®
BUSH HOG
ATH 900
Air Tunnel Finishing Mower
Operator’s Manual
ASSEMBLY l OPERATION l MAINTENANCE
04/09 Rev. 1
$4.00
90789
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ATH 900 FINISHING MOWER
Operator’s Manual
TABLE OF CONTENTS
SECTION/PARA
PAGE
SECTION/PARA
PAGE
IV MAINTENANCE . . . . . . . . . . . . . . . . . . . .10
4-1 Maintenance Check List . . . . . . . . . .10
4-2 Lubrication . . . . . . . . . . . . . . . . . . . . .10
4-3 Belt Adjustment . . . . . . . . . . . . . . . . .11
4-4 Belt Replacement . . . . . . . . . . . . . . .11
4-5 Blade Replacement . . . . . . . . . . . . . .12
4-6 Troubleshooting . . . . . . . . . . . . . . . . .12
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . .2
Dealer Preparation Check List . . . . . . . . .3
Safety Precautions . . . . . . . . . . . . . . . . . .4
Federal Laws and Regulations . . . . . . . . .5
I
INTRODUCTION AND DESCRIPTION . .6
1-1 Introduction . . . . . . . . . . . . . . . . . . . . .6
1-2 Description . . . . . . . . . . . . . . . . . . . . .6
V DEALER ASSEMBLY . . . . . . . . . . . . . . .13
5-1 Base Unit Assembly . . . . . . . . . . . . . .13
Safety Decals . . . . . . . . . . . . . . . . . . . . . .15
Torque Specifications . . . . . . . . . . . . . . .16
II PREPARATION FOR USE . . . . . . . . . . . .7
2-1 Attaching to Tractor . . . . . . . . . . . . . . .7
III OPERATING INSTRUCTIONS . . . . . . . . .9
3-1 General Safety . . . . . . . . . . . . . . . . . .9
3-2 Cutting Height Adjustment . . . . . . . . . .9
3-3 Operation . . . . . . . . . . . . . . . . . . . . . . .9
3-4 Transporting . . . . . . . . . . . . . . . . . . . . .9
RETAIL CUSTOMER’S RESPONSIBILITY
UNDER THE BUSH HOG WARRANTY
It is the Retail Customer and/or Operator’s responsibility to read the Operator’s
Manual, to operate, lubricate, maintain and store the product in accordance with all
instructions and safety procedures. Failure of the operator to read the Operator’s
Manual is a misuse of this equipment.
It is the Retail Customer and/or Operator’s responsibility to inspect the product and to
have any part(s) repaired or replaced when continued operation would cause damage
or excessive wear to other parts or cause a safety hazard.
It is the Retail Customer’s responsibility to deliver the product to the authorized Bush
Hog Dealer, from whom he purchased it, for service or replacement of defective parts
which are covered by warranty. Repairs to be submitted for warranty consideration
must be made within forty-five (45) days of failure.
It is the Retail Customer’s responsibility for any cost incurred by the Dealer for travel-
ing to or hauling of the product for the purpose of performing a warranty obligation or
inspection.
1
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LIMITED WARRANTY
OOOOOOOOOOOOOOOOOOOOOOOOOOOOOOO
Bush Hog warrants to the original purchaser of any new Bush Hog equipment, purchased from an
authorized Bush Hog dealer, that the equipment be free from defects in material and workmanship for a period
of one (1) year for non-commercial, state and municipalities’ use and ninety (90) days for commercial use from
date of retail sale. Model ATH 900 gearboxes are covered by a five (5) year limited warranty period. The oblig-
ation of Bush Hog to the purchaser under this warranty is limited to the repair or replacement of defective
parts.
Replacement or repair parts installed in the equipment covered by this limited warranty are warranted
for ninety (90) days from the date of purchase of such part or to the expiration of the applicable new equip-
ment warranty period, whichever occurs later. Warranted parts shall be provided at no cost to the user at an
authorized Bush Hog dealer during regular working hours. Bush Hog reserves the right to inspect any equip-
ment or parts which are claimed to have been defective in material or workmanship.
DISCLAIMER OF IMPLIED WARRANTIES & CONSEQUENTIAL DAMAGES
Bush Hog’s obligation under this limited warranty, to the extent allowed by law, is in lieu of all war-
ranties, implied or expressed, INCLUDING IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS
FOR A PARTICULAR PURPOSE and any liability for incidental and consequential damages with respect to
the sale or use of the items warranted. Such incidental and consequential damages shall include but not be
limited to: transportation charges other than normal freight charges; cost of installation other than cost
approved by Bush Hog; duty; taxes; charges for normal service or adjustment; loss of crops or any other loss
of income; rental of substitute equipment, expenses due to loss, damage, detention or delay in the delivery of
equipment or parts resulting from acts beyond the control of Bush Hog.
