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COMPLETE CONTENTS
SECTION 35 -- HYDRAULIC SYSTEM
Chapter 1 -- Hydraulic System

CONTENTS
Section Description Page

General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic System Layout/Components (770GC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic Cylinder (770GC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic Cylinder Specifications (770GC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic Cylinder Parts List (770GC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hydraulic System Layout/ Components (780GC Three Cylinder Hydraulic Circuit) . . 10
Center Deck Hydraulic Cylinder (780GC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Center Deck Hydraulic Cylinder Specifications (780GC) . . . . . . . . . . . . . . . . . . . . . . . . . 11
Center Deck Hydraulic Cylinder Parts List (780GC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Center Deck Hydraulic Cylinder (780GC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Wing Hydraulic Cylinders (780GC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Wing Hydraulic Cylinders Specifications (780GC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Wing Hydraulic Cylinders Parts List (780GC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Hydraulic System Layout/Components (Optional Self Leveling Five
Cylinder Hydraulic Circuit) (Phasing Circuit) (780GC) . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Chapter 1 -- Hydraulic System (Continued)

CONTENTS

Center Deck Hydraulic Cylinder (Phasing) (780GC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Center Deck Phasing Hydraulic Cylinder Specifications (780GC) . . . . . . . . . . . . . . . . 19
Center Deck Phasing Hydraulic Cylinder Parts List (780GC) . . . . . . . . . . . . . . . . . . . . 20
Center Deck Phasing Hydraulic Cylinder (780GC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Preparation and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Wing Phasing Hydraulic Cylinders (780GC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Wing Phasing Hydraulic Cylinders Specifications (780GC) . . . . . . . . . . . . . . . . . . . . . . 22
Wing phasing hydraulic cylinders (780GC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SECTION 58 -- CUTTER COMPONENTS
Chapter 1 -- Blade Service

CONTENTS

Blade Removal and Installation (770GC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Blade Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Blade Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Blade Sharpening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Blade Removal (Center Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Blade Removal (Wing Decks) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Blade Installation (Center Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Blade Installation (Wing Decks) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Blade Sharpening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Blade Carrier Removal and Installation (770GC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Blade Carrier Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Blade Carrier Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Blade Carrier Removal (Center Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Blade Carrier Removal (Wing Decks) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Blade Carrier Installation (Center Deck/Wing Decks) . . . . . . . . . . . . . . . . . . . . . . . 15
Chapter 2 -- PTO Shaft Lubrication and Maintenance

CONTENTS

PTO Shaft Lubrication (770GC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
U-joint and CV Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Plastic Shield Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Inner and Outer Drive Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Plastic Shield Support Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Plastic Shield Support Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Chapter 3 – Slip Clutches

CONTENTS

Slip Clutch Adjustment (770GC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PTO Shaft Removal (Divider Gearbox) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PTO Shaft Removal (Deck Gearboxes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
PTO Shaft Installation (Deck Gearboxes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
PTO Shaft Installation (Divider Gearbox) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Seasonal Clutch Maintenance (770GC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Slip Clutch Repair (770GC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Slip Clutch Components (770GC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Chapter 4 – Skid Shoe/Side Skirt (780GC Only) and

Front Tongue Assembly (780GC Only)
CONTENTS

Skid Shoes (780GC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Skid Shoe Replacement (Center Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Skid Shoe/Side Skirt Replacement (Wing Decks) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Front Tongue Assembly (780GC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Leveling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Front Tongue Assembly Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Chapter 5 -- Axle Suspension (780GC Only)

CONTENTS

Axle Compression springs (Center Section Axles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Axle Compression springs (Wing Axles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Emergency Axle Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Chapter 6 – Wheel Hubs

CONTENTS

Wheel Hub Assembly (770GC and 780GC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Wheel Hub Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Chapter 7 – Gearbox Repair

CONTENTS

Outer Gearboxes (770GC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Gearbox Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Output Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Chapter 7 – Gearbox Repair (Continued)

CONTENTS

Gearbox Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Backlash Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Center Gearbox (770GC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Through Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Flex Coupler Repair (770GC Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Rubber Disc Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Divider Gearbox (780GC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

CONTENTS

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Output Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Backlash Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Final Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Main PTO/Gearbox PTO Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Divider Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Left Wing, Center Deck and Right Wing Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Output Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

CONTENTS

Input Shaft/Input Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Final Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Left Wing, Center Deck and Right Wing PTO Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1
CONTENTS

General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
35-1

Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
35-2
GENERAL SAFETY
WARNING
Hydraulic oil or diesel fuel leaking under
pressure can penetrate the skin and cause
infection or other injury. To prevent personal
injury: relieve all pressure, before disconnecting
fluid lines or performing work on the hydraulic
system. Before applying pressure, make sure all
connections are tight and components are in
good condition. Never use your hand to check for
suspected leaks under pressure. Use a piece of
cardboard or wood for the purpose. If injured by
leaking fluid, see your doctor immediately.
M149C
HYDRAULIC SYSTEM LAYOUT/

COMPONENTS (770GC)
1 2
86086752
Item Description Qty. Part No.

1 Hydraulic Cylinder, 3 inch Bore x 8 inch Stroke 1 263--3288
2 Elbow, 90° Hydraulic Fitting 1 800--0203
3 Hydraulic Hose, 3/8 x 140 inch 1 415--0140
35-3
HYDRAULIC CYLINDER (770GC)

Preparation
1. Before removing the hydraulic cylinder from the
770GC Rotary Cutter, make sure the 770GC
Rotary Cutter is parked on level ground.
2. Lower the cutter to the ground. This will relieve
the pressure in the hydraulic cylinder.
Removal
1 2 4 5
1. Disconnect the 3/8 x 140 inch hydraulic hose, 1,
from the 90° hydraulic fitting, 2, on the hydraulic
cylinder, 3.
2. Remove the hairpin cotter pin, 4, and pin, 5, from
the hydraulic cylinder, 3, and axle weldment, 6.
3. Remove the remaining hairpin cotter pin, 7, and
pin, 8, from the hydraulic cylinder, 3, and mount,
9. 3
7 8 9
4. The hydraulic cylinder, 3, can now be removed 6
from the rotary cutter. 86086762
HYDRAULIC CYLINDER SPECIFICATIONS

(770GC)
76080465
Cylinder Description Rod Closed Mounting Pin PSI Seal Kit

Part No. Diameter Length Diameter Part No.
263--3288 3 inch Bore x 1-1/4 inch 20-1/4 inch 1 inch 2500 263--46905
8 inch Stroke
35-4
16 15 12
17
1
11
13
14
10
8
5
9
8
7
4
6
3
18
76080466 1
4
HYDRAULIC CYLINDER PARTS LIST
(770GC)
Item Description Qty. Item Description Qty.

