good condition and of adequate size to lift the attachment. Raise the flail cutter and rotate the flail cutter clockwise, then lower the flail cutter and position it upside down on the ground. Replace the worn knives, bolts and nuts.

P-57756

Installation: With nut tighten against the flail support, use a hammer and punch to deform the side of the nut into the notches in the end of the bolt. This must be done for both notches. This procedure locks the nuts in place and prevents them from coming loose during operation [Figure 30-60-3].

30-60-1 89 of 110



30-60-2 90 of 110


RUBBER STOP

Rubber Stop With Isolator Support


Figure 30-70-2 3

WARNING

2


3 1

2

P-83020

W-2019-0907

1

P-79962

Figure 30-70-1 Place the rubber stop (Item 1) inside the isolator support (Item 2) [Figure 30-70-2]. 2

Install the rubber stop and isolator support through the flail cutter mount. e l a s

Install the lock washer and nut (Item 3) [Figure 30-70-2]. e R Tighten the nut. 1

Repeat procedure on opposite side of the flail cutter.

P-57677

To remove rubber stop (Item 1), remove bolt, nut and washer (Item 2) [Figure 30-70-1].

30-70-1 91 of 110


r o f t o N y p o C r e l a e D


30-70-2 92 of 110


LINKAGE

Figure 30-80-3

Removal and Installation Side Linkage 1


P-57680

Remove side link (Item 1) [Figure 30-80-3].

W-2019-0907

Center Linkage

Figure 30-80-1

Figure 30-80-4

1

1

1

1

P-57682

P-57678

Block attachment to raise mounting frame slightly off the ground.

Remove bolts (Item 1) [Figure 30-80-4].

Remove bolt and nut (Item 1) [Figure 30-80-1].



Figure 30-80-5

Figure 30-80-2 2 1 1

1

1

P-57683

P-57679

Remove pins (Item 1) and remove center link (Item 2) [Figure 30-80-5].

Remove collar (Item 1) [Figure 30-80-2].

30-80-1 93 of 110




30-80-2 94 of 110


WEAR STRIP Removal and Installation


Figure 30-90-1


1 1

P-57685

Remove bolts (Item 1) [Figure 30-90-1] and replace if necessary.

30-90-1 95 of 110



30-90-2 96 of 110



DRIVE BELTS Removal And Installation

Figure 30-100-3 1

WARNING

1


P-57637

W-2019-0907

P-57638

Loosen the four bolts (Item 1) [Figure 30-100-3] supporting the gear box and extension.

Figure 30-100-1


1 1

Figure 30-100-4

2

2

1 P-57634

Remove bolts (Item 1) [Figure 30-100-1]. Remove brush guard (Item 2) [Figure 30-100-1]. Installation: Tighten bolts to 65-70 ft.-lb. (88-95 N•m) torque. Figure 30-100-2

P-57639

Loosen jam nut (Item 1), then turn the tension bolt (Item 2) [Figure 30-100-4] counterclockwise to increase belt tension. Turn the tension bolt clockwise to decrease belt tension.

2 1

P-57635

Remove bolts (Item 1) and drive pulley shield (Item 2) [Figure 30-100-2].

30-100-1 97 of 110



DRIVE BELTS (CONT’D) Removal And Installation (Cont’d) Figure 30-100-5

1

P-57641

Remove and replace belts (Item 1) [Figure 30-100-5]. NOTE: Once the belts have been replaced, adjust belt tension. For the proper belt tension adjustment procedure (See Adjustment on Page 10-50-1.)

30-100-2 98 of 110



SPECIFICATIONS AND SCHEMATICS HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1 S/N A01P00143 & Below, S/N 467500153 & Below, S/N 467300196 & Below. . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1 S/N A01P00144 & Above, S/N 467500154 & Above, S/N 467300197 & Above . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1

SPECIFICATIONS AND SCHEMATICS


SPEC-01 99 of 110



SPEC-02 100 of 110


SPECIFICATIONS Dimensions •

All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

•

Where applicable, specifications conform to SAE and ISO standards and are subject to change without notice.