THIS LIMITED WARRANTY SHALL NOT APPLY:
1. To vendor items which carry their own warranties, such as engines, tires, and tubes.
2. If the unit has been subjected to misapplication, abuse, misuse, negligence, fire or other accident.
3. If parts not made or supplied by Bush Hog have been used in connection with the unit, if, in the sole judge-
ment of Bush Hog such use affects its performance, stability or reliability.
4. If the unit has been altered or repaired outside of an authorized Bush Hog dealership in a manner
which, in the sole judgement of Bush Hog, affects its performance, stability or reliability.
5. To normal maintenance service and normal replacement items such as gearbox lubricant, hydraulic fluid,
worn blades, or to normal deterioration of such things as belts and exterior finish due to use or
exposure.
6. To expendable or wear items such as teeth, chains, sprockets, belts, springs and any other items that in the
company’s sole judgement is a wear item.
NO EMPLOYEE OR REPRESENTATIVE OF BUSH HOG IS AUTHORIZED TO CHANGE THIS LIMITED
WARRANTY IN ANY WAY OR GRANT ANY OTHER WARRANTY UNLESS SUCH CHANGE IS MADE I
N
WRITING AND SIGNED BY BUSH HOG’S SERVICE MANAGER, 2501 GRIFFIN AVE., SELMA, ALABAMA
36703.
OOOOOOOOOOOOOOOOOOOOOOOOOOOOOOO
Record the model number, serial number and date
MODEL NUMBER
purchased. This information will be helpful to your
dealer if parts or service are required.
SERIAL NUMBER
MAKE CERTAIN THE WARRANTY INFORMATION
HAS BEEN FILED ONLINE WITH BUSH HOG
DATE OF RETAIL SALE
SELMA, ALABAMA
.
2
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DEALER PREPARATION CHECK LIST
ATH 900 FINISHING MOWERS
BEFORE DELIVERING MACHINE — The following check list should be completed.
Use the Operator’s Manual as a guide.
o 1. Assembly completed.
o 2. Gearboxes filled with oil.
o 3. All fittings lubricated.
o 4. All shields in place and in good condition.
o 5. All fasteners torqued to specifications given in Torque Chart
r 6. All decals in place and readable. (See decal page.)
o 7. Overall condition good (i.e. paint, welds)
o 8. Operators manual has been delivered to owner and he has been instructed
on the safe and proper use of the cutter.
o 9. Warranty information has been filed online with Bush Hog.
Dealer’s
Signature
THIS CHECKLIST TO REMAIN IN OWNER’S MANUAL
It is the responsibility of the dealer to complete the procedures listed
above before delivery of this implement to the customer.
3
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IMPORTANT SAFETY PRECAUTIONS
This symbol is used to call attention to safety
precautions that should be followed by the
operator to avoid accidents. When you see this
symbol, carefully read the message that fol-
lows and heed its advice. Failure to comply
with safety precautions could result in death or
serious bodily injury.
In addition to the design and configuration of equipment, hazard control and accident prevention are depen-
dent upon the awareness, concern, prudence and proper training of personnel in the operation, transport,
maintenance and storage of equipment. Lack of attention to safety can result in accident, personal injury,
reduction of efficiency and worst of all—loss of life. Watch for safety hazards and correct deficiencies
promptly. Use the following safety precautions as a general guide to safe operations when using this
machine. Additional safety precautions are used throughout this manual for specific operating and mainte-
nance procedures. Read this manual and review the safety precautions often until you know the limitations.
1. Read the Operator’s Manual. Failure to read the Operator’s Manual is considered a misuse of this
equipment.
2. Become familiar with all the machine’s controls and all the caution, warning and danger decals affixed
to the machine before attempting to start or operate.
3. Before starting or operating the machine, make a walk around inspection and check for obvious
defects such as loose mounting bolts and damaged components. Correct any deficiency before
starting.
4. Do not allow children to operate the cutter. Do not allow adults to operate it without proper instruction.
5. Do not carry passengers.
6. Keep the area of operation clear of all persons, particularly small children and pets. The operator
should cease mowing whenever anyone comes within the operating area.
7. Clear the work area of objects which might be picked up and thrown.
8. Use a piece of cardboard or wood rather than hands to search for hydraulic leaks. Escaping hydraulic
oil under pressure can penetrate skin. If fluid is injected into the skin, it must be surgically removed
within a few hours by a doctor familiar with this form of injury or gangrene may result.
9. Do not operate without all guards and shields in place and in good condition.
10. Lower implement to ground, stop tractor engine, apply parking brake, and allow blades to completely
stop before leaving the tractor.
11. Keep hands and feet away from blades.
12. This cutter is not to be operated along highways or in any area where people may be present unless
all sides of the unit are enclosed by permanent bands, safety chains or other factory approved safety
shields that are in good repair.
13. Wear personal protective equipment such as, but not limited to, protection for eyes, ears, feet, hands
and head when operating or repairing the equipment. Do not wear loose clothing or jewelry that may
catch on equipment moving parts.
14. When performing adjustments or maintenance on the cutter, first lower it to the ground or block it
securely at a workable height.