1 Tie Rod Nuts 8 10* O-Ring 1
2 Tie Rod 4 11 Rod 1
3 Base Clevis 1 12 Rod Clevis 1
4* O-Ring 1 13 Cylinder Head 1
5 Cylinder Tube 1 14* O-Ring 1
6 Piston Nut 1 15* Wiper Seal 1
7 Piston 1 16* Backup Ring 1
8* Backup Ring 2 17* O-Ring 1
9* O-Ring 1 18 Pipe Plug 1
*Included in seal kit
35-5
HYDRAULIC CYLINDER (770GC)

1
Disassembly
1. Remove all the tie rod nuts, 1, and remove tie
rods, 2. 2
76080466 1
5
2. Remove the base clevis, 1, O-ring, 2, and
cylinder tube, 3.
3
2
1
76080466
6
3. Remove the piston nut, 1, piston, 2, backup
washers, 3, and O-rings, 4 and 5.
3
4
3
2
5
1
76080466
35-6
4. Slide the cylinder head, 1, off the rod, 2, and
remove the O-ring, 3. 1
2
3
76080466
8
5. Remove the wiper seal, 1, backup ring, 2, and
O-ring, 3, from the cylinder head, 4, by using a 4
seal removal tool. 1
2
76080466
9
Inspection
1. Clean and inspect the cylinder, rod, and related
components for any wear or damage. Replace as
necessary.
2. Replace all the seals during assembly.
35-7
Assembly
2
1. Install the new O-ring, 1, onto the cylinder head, 6
2. 1 5
2. Install the new O-ring, 3, new backup ring, 4, and 4
new wiper seal, 5, into the cylinder head, 2.
3
NOTE: Tap the wiper seal into place using a soft face
hammer.
NOTE: Lubricate all seals and O-rings with clean

hydraulic oil during reassembly.
76080466
3. Slide the cylinder head, 2, onto the rod, 6.
10
4. Install the new O-ring, 1, new backup rings, 2,
and new O-ring, 3, onto the rod, 4.
4
5. Slide the piston, 5, onto the rod, 4, and secure
using the nut, 6.
2
3
2 1
5
6
76080466
11
6. Install the new O-ring, 1, onto the base clevis, 2.
7. Slide the cylinder tube, 3, over the rod and piston 3
assembly.
2
76080466
12
35-8
8. Install the tie rods, 1, through the base clevis, 2,
and cylinder head, 3. Secure using the tie rod 4
nuts, 4, that were previously removed. 3
NOTE: Tighten all the tie rod nuts evenly.
1
76080466
4
13
Installation
8 9 6 7
1. Attach the hydraulic cylinder, 1, to the mount, 2,
on the cutter and secure using the pin and hairpin
cotter pin, 3 and 4, that were previously removed.
2. Attach the rod end of the hydraulic cylinder, 1, to
the axle weldment, 5, and secure using the pin
and hairpin cotter pin, 6 and 7, that were
previously removed.
3. Reattach the 3/8 x 140 inch hydraulic hose, 8, to 3 4 2 1 5
the 90° hydraulic fitting, 9, located on the
hydraulic cylinder, 1.
86086762
4. With the rotary cutter connected to the tractor.
Raise and lower the cutter several times until all 14
the air is bled out of the hydraulic cylinder.
NOTE: Check the hydraulic oil level in the tractor and
add oil as necessary.
5. Once all the air is bled out from the hydraulic

cylinder, the cutter should move and up and
down smoothly.
35-9
HYDRAULIC SYSTEM LAYOUT/

COMPONENTS (780GC THREE CYLINDER
HYDRAULIC CIRCUIT)
6 5
6 3
5
1 2
4
4
86091120
15
Item Description Qty. Part No.

1 Hydraulic Cylinder, 3-1/2 inch Bore x 12 inch Stroke 1 415--1600
2 Elbow, 90 Degree Hydraulic Fitting 1 800--0203
4 Hydraulic Cylinder, 3 inch Bore x 14 inch Stroke 2 415--0054
5 Restrictor, 90° Hydraulic Fitting 2 800--0202
35-10
CENTER DECK HYDRAULIC CYLINDER

(780GC)
Preparation
1. Before removing the center hydraulic cylinder
from the 780GC Flex Wing Rotary Cutter, make
sure the 780GC Flex Wing Rotary Cutter is
parked on level ground.
2. Lower the center deck to the ground. This will
relieve the pressure in the center hydraulic
cylinder.
Removal
7 8
1. Disconnect the 3/8 x 195 inch hydraulic hose, 1, 3
from the 90° hydraulic fitting, 2, on hydraulic
cylinder, 3.
1
2. Remove the hairpin cotter pin, 4, and pin, 5, from
the hydraulic cylinder, 3, and center axle beam,
6
6. 2
3. Remove the remaining hairpin cotter pin, 7, and
pin, 8, from the hydraulic cylinder, 3, and mount
located on the center cutter deck. 4 5
4. The center hydraulic cylinder, 3, can now be 86091121
removed from the rotary cutter.
16

SPECIFICATIONS (780GC)
76080465
17
Cylinder Description Rod Diame- Closed Mounting Pin PSI Seal Kit Part
Part No. ter Length Diameter No.
415--1600 3-1/2 inch Bore 1-1/4 inch 22-1/4 inch 1 inch 2500 263--46906
x 12” Stroke
35-11
16 15 12
17
1
11
13
14
10
8
5
9
8
7
4
6
3
18
76080466 1
18
PARTS LIST (780GC)