C

D

E

A B

DESCRIPTION

FC155 (Europe Only)

FC175 (Europe Only)

FC200

1279 lb. (580kg)

1530 lb. (696 kg)

1640 lb. (746 kg)

61 in. (1.5 m)

69 in. (1.75 m)

78 in. (2 m)

Total Width (B)

73 in. (1856 mm)

81 in. (2057 mm)

91 in. (2306 mm)

Total Offset (C)

10.9 in. (277 mm)

10.4 in. (264 mm)

15.3 in. (388 mm)

Total Height (D)

26.8 in. (683 mm)

29.7 in. (754 mm)

29.7 in. (754 mm)

Total Length (E)

57.4 in. (1457.4 mm)

56.9 in. (1445 mm)

56.9 in. (1445 mm)

2200 RPM

2200 RPM

2200 RPM

Maximum Hydraulic Flow

40 GPM (151 LPM)

40 GPM (151 LPM)

40 GPM (151 LPM)

Minimum Hydraulic Flow

17 GPM (64 LPM)

17 GPM (64 LPM)

17 GPM (64 LPM)

Maximum Hydraulic Motor Displacement

3.5 in. ^ 3 (58 cm ^ 3)

3.5 in. ^ 3 (58 cm ^ 3)

3.5 in. ^ 3 (58 cm ^ 3)

Minimum Hydraulic Motor Displacement

1.8 in. ^ 3 (29 cm ^ 3)

1.8 in. ^ 3 (29 cm ^ 3)

1.8 in. ^ 3 (29 cm ^ 3)

10 in. (254 mm)

10 in. (254 mm)

10 in. (254 mm)

Brush material up to 2 in. (51 mm) in diameter



Weight Cutting Width (A)

Maximum Rotor RPM

Shutoff Float Height Cutter Capacity

SPEC-10-1 101 of 110




SPEC-10-2 102 of 110


HYDRAULIC SCHEMATIC S/N A01P00143 & Below, S/N 467500153 & Below, S/N 467300196 & Below

ORIFICE (.030 in.) [.762 mm]


P-57753

SPEC-20-1 103 of 110


HYDRAULIC SCHEMATIC (CONT’D) S/N A01P00144 & Above, S/N 467500154 & Above, S/N 467300197 & Above

MODEL FC155 ONLY

ORIFICE (.030 in.) [.762 mm]

ORIFICE (.348 in.) [8.83 mm]


P-83972

SPEC-20-2 104 of 110


ROUTE TO ATTENTION

SERVICE MANUAL REVISION NOTICE Revision No: Revision Date: Product: Model: Manu Ma nual al No: No:

PARTS MANAGER SERVICE ICE MA MANA NAG GER X SALES MANAGER

Insert This Sheet With The Below Listed Manual For Future Reference.

Flail Flail Cutter Cutter-1 -1 23 March 2006 Attachment Flail 6903 69 033 303 (1-0 (1-05) 5)

Flail Cutter Service Manual (P/N 6903303) Dated (1-06) contains updated service information which replaces the previous Flail Cutter Service Manual (P/N 6903303) Dated (1-05).


Printed in U.S.A. 105 of 110


106 of 110

ROUTE TO ATTENTION

SERVICE MANUAL REVISION NOTICE Revision No: Date: Product: Model: Manual No:

PARTS MANAGER SERVICE MANAGER X SALES MANAGER


Flail Cutter-2 1 November 2006 Attachment Flail Cutter 6903303 (11-06)

The following sections are a revision to the above Service Manual.

COVER ALPHABETICAL INDEX


10-01 10-20 20-01 20-20 Added 20-21 30-01 30-40 SPEC-01 SPEC-10 Added SPEC-20

Printed in U.S.A. 107 of 110


108 of 110

ROUTE TO ATTENTION

SERVICE MANUAL REVISION NOTICE Revision No: Date: Product: Model: Manual No:

PARTS MANAGER SERVICE MANAGER X SALES MANAGER


Flail Cutter-3 1 November 2008 Attachment Flail Cutter 6903303 (11-08)

The following sections are a revision to the above Service Manual. COVER ALPHABETICAL INDEX CONTENTS


10-01 10-20 30-70

109 of 110

Printed in U.S.A

Flail Cutter 6903303 EnUS Sm 11-08

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