15. Never stand between tractor and cutter while tractor is being backed to the cutter hitch.
16. Reduce speed when transporting cutter to avoid bouncing and momentary loss of steering.
17. Use tractor flashing warning lights, day or night, when transporting cutter on road or highways unless
prohibited by law.
18. It is recommended that tractor be equipped with Rollover Protective System (ROPS) and seat belt be
used in all mowing operations.
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IMPORTANT FEDERAL LAWS AND REGULATIONS* CONCERNING
EMPLOYERS, EMPLOYEES AND OPERATIONS.
*(This section is intended to explain in broad terms the concept and effect of the following federal laws and
regulations. It is not intended as a legal interpretation of the laws and should not be considered as such).
U.S. Public Law 91-596 (The Williams-Steiger Occupational and Health Act of 1970) OSHA
This Act Seeks:
“...to assure so far as possible every working man and woman in the nation safe and healthful working
conditions and to preserve our human resources...”
DUTIES
Sec. 5 (a) Each employer—
(1) shall furnish to each of his employees employment and a place of employment
which are free from recognized hazards that are causing or are likely to cause
death or serious physical harm to his employees;
(2) shall comply with occupational safety and health standards promulgated under
this Act.
(b) Each employee shall comply with occupational safety and health standards
and all rules, regulations and orders issued pursuant to this Act which are
applicable to his own actions and conduct.
OSHA Regulations
Current OSHA regulations state in part: “At the time of initial assignment and at least annually thereafter, the
employer shall instruct every employee in the safe operation and servicing of all equipment with which the
employee is, or will be involved.” These will include (but are not limited to) instructions to:
Keep all guards in place when the machine is in operation;
Permit no riders on equipment;
Stop engine, disconnect the power source, and wait for all machine movement to stop before
servicing, adjusting, cleaning or unclogging the equipment, except where the machine must be
running to be properly serviced or maintained, in which case the employer shall instruct employees
as to all steps and procedures which are necessary to safely service or maintain the equipment.
Make sure everyone is clear of machinery before starting the engine, engaging power, or operating
the machine.
Child Labor Under 16 Years Old
Some regulations specify that no one under the age of 16 may operate power machinery. It is your
responsibility to know what these regulations are in your own area or situation. (Refer to U.S. Dept. of
Labor, Employment Standard Administration, Wage & Home Division, Child Labor Bulletin #102.)
EMPLOYEE TRACTOR OPERATING INSTRUCTIONS:
1. Securely fasten your seat belt if the tractor has a
ROPS.
5. Watch where you are going, especially at row
ends, on roads, and around trees.
2. Where possible, avoid operating the tractor near
ditches, embankments, and holes.
6. Do not permit others to ride.
7. Operate the tractor smoothly - no jerky turns,
starts, or stops.
3. Reduce speed when turning, crossing slopes, and
on rough, slick, or muddy surfaces.
8. Hitch only to the drawbar and hitch points recom-
mended by tractor manufacturers.
4. Stay off slopes too steep for safe operation.
9. When tractor is stopped, set brakes securely and
use park lock if available.
5
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SECTION I
INTRODUCTION AND DESCRIPTION
where a clean, uniform finish is desired. Three paral-
1-1 INTRODUCTION
lel uplift blades form a suction during operation to lift
the grass before cutting it. The four caster wheel
arrangement, along with the floating lift linkage and
an optional front mounted roller, all work together to
give an even cut and minimize scalping.
We are pleased to have you as a Bush Hog cus-
tomer. Your Air Turf Hog Series Rotary Cutter has
been carefully designed to give maximum service
with minimum down time.This manual is provided to
give you the necessary operating and maintenance
instructions for keeping your rotary cutter in top
operating condition. Please read this manual thor-
oughly. Understand what each control is for and how
to use it. Observe all safety precautions decaled on
the machine and noted throughout the manual for
safe operation of implement. If any assistance or
additional information is needed, contact your autho-
rized Bush Hog dealer.
Power from the tractor is transmitted through a trian-
gular, telescoping driveline to the 90 degree gear-
box. It is then passed to the spindle housings and
blades by a single, C-section, Kevlar reinforced belt.
Drivetrain protection is provided by belt slippage.
Table 1-1 ATH900 Specifications
Cutting Width (in.)
Cutting Height (in.)
Horsepower Range
Blade Tip Speed (fpm)
Weight (lbs.)
90
1 to 6
35-65
15,621
1,164
NOTE
All references made to right, left, top,
bottom, front or rear are as viewed
facing the direction of travel with
implement properly attached to trac-
tor.
1-2 DESCRIPTION
The ATH 900 cutter (Figure 1-1) is intended for cut-
ting lawns, golf courses, or any maintained area
Figure 1
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SECTION II
PREPARATION FOR USE
NOTE
2-1 ATTACHING TO TRACTOR
Due to the many variations in trac-
tor/implement hitch points and corre-
sponding differences in distances between
tractor PTO shafts and implement input
shafts, drivelines may need to be short-
ened as described in the following steps:
WARNING
NEVER STAND BETWEEN TRACTOR
AND CUTTER WHILE TRACTOR IS
BEING BACKED TO HITCH.