35-12

(780GC)
Disassembly and Assembly
For disassembly and assembly instructions for the
center deck hydraulic cylinder refer to “Hydraulic
Cylinder (770GC), Disassembly” listed earlier in this
section.
Installation
2 3
1. Attach the hydraulic cylinder, 1, to the mount 1
located on the center cutter deck and secure
using the pin and hairpin cotter pin, 2 and 3, that
were previously removed.
8
2. Attach the rod end of the hydraulic cylinder, 1, to

4
the center axle beam, 4, and secure using the pin 9
and hairpin cotter pin, 6 and 7, that were
previously removed.
3. Reattach the 3/8 x 195 inch hydraulic hose, 8, to 6 7
the 90° hydraulic fitting, 9, located on the
hydraulic cylinder, 1. 86091121
4. With the rotary cutter connected to the tractor. 19

Raise and lower the cutter several times until all
the air is bled out of the hydraulic cylinder.

down smoothly.
35-13
WING HYDRAULIC CYLINDERS (780GC)

Preparation
1. Before removing the wing hydraulic cylinders
from the 780GC Flex Wing Rotary Cutter, make
sure the 780GC Flex Wing Rotary Cutter is
parked on level ground.
2. Lower all the cutter decks to the ground. This will
relieve the pressure in the hydraulic cylinders.
3. In order to lower the wing decks, the transport
lock braces, 1, will need to be removed from the 2 3
hydraulic cylinders on each wing.
4. Remove the two lynch pins and flat washers, 2
and 3, from the pins on the hydraulic cylinders.
Remove the transport lock braces, 1.
1
5. Reattach the flats washers and lynch pins, 2 and
3, to the hydraulic cylinders, 1, after the transport
lock braces are removed. 4
NOTE: It may be necessary to raise or lower the wing 2 3
with the wing hydraulic cylinder in order to remove
the lock brace. After the lock braces are removed, 86086789
place them in the stowage position, 4, located on 20
both sides of the center deck.
Removal
1. Disconnect the 3/8 x 228 inch hydraulic hose, 1,
from the 90° restrictor hydraulic fitting, 2, on the 6 7
hydraulic cylinder, 3, that is to be removed.
2. Remove the lynch pin, 4, and flat washer, 5, from 1
the pin attached to the hydraulic cylinder, 3, and 3 2
mount located on the wing deck.
3. Drive the pin out from the hydraulic cylinder and
mount, by using a hammer and a drift.
4. Remove the remaining lynch pin, 6, and flat 4 5
washer, 7, from the clevis pin attached to the 86091122
hydraulic cylinder, 3, and mount located on the
center cutter deck. 21
5. Drive the clevis pin out from the hydraulic
cylinder and mount, by using a hammer and a
drift.
6. The wing hydraulic cylinder, 3, can now be
removed from the rotary cutter.
35-14
WING HYDRAULIC CYLINDERS

76080465
22
Cylinder Description Rod Closed Mounting Pin PSI Seal Kit Part
Part No. Diameter Length Diameter No.
415--0054 3 inch Bore x 1-1/4 inch 24-1/4 inch 1 inch 2500 263--46905
14 inch Stroke
35-15
16 15 12
17
1
11
13
14
10
8
5
9
8
7
4
6
3
18
76080466 1
23
WING HYDRAULIC CYLINDERS PARTS
LIST (780GC)

35-16
WING HYDRAULIC CYLINDERS (780GC)

Disassembly and Assembly
For disassembly and assembly instructions for the
wing deck hydraulic cylinders refer to “Hydraulic
Cylinder (770GC), Disassembly and Assembly”
listed earlier in this section.
Installation
1. Attach the hydraulic cylinder, 1, to the mount
located on the center cutter deck and secure 2 3
using the clevis pin, flat washer, 2, and lynch pin,
3, which were previously removed. 6
2. Attach the rod end of the hydraulic cylinder, 1, to 1 7
the mount located on the wing deck and secure
using the pin, flat washer, 4, and lynch pin, 5,
which were previously removed.
3. Reattach the 3/8 x 228 inch hydraulic hose, 6, to 4 5
the 90° restrictor hydraulic fitting, 7, located on
the hydraulic cylinder, 1. 86091122
4. With the rotary cutter connected to the tractor. 24

Raise and lower the wings several times until all
the air is bled out of the hydraulic cylinders.

down smoothly.
35-17
HYDRAULIC SYSTEM LAYOUT/COMPO-

NENTS (OPTIONAL SELF LEVELING FIVE
CYLINDER HYDRAULIC CIRCUIT)
(PHASING CIRCUIT) (780GC)
3
1 2 1
14 14 14
10 10 14
5 13 16 5
13
16 16
17 17
16 16
12
16
14 15 16 15 14
13 9
13
7 9
11
14 14
11
4
6
13 8
11
14 13 3
14
13
86091122
25
Item Description Qty. Part No. Item Description Qty. Part No.
1 Hydraulic Hose, 2 415--0228 8 Phasing Hydraulic Cylinder, 1 415--645033
3/8 x 228 inch 3-1/4 inch x 12 inch Stroke
2 Hydraulic Hose, 1 415--0249 9 Elbow 90°, Hydraulic Fitting 2 800--0207
3/8 x 249 inch 10 Restrictor, 90° Hydraulic 2 800--0202
3 Hydraulic Hose, 2 415--0041 Fitting
3/8 x 195 inch 11 Straight Hydraulic Fitting 4 800--0206
4 Hydraulic Hose, 1 415--0043 12 Clevis Pin 2 150--7104
3/8 x 90 inch
13 Cylinder Pin 6 261--700
5 Hydraulic Cylinder, 2 415--0054
3 inch Bore x 14 inch Stroke 14 Clips 6 412--5115
6 Phasing Hydraulic Cylinder, 3 1 415--645032 15 Transport Lock Braces 2 116--1572

inch Bore x 12 inch Stroke 16 Flat Washer, 1 inch 8 412--7975
7 Phasing Hydraulic Cylinder, 3-1/2 1 415--645034 17 Cylinder Pin 2 150--6306
inch Bore x 12 inch Stroke
35-18