WARNING
B. Raise and lower cutter to determine position
with shortest distance between the tractor PTO shaft
and gearbox input shaft. Shut down tractor leaving
cutter in position of shortest distance. SECURELY
BLOCK CUTTER IN POSITION.
C. Pull driveline apart. Attach outer (female) sec-
tion to tractor PTO shaft. Pull on driveline section to
be sure yoke locks into place.
D. Hold driveline sections parallel to each other to
determine if too long. Each section should end
approximately 3 inches (76mm) short of reaching
universal joint shield on opposite section. If too long,
measure 3 inches (76mm) back from universal joint
shield and mark opposite section. (Figure 2-1). Do
this for both sections.
ADDITIONAL
TRACTOR
FRONT
BALLAST MAY BE NEEDED FOR
STABLE OPERATION AND TRANSPORT
OF CUTTER. SEE TRACTOR OPERA-
TOR’S MANUAL FOR RECOMMENDED
WEIGHTS. IT IS RECOMMENDED THAT
TRACTOR BE EQUIPPED WITH
ROLLOVER PROTECTIVE SYSTEM
(ROPS) AND SEAT BELTS.
A. Attach to tractor Cat. I three point hitch as
described in tractor operator’s manual.
E. Raise and lower cutter to determine position
with greatest distance between PTO shaft and gear-
box input shaft. Shut down tractor leaving cutter in
position of greatest distance. SECURELYBLOCK
CUTTER IN POSITION.
F. Hold down driveline sections parallel to each
other and check for minimum 6 inches (152mm)
overlap. (Figure 2-2) If driveline has been marked for
cutting, overlap will be the distance between two
marks. If driveline has less than minimum overlap,
DO NOT USE. Contact authorized Bush Hog dealer.
NOTE
If driveline is correct length, omit the fol-
lowing steps “G” through “J” and proceed
to step “K”.
Figure 2-1
Figure 2-2
Minimum
Overlap
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G. Clamp end of driveline in a vice. Cut off shield
where marked. (Figure 2-3).
Figure 2-5
Figure 2-3
DANGER
MAKE CERTAIN DRIVELINE YOKES
ARE SECURELY FASTENED. FAILURE
TO DO SO MAY RESULT IN SERIOUS
INJURY.
H. Using cut off section of shield as a guide, cut
shaft the same amount. (Figure 2-4)
Figure 2-4
L. Raise cutter off ground and adjust lower lift
arms to level cutter right to left. Refer to tractor oper-
ator’s manual.
M. Lower cutter to work position. Adjust tractor
top link to position cutter top flex link as shown in
Figure 2-6. This allows cutter to “float” during opera-
tion. Also lower the tractor lift arms so that lower
links can also “float”.
N. Adjust tractor sway chains, stabilizer bar or
equivalent to prevent side sway.
Figure 2-6
Flex-Link
Tractor
Top Link
I. Repeat steps “G” and “H” to other driveline sec-
tion.
J. Deburr ends of driveline sections and clean
away all chips and filings. (Figure 2-5)
Tractor
Lower Lift Arm
K. Apply multi-purpose grease to outside of male
driveline section. Assemble driveline and install on
tractor and cutter. Pull on each driveline section to
be sure yokes lock into place. Make certain driveline
shielding is in place and in good condition.
Lower Link
8
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SECTION III
OPERATING INSTRUCTIONS
Figure 3-1
3-1 GENERAL SAFETY
Only qualified people familiar with this operator’s
manual and tractor operator’s manual should oper-
ate this machine. Operator should wear hard hat,
safety glasses and safety shoes. The operator
should read, understand and practice all safety mes-
sages shown on the caution, warning and danger
decals affixed to the cutter to avoid serious injury or
death. It is recommended that tractor be equipped
with Rollover Protective System (ROPS) and a seat
belt be used. Before beginning operation, clear work
area of any objects that may be picked up and
thrown. Check for ditches, stumps, holes or other
obstacles that could upset tractor or damage cutter.
Always lower cutter to ground and allow blades to
come to a complete stop, set parking brake and turn
off tractor engine before leaving tractor operator’s
seat.
Spacers
Caster
Wheel
3-2 CUTTING HEIGHT ADJUSTMENT
DANGER
The cutter should be operated at the highest position
that will give desired cutting results. This will help
prevent blades from striking the ground, reducing
blade wear and undue strain on the machine. Adjust
as follows:
A. Raise cutter off ground using tractor 3-point lift.
SECURELY BLOCK CUTTER IN POSITION.
STAND CLEAR OF ROTATING CUTTER
BLADES UNTIL ALL MOTION HAS
STOPPED. TO AVOID ACCIDENTAL FALL
AND POSSIBLE INJURY FROM CUTTER,
IT IS RECOMMENDED THAT TRACTOR
BE EQUIPPED WITH ROLLOVER PRO-
TECTIVE SYSTEM AND THAT A SEAT
BELT BE USED FOR ALL OPERATIONS.
WARNING
THE CUTTER CAN FALL FROM HYDRAULIC
SYSTEM FAILURE. TO AVOID SERIOUS
INJURY OR DEATH, SECURELY SUPPORT
CUTTER BEFORE WORKING UNDERNEATH.
C. With tractor at idle speed, engage PTO drive.
Advance throttle to 540 PTO rpm.
D. Place tractor in low gear and begin cutting.
Tractor forward speed should be controlled by gear
selection, not engine speed. For maximum cutting
efficiency, forward speed should allow cutter to
maintain a constant maximum blade speed.
B.Remove pin securing caster stem to caster arm.
(Figure 3-1). Remove caster stem from caster arm.
C. Place amount of spacers on caster stem to
give desired cutting height. With no spacers on the
bottom, a 1” or slightly lower cutting height is given.
D. Reinstall caster stem into caster arm. Place
remaining spacers on caster stem above caster arm
and install pin to retain.
If tractor engine or cutter stalls, do not slip tractor
clutch to allow engine to retain speed as this will
exert undue strain on the implement drivetrain.
When stalling occurs, disengage PTO drive, move to
a cut area, set tractor throttle to idle, then re-engage
PTO drive.
E. Repeat operation for all caster wheels. Make
certain all wheels are adjusted to the same height.
3-3 OPERATION
A. Perform BEFORE EACH USE maintenance list
in paragraph 4-1.
Always cut up and down the face of slopes, never
across.
B. Start tractor. Lower cutter until it is supported
by caster wheels. Position tractor lower lift arms so
cutter lower links are parallel to ground.
Check belt tension after first 8 hours. Adjust per-
paragraph 4-3 if needed.
3-4 TRANSPORTING
DANGER
Turn off PTO drive and fully raise tractor 3-point lift
before transporting. When implement is transported
on road or highway, day or night, use tractor flashing
warning lights unless prohibited by law. A slow mov-
ing vehicle (SMV) sign must be visible from the rear
by approaching vehicles.
STAY CLEAR OF ROTATING DRIVELINE. DO
NOT OPERATE WITHOUT DRIVELINE SHIELDS
IN PLACE AND IN GOOD CONDITION. FAILURE
TO HEED THESE WARNINGS MAY RESULT IN
PERSONAL INJURY OR DEATH.
9
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SECTION IV
MAINTENANCE
8.During operation, listen for abnormal sounds
4-1 MAINTENANCE CHECK LIST
which might indicate loose parts, damaged bearings,
or other damage. Correct any deficiency before con-
tinuing operation.
Perform scheduled maintenance as outlined below.
Lower implement to ground, turn off tractor, and set
parking brake before doing maintenance inspections
or work. Some checks may require raising machine
off ground and supporting with blocks. All bolts
should be torqued as indicated in torque chart on
page 16 unless otherwise indicated.
AFTER EACH USE
1. Clean all debris from machine especially under-
side of deck, underneath belt shield and off safety
decals. Replace any missing or illegible decals.
2. Inspect cutter for worn or damaged compo-
nents. Repair or replace before next use. Any
replacement components installed during repair shall
include the components’ current safety decals speci-
fied by the manufacturer to be affixed to the compo-
nent.
WARNING
THE CUTTER CAN FALL FROM
HYDRAULIC SYSTEM FAILURE. TO
AVOID SERIOUS INJURY OR DEATH,
SECURELY SUPPORT CUTTER BEFORE
WORKING UNDERNEATH.
3. Store cutter in a dry place.
40 HOURS
1. Check belt for proper tension. Refer to para-
graph 4-3.
BEFORE EACH USE.
1. Check tractor tire air pressure. Refer to
tractor operator’s manual. Check mower tire pres-
sure. Tire pressure should be 40 psi.
4-2 LUBRICATION (Figures 4-1A, B & C)
2. Check blades and spindles to be sure that no
foreign objects such as wire or steel strapping bands
are wrapped around them.
3. Check blade bolts for tightness. Tighten to 76
ft./lbs.
4. Inspect blades for wear. Replace if necessary
per paragraph 4-5. Use only genuine Bush Hog
replacement parts. If it is necessary to sharpen the
blades, remove the blades from the spindles before
sharpening. DO NOT sharpen blades while still
attached to mower.
5. Make certain all shields are in place and in
good condition. Repair or replace any missing or
damaged shields.
NOTE
The multi-purpose grease referenced in this
secftion is an NLGI Grade 2 type grease.
BEFORE EACH USE
1. Driveline Universal Joints - Apply multi-pur-
pose grease with grease gun.
2. Driveline Guard - Apply 2-3 shots of multi-pur-
pose grease with grease gun to plastic fitting.
3. Wheels - Apply multi-purpose grease wiith
grease gun.
4. Caster Pivot - Apply multi-purpose grease with
grease gun.