(PHASING) (780GC)
Preparation
1. Before removing the center phasing hydraulic
cylinder from the 780GC Flex Wing Rotary
Cutter, make sure the 780GC Flex Wing Rotary
Cutter is parked on level ground.
2. Lower the center deck to the ground. This will
relieve the pressure in the center hydraulic
cylinder.
Removal
To remove the center phasing hydraulic cylinder,
refer to “Center Deck Hydraulic Cylinder (780GC),
Removal” listed earlier in this section.
NOTE: The center phasing hydraulic cylinder has

two hydraulic hoses connected to it. Both hoses will
need to be removed during removal.
CENTER DECK PHASING HYDRAULIC

CYLINDER SPECIFICATIONS (780GC)
76080465
26
Cylinder Description Rod Diameter Closed Mounting Pin PSI Seal Kit Part
Part No. Length Diameter No.
415--640534 3-1/2 inch Bore 1-1/4 inch 22-1/4 inch 1 inch 3000 415-639561
x 12 inch Stroke
35-19
CENTER DECK PHASING HYDRAULIC

CYLINDER PARTS LIST (780GC)
16 15 12
17
1
11
13
14
10
8
5
9
8
7
4
6
3
18
76080466 1
27

35-20
CENTER DECK PHASING HYDRAULIC WING HYDRAULIC CYLINDERS (780GC)

CYLINDER (780GC) Preparation and Removal
Disassembly and Assembly For preparation and removal instructions for the wing
For disassembly and assembly instructions for the hydraulic cylinders refer to “Wing Hydraulic
center deck phasing hydraulic cylinder refer to Cylinders (780GC), Preparation and Removal” listed
“Hydraulic Cylinder (770GC), Disassembly and earlier in this section.
Assembly” listed earlier in this section.
NOTE: The specifications and parts list for the wing
Installation hydraulic cylinders are the same for the standard
For installation instructions for the center deck three cylinder circuit and the five cylinder circuit.
phasing hydraulic cylinder refer to “Center Deck
Hydraulic Cylinder (780GC), Installation” listed Disassembly and Assembly
earlier in this section. For disassembly and assembly instructions for the
wing hydraulic cylinders refer to “Wing Hydraulic
NOTE: The center phasing hydraulic cylinder has Cylinder (770GC), Disassembly and Assembly”
two hydraulic hoses connected to it. Both hoses will listed earlier in this section.
need to be reconnected during installation.
Installation
For installation instructions for the wing hydraulic
cylinders refer to “Wing Hydraulic Cylinder (780GC),
Installation” listed earlier in this section.
35-21
WING PHASING HYDRAULIC CYLINDERS

(780GC)
Preparation
For preparation instructions for the wing phasing
hydraulic cylinders refer to “Wing Hydraulic
Cylinders (780GC), Preparation” listed earlier in this
section.
Removal
1. To remove the wing phasing hydraulic cylinders
refer to “Center Deck Hydraulic Cylinder
(780GC), Removal” listed earlier in this section.
NOTE: The wing phasing hydraulic cylinders have
two hydraulic hoses connected to each cylinder; both
hoses will need to be removed during removal.
NOTE: The wing phasing hydraulic cylinders are

attached to each wing deck and each wing axle
beam.
NOTE: The left and right wings use different phasing

hydraulic cylinders.
WING PHASING HYDRAULIC CYLINDERS

76080465
28
Cylinder Description Rod Diameter Closed Mounting Pin PSI Seal Kit Part No.
Part No. Length Diameter
415--645032 3 inch Bore x 1-1/4 inch 22--1/4 1 inch 3000 415--639558
(Left Side) 12 inch Stroke inch
415--654033 3-1/4 inch Bore x 1-1/4 inch 22--1/4 1 inch 3000 415--639560
(Right Side) 12 inch Stroke inch
35-22
NOTE: The parts list for the wing phasing hydraulic Installation
cylinders is the same as the center phasing hydraulic For installation instructions for the wing phasing
cylinder. hydraulic cylinders refer to “Center Deck Hydraulic
Cylinder (780GC), Installation” listed earlier in this
WING PHASING HYDRAULIC CYLINDERS section.
(780GC)
NOTE: The wing phasing hydraulic cylinders have
Disassembly and Assembly two hydraulic hoses connected to each cylinder; both
For disassembly and assembly instructions for the hoses will need to be reconnected during installation.
wing phasing hydraulic cylinders refer to “Hydraulic
Cylinder (770GC), Disassembly and Assembly” NOTE: The wing phasing hydraulic cylinders are
listed earlier in this section. attached to each wing deck and each wing axle
beam.
35-23
35-24
SECTION 58 -- CUTTER COMPONENTS -- CHAPTER 1
CONTENTS

Blade Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
58-1
BLADE REMOVAL AND INSTALLATION

(770GC)
WARNING
Never work under equipment supported by
hydraulic equipment because it may fall if the
lever is moved or hose failure could occur.
Always stop engine and remove key before
starting repairs. Always use suitable jacks or
jack stands to support equipment that has to be
repaired in the raised position. Failure to comply
could result in death or serious injury.
M1340
CAUTION
To avoid injury when handling blades, wear
leather gloves or wrap the blades in the area
where they will be held with heavy cloth or other
protective material. Failure to comply may result
in minor or moderate injury.
M1354
Blade Removal
1. Remove the 1/2 inch nut, 1, and 1/2 inch lock
washer, 2, from the inspection cover plate, 3, 4
located by each outer gearbox, 4.
NOTE: The 770GC Rotary Cutter has two inspection
cover plates located next to each outer gearbox. 1 2
NOTE: The 1/2 x 1-1/2 inch carriage bolt may fall out
after the 1/2 inch nut is removed.
3
86086755
1
2. Remove the inspection cover plate to gain
access to the blade carrier, 1. 1
3. Raise the cutter to maximum height possible with
the tractor to allow access under the cutter.
4. Place jack stands under the cutter to support the
weight of the cutter in case the hydraulic system
on the tractor failed.
86086756
58-2
5. Remove the 3/4 inch nut, 1; 3/4 inch lock washer,
2, and 3/4” bolt, 3, from the blade carrier, 4, to 2
4
remove the blade. 1
NOTE: Inspect the nut after removal, and replace if
threads are damage. Always replace the nut if the
bolt is replaced.
NOTE: Each blade carrier has two blades attached