5. Input Gearbox - Add EP80W-90 gear oil, if
necessary, to bring oil level to check plug.
6. Inspect wheel(s) for wear, damage or foreign
objects. Repair or replace if necessary.
7. Perform BEFORE EACH USE lubrication per
paragraph 4-2.
20 HOURS
6. Driveline - Disconnect PTO driveline, pull the
two sections apart, apply thin coat of multi-purpose
grease to outside of inner (male) section.
Reassemble sections and install. Pull each section
to be sure driveline and shields are securely con-
nected. Make certain PTO shielding is in good con-
dition.
Figure 4-1A
Figure 4-1B
(6) 20 Hours
(2) Before EachUse
(3)
(4)
(1) Before Each Use
(5) Before Each Use
10
Before Each Use
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D. Install new belt, referring to the diagram below
(also refer to the decal on the mower deck). Be sure
that the belt is properly positioned in all sheave
grooves.
E. Adjust tension on belt by adjusting the length of
the spring on the movable idler. The correct spring
length is 8-3/4”.
40 HOURS
7. Spindle Assembly - Apply multi-purpose grease
with grease gun until grease purges out top seal.
Grease fittings for spindles should be accessed by
removing the plastic plugs in the shields. After com-
pleting lubrication, replace plastic plugs.(Figure 4-1C)
F. Replace right and left side shields.
4-3 BELT ADJUSTMENT
Belt tension should be checked every 40 hours to
get maximum life from drive belt and best perfor-
mance from cutter. Belt tension is adjusted by
increasing or decreasing the length of the spring on
the movable idler. For proper belt tension, the spring
length should be set at 8-3/4”. (Figure 4-1C) To
adjust the spring length, loosen or tighten the 3/8”
hex nuts on the spring adjustment rod until the cor-
rect spring length is reached.
4-5 BLADE REPLACEMENT
CAUTION
WEAR HEAVY WORK GLOVES TO PRO-
TECT HANDS FROM SHARP EDGES.
A. Raise cutter using tractor 3-point lift and
SECURELY BLOCK INTO POSITION.
B. Set parking brake, turn off tractor and remove
key
C. Remove bolts, nuts and lockwashers, securing
blade and blade support bar to blade mounting bar.
Remove blade and blade support bar.
Figure4-1C
D. Install new blade(s) and reinstall blade support
bar(s) as shown in Figure 4-2. Be sure that blades
are installed with offset in proper direction. Tighten
retaining bolts to 76 ft./lbs.
Spring Length Adjustment - 3/8” Hex Nuts
Figure 4-2
(7) 40 Hours
Spring Length 8-3/4”
BELT DIAGRAM
4-4 BELT REPLACEMENT
Use only genuine Bush Hog replacement parts.
A. Remove right and left side shields.
B. Relieve spring tension by loosening the two
3/8” hex nuts on the spring adjustment rod. (Figure
4-1C.
C. Remove old belt.
11
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4-6 TROUBLESHOOTING
Troubleshooting procedures are listed in Table 4-1 below. If the problem cannot be solved or replacement parts
are necessary, contact your authorized Bush Hog dealer. Please have ready your machine name, model num-
ber, serial number, purchase date and exact cause or description of problem.
Table 4-1 Troubleshooting
PROBLEM
PROBABLE CAUSE
REMEDY
Uneven Cut
Cutter not level
side to side or
front to rear.
See SECTION III.
Belt slipping.
Adjust belt per
paragraph 4-3.
Worn or bent blade(s).
Replace blade(s).
Streaking or Windrowing
Possible build-up
of material under
cutter.
Clean cutter.
Cutter not level.
Worn blades.
Belt slipping.
See SECTION III.
Replace blades.
Adjust belt per
paragraph 4-3.
Noisy Cutter
Loose components.
Low oil in gearbox.
Check all bolts for
tightness.
Check oil per paragraph 4-2.
Rapid Blade Wear
(cutting edge)
Blade contacting
ground.
Adjust cutting height to
eliminate ground contact.
Rapid Blade
Wear
Cutter not being
operated at rated PTO speed.
Set tractor throttle for
proper PTO speed.
Use lower gear.
Cutter Vibrating
Cutter not being
operated at rated
PTO speed.
Set tractor throttle for
proper PTO speed.
Blade(s) bent.
Replace blades.
Remove object.
Foreign object wrapped
around spindle or blade.
12
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SECTION V
DEALER ASSEMBLY
10. If the assembly calls for welding or cutting, be
CAUTION
sure that there are no flammable materials close at
hand and that bystanders have taken necessary
precautions.
AFTER COMPLETING ANY ASSEMBLY STEP,
THOROUGHLY READ THE NEXT STEP IN THE
ASSEMBLY INSTRUCTIONS BEFORE PRO-
CEEDING WITH THAT STEP.
THE FOLLOWING SAFETY PRECAUTIONS
SHOULD BE THOROUGHLY UNDERSTOOD
BEFORE ATTEMPTING MACHINE ASSEMBLY.
1. Wear personal protective equipment such as,
but not limited to, protection for eyes, ears, feet,
hands, lungs and head when assembling the equip-
ment. Do not wear loose clothing or jewelry that may
catch on equipment moving parts.
2. Do not lift heavy parts or assemblies. Use
crane, jack, tackle, fork trucks or other mechanical
devices.
11. After completing assembly, thoroughly inspect
the machine to be sure that all nuts, bolts, hydraulic
fittings or any other fastened assemblies have been
thoroughly tightened.
12. After completing assembly, be sure that all
safety locking devices or guards are in place.
13. Before operating the machine, thoroughly
read the operation section of this manual.
3. Select an area for assembly that is clean and
free of any debris which might cause persons work-
ing on the assembly to trip.
4. Arrange parts to be assembled neatly in the
work area and have tools or other mechanical assist-
ing devices in easy reach.
5. Inspect all parts and assemblies thoroughly and
remove any sharp edges, grease, oil or dirt which-
might cause pieces to slip when handling.
6. Preview the assembly instructions in your oper-
ator’s manual before proceeding further.
7. If the assembly instructions call for parts or
assemblies to be blocked up, use only blocking
material that is in good condition and is capable of
handling the weight of the assembly to be blocked.
Also, insure that the blocking material is on a clean,
dry surface.
8. Never put hands or any other part of body
under blocked up assemblies if at all possible.
9. Always wear goggles or safety glasses when
hammering, grinding, or drilling metal parts.
14. Before operating the machine, read the main-
tenance section of this manual to be sure that any
parts requiring lubrication such as gearboxes are full
to avoid any possible damage.
BEFORE OPERATING THE EQUIPMENT, IF YOU
HAVE ANY QUESTIONS REGARDING THE
PROPER ASSEMBLY OR OPERATION, CON-
TACT YOUR AUTHORIZED BUSH HOG DEALER
OR REPRESENTATIVE.
5-1 BASE UNIT ASSEMBLY
A. Remove mast support from deck assembly by
removing the 5/8” x 2-1/2” bolts, flatwashers, lock-
washers, and hex nuts. (Figure 5-1)
B. Attach lower lift links to deck assembly using
5/8” x 2-1/2” bolts, flatwashers, lockwashers, hex
nuts and pivot bushings. (Figure 5-2)
Figure 5-2
Figure 5-1
Gearbox
Flex Link
Mast
Support
Mast Half
Caster Arm
Spacers
Lower Lift Link
Lower Lift Link
5/8” x 2-1/2” Bolt
13
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nut (Figure 5-5).
C. Install lift pins onto lower links, securing with
7/8 lockwashers and hex nuts.
F. Place two long spacers on the caster stems
and insert into caster arms. Place two long spacers
and two short spacers on the caster stem above the
caster arms. This arrangement will give a cutting
height of approximately three inches. Secure caster
stems with lynch pin retainers. With the weight of
cutter resting on all four wheels, be sure that cutter
is level.
G. If front roller option is purchased, install by
securing the roller mounts to the deck in the holes
provided by using 3/8 x 1-1/4 carriage bolts, flat-
washers, lockwashers and hex nuts provided. Install
bolts with heads to inside of deck. Assemble rollers,
roller shaft, retaining pin and roll pin as shown in
Figure 5-6 and 5-6A.
D. Remove caster arms by removing eight (8) 5/8
x 4 bolts, lockwashers and nuts securing them to
the deck assembly. Slide caster arms, in channel,
toward rear of machine until holes in rear of caster
arm align with holes in rear of mounting channel.
Secure caster arms (2) and caster arm mounts (2
front, 2 rear) to front and rear of channel using 5/8 x
4 bolts, lockwashers and hex nuts previously
removed (Figure 5-3). Attach the two (2) mast sup-
ports to the inside of the channels at the top, rear
hole in each channel, also with the hardware previ-
ously removed (Figure 5-3). Secure the caster arm
mounts (2 front, 2 rear) to the deck with 1/2 x 1
bolts, lockwashers and hex nuts provided (Figure 5-
4).
H. Fill gearbox with EP80W-90 gear oil unti oil
level is at check plug on front of gearbox housing.
E. Swing mast halves upward into position so that
they align with mast supports from rear of machine.
Fasten mast supports and upper flex link to mast
halves using 5/8 x 6 bolt, 2-5/8 pivot tube and lock-
Figure 5-6
Figure 5-6A
3/8” x 1-1/4” Carriage Bolt
L.H. Mount
Bracket
3/8” Flatwasher
3/8” Lockwasher
3/8” Hex Nut
3/16” x 2”
Roll Pin
R.H. Mount
Bracket
R.H. Mount
L.H. Mount
Roller
Roller
Bracket
Bracket
3/4” Flatwashers
1/4” x 2-1/2” Cotter Pin
1/4” x 1” Carriage Bolt
1/4” Flatwasher
1/4” Lockwasher
1/4” Hex Nut
14
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SAFETY DECALS
To promote safe operation, Bush Hog supplies safety decals on all products manufactured. Because damage
can occur to safety decals either through shipment, use or reconditioning, Bush Hog will, upon request, provide
safety decals for any of our products in the field at no charge. Contact your authorized Bush Hog dealer for
more information.