to it.
3
86086756
3
Inspection
DANGER
Failure to replace abnormally worn blades will
lead to catastrophic failure of the blades and
ejection of the broken blade with tremendous
force. Failure to comply will result in death or
serious injury.
M1355
Inspect the blades daily for any cracks, bends or

chipped areas. Any damage that is not repairable
through blade sharpening warrants blade replace-
ment. Use only genuine New Holland blades on this
cutter.
Blade Installation
1. Install the new or sharpened balanced blade on
1
the blade carrier, 1, with the offset of the blade
facing “down” away from the cutter.
86086756
58-3
NOTE: Make sure each blade is facing the correct
direction. The left and right blade carriers rotate
toward the center of the cutter as shown in the
Caution Decal.
MAG490D1022
5
2. Secure the blade with the 3/4 inch bolt, 1; 3/4 inch
lock washer, 2, and 3/4 inch nut, 3. Torque the nut 3
to 407 N⋅m (300 lb-ft). 2
NOTE: When installing the 3/4 inch bolt through the
blade, and blade carrier. Take notice the blade and
blade carrier have a slot located in the hole for the
spline of the bolt to line up with.
3. When installing the blades, be sure to check the

blade bolt for wear. If the blade bolt is worn more 1
than 6.35 mm (0.25 in) at any point replace the
bolt and nut.
86086756
IMPORTANT: Re-torque the blade after the first hour 6

of cutter operation, and then daily thereafter.
IMPORTANT: The cutter blades must be indexed 90°
as shown in the Caution Decal to prevent the blades
from colliding with each other.
MAG490D1022
58-4
4. Reinstall the inspection cover plate, 1, and
secure using the 1/2 inch lock washer, 2, and 1/2
inch nut, 3, that were previously removed.
NOTE: Reinstall the 1/2 x 1-1/2 inch carriage bolt if
it fell out during removal.
5. Remove the jack stands from under the cutter. 2 3
1
86086755
58-5
BLADE SHARPENING
Inspect the blades daily before each use to be sure
they are properly installed and in good condition.
Replace any blade that is bent, cracked, or
excessively nicked or worn. Small nicks can be
ground out when sharpening. Use only genuine New
Holland blades on this cutter.
WARNING
M1340
CAUTION
protective material. Always wear eye protection
when sharpening blades. Failure to comply may
result in minor or moderate injury.
M1354
IMPORTANT: When sharpening blades, remove the

same amount of material from each blade to maintain
balance. Unbalanced blades will cause excessive
vibration, which could damage the gearbox and other
components. The difference in blade weights should
not exceed 1 ounce.
1. To remove the blades refer to “Blade Removal
and Installation” listed earlier in this section.
2. Use a mill file or grinder to sharpen the blades
1
following the original sharpening pattern. If using
a grinder, use care so the cutting edge doesn’t
get too hot from friction, causing it to lose its heat
treatment.
2
IMPORTANT: DO NOT sharpen the cutting edge to
a razor edge. Leave a 1/16 inch blunt edge as shown.
1/16 in
3. To install the blades refer to “Blade Removal and
36084246
Installation” listed earlier in this section.
9
1. Follow original pattern
2. Maintain corner
58-6
BLADE REMOVAL AND INSTALLATION

(780GC)
WARNING
M1340
CAUTION
M1354
Blade Removal (Center Deck)

3
1. Loosen the 1/2 inch nut, 1, on the inspection
cover plate, 2, located by the center deck
gearbox, 3.
2. Slide the inspection cover plate, 2, over to gain
access to the blade carrier.
3. Raise the center deck all the way up to allow 1
access under the center deck, support the center
deck by placing jack stands under the deck.
2
86086801
10
4. Remove the 3/4 inch nut, 1, 3/4 inch lock washer,
2, and the 3/4 inch bolt, 3, from the blade carrier,
4, then remove the blade. 2
NOTE: Each blade carrier has two blades attached 1 4
to it.

the threads are damaged. Always replace the nut if
the bolt is replaced.
3
86086802
11
58-7
Blade Removal (Wing Decks)
1. Loosen 1/2 inch nut, 1, on the inspection cover
plate, 2, located by the gearbox, 3.
NOTE: The inspection cover plates on the wing
decks are located next to the gearboxes.
3 2
2. Slide the inspection cover plate, 2, over to gain
access to the blade carrier.
WARNING
1
hydraulic equipment because it may fall if the 86086803
Always stop engine and remove key before 12
M1340
CAUTION
M1354
3. Raise the wing decks up and lock the decks in

place with the transport lock braces, 1.
3 4
4. To install the transport lock braces, 1, remove the
lock braces from the stowed position, 2, located
on both sides of the center deck.
5. Remove the two lynch pins, 3, and 1 inch flat 1
washers, 4, from the pins on the hydraulic
cylinders. Place each lock brace, 1, over the pins 2
on the hydraulic cylinders and secure the lock
braces using the two 1 inch flat washers and two
lynch pins that were previously removed. 3 4
86086789
13
58-8
6. Remove the 3/4 inch nut, 1, 3/4 inch lock washer,
2, and the 3/4 inch bolt, 3, from the blade carrier,
4, then remove the blade. 4
NOTE: Each blade carrier has two blades attached 2 1
to it.

the threads are damaged. Always replace the nut if
the bolt is replaced.
3
86086804
14
Inspection
DANGER
Failure to replace abnormally worn blades will
lead to catastrophic failure of the blades and
ejection of the broken blade with tremendous
force. Failure to comply will result in death or
serious injury.
M1355
Inspect the blades daily for any cracks, bends or

chipped areas. Any damage that is not repairable
through blade sharpening warrants blade replace-
ment. Use only genuine New Holland blades on this
cutter.
Blade Installation (Center Deck)

1. Install the new or sharpened balanced blade onto
facing “down” away from the underside of the 3 4 1
cutter.
NOTE: Make sure the blades are installed facing the
correct direction. The left wing blade carrier rotates
clockwise, and the blade carriers on the center
section and right wing rotate counter clockwise. 2
2. Secure the blade using the 3/4 inch bolt, 2; 3/4
inch lock washer, 3, and 3/4 inch nut, 4. Torque 86086802
the nut to 407 N⋅m (300 lb-ft).
15
NOTE: When installing the 3/4 inch bolt through the
spline of the bolt to line up with.

blade bolt for wear. If the blade bolt is worn more
bolt and nut.
IMPORTANT: Re-torque the blade after the first hour

58-9
4. Slide the inspection cover plate, 1, back into
place, and then tighten the 1/2 inch nut, 2. 3
1
86086801
16
Blade Installation (Wing Decks)
1. Install the new or sharpened balanced blade onto 1
facing “down” away from the underside of the 3 4
cutter.
2. Secure the blade using the 3/4 inch bolt, 2; 3/4
inch lock washer, 3, and 3/4 inch nut, 4. Torque
the nut to 407 N⋅m (300 lb-ft).
NOTE: When installing the 3/4 inch bolt through the 2
spline of the bolt to line up with. 86086804
17
blade bolt for wear. If the blade bolt is worn more
bolt and nut.
IMPORTANT: Re-torque the blade after the first hour
4. Slide the inspection cover plate, 1, back into
place, and then tighten the 1/2 inch nut, 2.
2
86086803
18
58-10
BLADE SHARPENING
Inspect the blades daily before each use to be sure
they are properly installed and in good condition.
Replace any blade that is bent, cracked, or
excessively nicked or worn. Small nicks can be
ground out when sharpening. Use only genuine New
Holland blades on this cutter.
WARNING
M1340
CAUTION
M1354
IMPORTANT: When sharpening blades, remove the

same amount of material from each blade to maintain
balance. Unbalanced blades will cause excessive
vibration, which could damage the gearbox and other
components. The difference in blade weights should
not exceed 1 ounce.
1. To remove the blades refer to “Blade Removal
2. Use a mill file or grinder to sharpen the blades
1
following the original sharpening pattern. If using
a grinder, use care so the cutting edge doesn’t
get too hot from friction, causing it to lose its heat
treatment.
2
IMPORTANT: DO NOT sharpen the cutting edge to
a razor edge. Leave a 1/16 inch blunt edge as shown.
1/16 in
3. Too install the blades refer to “Blade Removal
36084246
19
1. Follow original pattern
2. Maintain corner
58-11
BLADE CARRIER REMOVAL AND

INSTALLATION (770GC)
WARNING
M1340
Blade Carrier Removal

1. Raise the cutter to the maximum height possible
with the tractor to allow access under the cutter. 2
2. Place jack stands under the cutter to support the
weight of the cutter in case the hydraulic system
on the tractor failed.
3. Remove the cotter pin, 1, and loosen the 1 inch
castle nut, 2, on the gearbox output shaft. Do not 1
remove the nut at this time.
4. Use a suitable two-jaw puller to loosen the blade
carrier off the tapered gearbox output shaft, and 86084247
then remove the 1 inch castle nut.
20
NOTE: The 770GC Rotary Cutter has two blade
carriers, located under the outer gearboxes.
NOTE: If a gear puller is not available use a long bar

inserted through inspection cover plate to remove
the blade carrier. With the end of the bar against the
blade carrier, hit the end of the bar with a hammer.
Rotate the blade carrier 180 degrees and repeat
process until the blade carrier is removed.
5. The blade carrier can now be removed from the
gearbox output shaft.
Blade Carrier Installation

1. Clean the splines on both the blade and gearbox
output shaft.
2. Position the blade carrier in line with the splines
on the gearbox output shaft. Strike the carrier on
the hub several times with a heavy dead blow
hammer to seat the hub onto the gearbox output
shaft.
58-12
3. Reinstall the 1 inch castle nut, 1, and torque to
610 N⋅m (450 lb-ft).
4. Install a new cotter pin, 2. 1
IMPORTANT: Recheck the blade carrier retaining

nut torque after the first hour of operation, then every
8 hours thereafter.
5. Remove the jack stands from under the cutter. 2
86084247
21
58-13
BLADE CARRIER REMOVAL AND

INSTALLATION (780GC)
WARNING
M1340
Blade Carrier Removal (Center Deck)

1. Raise the center deck all the way up to allow 2
access under the center deck, support the center
deck by placing jack stands under the deck.
2. Remove the cotter pin, 1, and loosen the 1-1/4
inch castle nut, 2, on the gearbox output shaft. Do
not remove the nut at this time.
3. Use a suitable two-jaw gear puller to loosen the 1
blade carrier off the tapered gearbox output
shaft, and then remove the 1-1/4 inch castle nut.
NOTE: If a gear puller is not available use a long bar 86086805
the blade carrier. With the end of the bar against the 22
process until the blade carrier is removed.
4. The blade carrier can now be removed from the
Blade Carrier Removal (Wing Decks)