83056
88655
50042284
50012815
50042285
50042283
50012816
78608
78786
50042282
15
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TORQUE SPECIFICATIONS
Proper toque for American fasteners used on Bush Hog equipment.
Recommended Torque in Foot Pounds (Newton Meters).*
AMERICAN
BOLT DIAMETER
Bolt Head Markings
WRENCH
(IN.) “B” AND
THREAD SIZE
SAE
SAE
SAE
SIZE (IN.) “A”
GRADE 2
GRADE 5
GRADE 8
7/16
7/16
1/4 - 2O UNC
1/4 - 28 UNF
5/16 - 18 UNC
5/16 - 24 UNF
3/8 - 16 UNC
3/8 - 24 UNF
7/16 - 14 UNC
7/16 - 20 UNF
1/2 - 13 UNC
1/2 - 20 UNF
9/16 - 12 UNC
9/16 - 18 UNF
5/8 - 11 UNC
5/8 - 18 UNF
3/4 - 10 UNC
3/4 - 16 UNF
7/8 - 9 UNC
6 (7)
8 (11)
10 (13)
12 (16)
14 (18)
6 (8)
1/2
11 (15)
17 (23)
25 (33)
SAE Grade 2
(No Dashes)
1/2
13 (17)
19 (26)
27 (37)
9/16
20 (27)
31 (42)
44 (60)
9/16
23 (31)
35 (47)
49 (66)
5/8
32 (43)
49 (66)
70 (95)
5/8
36 (49)
55 (75)
78 (106)
3/4
49 (66)
76 (103)
106 (144)
120 (163)
153 (207)
172 (233)
212 (287)
240 (325)
376 (509)
420 (569)
606 (821)
668 (905)
909 (1232)
995 (1348)
1019 (1381)
1288(1745)
1444 (1957)
1817 (2462)
2013 (2728)
2382 (3228)
2712 (3675)
3161 (4283)
3557 (4820)
3/4
55 (75)
85 (115)
7/8
70 (95)
109 (148)
122 (165)
150 (203)
170 (230)
266 (360)
297 (402)
430 (583)
474 (642)
644 (873)
705 (955)
721 (977)
795 (1077)
890 (1206)
1120 (1518)
1241 (1682)
1470 (1992)
1672 (2266)
1950 (2642)
2194 (2973)
7/8
79 (107)
97 (131)
110 (149)
144 (195)
192 (260)
166 (225)
184 (249)
250 (339)
274 (371)
280 (379)
354 (480)
397 (538)
500 (678)
553 (749)
655 (887)
746 (1011)
870 (1179)
979 (1327)
SAE Grade 5
(3 Dashes)
15/16
15/16
1-1/8
1-1/8
1-5/16
1-5/16
1-1/2
1-1/2
1-1/2
1-11/16
1-11/16
1-7/8
1-7/8
2-1/16
2-1/16
2-1/4
2-1/4
7/8 - 14 UNF
1 - 8 UNC
1 - 12 UNF
Wrench
Size “A”
1 - 14 UNF
SAE Grade 8
(6 Dashes)
1-1/8 - 7 UNC
1-1/8 - 12 UNF
1-1/4 - 7 UNC
1-1/4 - 12 UNF
1-3/8 - 6 UNC
1-3/8 - 12 UNF
1-1/2 - 6 UNC
1-1/2 - 12 UNF
Proper torque for metric fasteners used on Bush Hog equipment.
Recommended torque in foot pounds (newton Meters).*
METRIC
WRENCH
BOLT
DIA.
SIZE
(mm) “A”
ASTM
4.6
ASTM
8.8
ASTM
9.8
ASTM
10.9
(mm) “B”
8
5
1.8 (2.4)
3 (4)
5.1 (6.9)
8.7 (12)
21.1 (29)
42 (57)
6.5 (8.8)
11.1 (15)
27 (37)
10
13
16
18
21
24
30
33
36
41
46
6
8
7.3 (10)
14.5 (20)
25 (34)
40 (54)
62 (84)
122 (165)
Wrench
Size “A”
10
12
14
16
20
22
24
27
30
53 (72)
8.8
74 (100)
118 (160)
167 (226)
325 (440)
443 (600)
563 (763)
821 (1112)
1119 (1516)
73 (99)
93 (126)
116 (157)
181 (245)
148 (201)
230 (312)
449 (608)
611 (828)
778 (1054)
1138 (1542)
1547 (2096)
Numbers appearing on bolt heads
indicate ASTM class.
*Use 75% of the specified torque value for plated
fasteners. Use 85% of the specified torque values
for lubricated fasteners.
211 (286)
418 (566)
16
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