1. Raise the wing decks up and lock the decks in
3 4
place with the transport lock braces, 1.
2. To install the transport lock braces, 1, remove the
lock braces from the stowed position, 2, located
on both sides of the center deck. 1
3. Remove the two lynch pins, 3, and 1 inch flat
washers, 4, from the pins on the hydraulic 2
cylinders. Place each lock brace, 1, over the pins
on the hydraulic cylinders and secure the lock
braces using the two 1 inch flat washers and two 3 4
lynch pins that were previously removed. 86086789
23
58-14
4. Remove the cotter pin, 1, and loosen the 1-1/4
inch castle nut, 2, on the gearbox output shaft. Do
not remove the nut at this time. 2
5. Use a suitable two-jaw gear puller to loosen the
blade carrier off the tapered gearbox output
shaft, and then remove the 1-1/4 inch castle nut.
NOTE: If a gear puller is not available use a long bar
the blade carrier. With the end of the bar against the 1
process until the blade carrier is removed. 86086805
6. The blade carrier can now be removed from the 24

Blade Carrier Installation (Center Deck/Wing

Decks)
1. Clean the splines on both the blade carrier and
2. Position the blade carrier in line with the splines
on the gearbox output shaft. Strike the carrier on
the hub several times with a heavy dead blow
hammer to seat the hub onto the gearbox output
shaft.
3. Reinstall the 1-1/4 inch castle nut, 1, and torque
to 610 N⋅m (450 lb ft).
1
4. Install a new cotter pin, 2.
IMPORTANT: Recheck the blade carrier retaining

nut torque after the first hour of operation, then every
8 hours thereafter.
5. Remove the jack stands from under the cutter. 2
86086805
25
58-15
58-16
CONTENTS

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
58-1
PTO SHAFT LUBRICATION (770GC)

To lubricate the PTO shaft the rotary cutter should be
disconnected from the tractor.
To disconnect the cutter from the tractor refer to

“Disconnecting the Rotary Cutter from the Tractor” in
Section 2 of the 770GC Rotary Cutter Operator’s
Manual.
U-Joint and CV Joint

The U-Joint and CV Joint on the PTO shaft undergo
extreme forces when the unit is turning. It is important
that the U-Joint and CV Joint be greased every eight
hours. The U-Joint is located on the cutter end of the
PTO shaft. The CV Joint is located on the tractor end
of the PTO shaft.
The U-Joint and CV Joint are accessible by rotating
the PTO shaft safety shield until the hole, 1, in the
PTO shaft shield, 2, matches up with the grease
fitting. 2
Plastic Shield Bearings

The plastic shield bearings will also need to be 3
lubricated. The PTO shaft shields have plastic lube
fittings, 3, at the base of the shields to lube the plastic
shield bearings.
1
Inner and Outer Drive Tubes
86086767
The inner and outer drive tubes should be lubricated
after every 40 hours of use. 1
The inner and outer drive tubes are lubricated by

sliding the two halves of each shaft apart. Lubricate
the inner and outer drive tubes with grease.
NOTE: Before separating the two halves of the PTO

shaft check to make sure the PTO shaft telescopes
easily. If the PTO shaft doesn’t telescope easily or
shows signs of wear, repair or replace the PTO shaft.
Once the inner and outer drive tubes are lubricated,

slide the inner and outer drive tubes together.
58-2
PLASTIC SHIELD SUPPORT BEARING

REPLACEMENT
If the plastic shield bearings ever need to be
replaced, first remove the cutter from the tractor.

Manual.
Removal
1. Locate the plastic shield support bearing to be 2
replaced, and then depress the plastic bearing
tabs, 1, on PTO shaft shield, 2.
86086767
2
1
86086768
2
2. Slide each PTO shaft shield, 1and 2, back away
from plastic shield support bearing, 3.
3. The plastic shield support bearing can now be
removed.
1
NOTE: When removing the rear half of the front PTO
shaft shield, 2; use a screwdriver to pry the front half, 3
4, off.
3
4
86086769
2
86086770
58-3
Inspection
Inspect the shield for worn areas or cracks. If the
shield has any dents or cracks, replace the shield.
While the shield is off, inspect the PTO shaft for signs
of abnormal wear, bent shaft or cracks in the shaft.
Also check to make sure the PTO shaft telescopes

Lubricate the inner and outer tubes of the PTO shaft

while the PTO shaft is apart. The inner and outer
tubes should be lubricated after every 40 hours of
use.
Assembly
1. Install the new plastic shield support bearing onto 2
the shaft.
NOTE: Apply a generous amount of grease on the
bearing.
2. Align the plastic tabs, 1, on the bearing with the

1
PTO shaft shields, 2 and 3. 4
3. Once the tabs are aligned, slide each shield onto 86086767
the tabs until they lock in place. 3
1
NOTE: When installing the rear half of the front PTO 86086768
shaft shield, 3, use a screwdriver to pry the front of
the shield, 4, onto the rear half. 4
Installation
To connect the rotary cutter to the tractor, refer to
“Connecting the Rotary Cutter to the Tractor” in
Manual.
58-4
PTO SHAFT LUBRICATION (780GC)

Before lubricating the PTO shafts, disconnect the
cutter from the tractor.

“Disconnecting the Flex Wing Rotary Cutter from the
Tractor” in Section 2 of the 780GC Flex Wing Rotary
Cutter Operator’s Manual.
U-Joint and CV Joint

The U-Joints and CV Joint on the PTO shafts
undergo extreme forces when the unit is turning or
when the wings are being raised. It is important that
the U-Joints and CV Joint be greased every eight
hours. The U-Joints are located at the each end of the
main, center and wing PTO shafts. The CV Joint is
located at the end of the main PTO shaft.
The U-Joint and CV Joint are accessible by rotating
the PTO shaft safety shield until the hole, 1, in the
PTO shaft shield, 2, matches up with the grease
fitting.
2
Plastic Shield Support Bearings
The plastic shield support bearings located on each 3
end of the main, center and wing PTO shafts will also
need to be lubricated. The PTO shaft shields have
plastic lube fittings, 3, at the base of the shields to
lube the plastic shield support bearings. 1
86086779
58-5
Inner and Outer Drive Tubes
The inner and outer drive tubes of each PTO shaft
should be lubricated after every 40 hours of use.
To lubricate the inner and outer drive tubes the PTO

shafts will need to be disconnected and removed
from the cutter.
The main PTO shaft should be disconnected from the

tractor before removing the main PTO shaft or any of
the other PTO shafts from the cutter. Refer to “Main
PTO shaft Removal” and “Gearbox PTO Shaft
Removal” in Section 3 of the 780GC Flex Wing
Rotary Cutter Operator’s Manual.
Once the PTO shafts are disconnected and removed

from the cutter. Slide the two halves of each shaft
apart, and lubricate the inner and outer drive tubes
with grease.
NOTE: Before separating the two halves of the PTO

shaft check to make sure the PTO shaft telescopes
Once the inner and outer drive tubes are lubricated,

slide the inner and outer drive tubes together.
The gearbox PTO shafts and main PTO shaft can be

reattached to the cutter. Refer to “Gearbox/Main
PTO shaft Installation” in Section 3 of the 780GC Flex
Wing Rotary Cutter Operator’s Manual.
58-6
PLASTIC SHIELD SUPPORT BEARING

REPLACEMENT
If the plastic shield support bearings ever need to be
replaced, first remove the cutter from the tractor.

Tractor” Section 2 of the 780GC Flex Wing Rotary
Removal
1. Locate the plastic shield support bearing to be
replaced, and then depress the plastic bearing
tabs, 1, on PTO shaft shield, 2.
2
86086779
6
2. Once all the plastic bearing tabs are depressed,
the PTO shaft shield, 1, can slide back to gain
access to the plastic shield support bearing, 2.
2
NOTE: In order to slide the main driveline PTO shaft
shield back at the tractor end of the driveline.
Remove the screws from the hard-shell shield.
NOTE: Figure is shown for reference only. 1
3. Remove the plastic shield support bearing from

the PTO shaft.
86086769
58-7
Inspection
Inspect the shield for worn areas or cracks. If the
shield has any dents or cracks, replace the shield.
While the shield is off, inspect the PTO shaft for signs
of abnormal wear, bent shaft or cracks in the shaft.
Also check to make sure the PTO shaft telescopes

Lubricate the inner and outer tubes of the PTO shaft

while the PTO shaft is apart. The inner and outer
tubes should be lubricated after every 40 hours of
use.
Assembly
1. Install the new plastic shield support bearing onto
the shaft.
NOTE: Apply a generous amount of grease on the 2
bearing.
2. Align the plastic tabs, 1, on the bearing with the

PTO shaft shields, 2.
1
3. Once the tabs are aligned, slide the shield onto
the tabs until it locks in place.
NOTE: If the main driveline PTO shaft shield was 86086779
removed from the tractor end of the PTO shaft,
reinstall the screws to the hard-shell shield. 8
Installation
1. To connect flex wing rotary cutter to the tractor
refer to “Connecting the Flex Wing Rotary Cutter
to the Tractor” Section 2 of the of the 780GC Flex
Wing Rotary Cutter Operator’s Manual.
58-8
CONTENTS

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
58-1
SLIP CLUTCH ADJUSTMENT (770GC)

To adjust the slip clutch the cutter will need
disconnected from the tractor, and the PTO shaft will
need to be removed from the center gearbox.

Manual.
Removal
4 1 2
1. Remove the 1/2 inch nylock nut, 1, and the 1/2
inch flat washer, 2, and then use a hammer and
a punch to drive the 1/2 inch threaded tapered
pin, 3, out from the PTO shaft, 4.
2. Slide the PTO shaft, 4, off the gearbox input
shaft, 5.
5
3. Place the PTO shaft on a clean work bench. 3
86086747
1
Adjustment
1. Check the length of the springs, 1, assembled on
the slip clutch. The length of each spring should
be 28.5 mm (1.12 in).
2. If the springs are not at the proper length,
2
adjustment is required. 1
IMPORTANT: Do not tighten the M10 nuts over half
a turn at any adjustment. Excessive tightening can
cause the clutch to become frozen and not slip which
could cause damage to the tractor PTO, drivelines,
or gearbox.
86085857
3. Tighten each M10 nut, 2, evenly half a turn at a 2
time, until each spring has a compressed length
of 28.5 mm (1.12 in).
58-2
Installation
1
IMPORTANT: Make sure the tapered pin on the PTO
shaft is securely locked onto the gearbox input shaft
prior to operating the cutter.
1. Reconnect the PTO shaft, 1, to the rotary cutter

center gearbox, 2. 2
2. Align the splines of the PTO shaft, 1, with those
of the gearbox input shaft, 3, and then slide the
PTO shaft onto the gearbox input shaft until the 3 4
hole, 4, in the PTO shaft lines up with the groove
on the gearbox input shaft. 86086746
NOTE: Apply a small amount of grease to the 3
gearbox input shaft before installing the PTO shaft.
NOTE: The 1/2 inch threaded pin, 1, is tapered on
one side. The pin is secured by a 1/2 inch flat washer, 2
2, and 1/2 inch nylock nut, 3.
3 1
86084325
4
3. Once the hole in the PTO shaft, 1, is aligned with
the groove on the gearbox input shaft, 2, the 1/2 1 4 5
inch threaded tapered pin, 3, can be installed.
4. Slide the 1/2 inch threaded tapered pin, 3, in with
the tapered side of the pin facing towards the
gearbox input shaft.
NOTE: The threaded pin will only go in from one side
2
of the PTO shaft. 3
NOTE: Apply a small amount of grease to the
threaded pin prior to installing it.
86086747
5. Secure the 1/2 inch threaded tapered pin, 3,
using the 1/2 inch flat washer, 4, and 1/2 inch 5
nylock nut, 5. Torque to 57 N⋅m (42 lb ft).
6. To reconnect the rotary cutter to the tractor; refer
to “Connecting the Rotary Cutter to The Tractor”
in Section 2 of the 770GC Rotary Cutter
Operator’s Manual.
58-3
SLIP CLUTCH ADJUSTMENT (780GC)

To adjust the slip clutch the cutter will need to be
disconnected from the tractor, and the PTO shafts
removed from divider gearbox and the three deck
gearboxes.
NOTE: The 780GC Flex Wing Rotary Cutter has

three PTO shafts that have a slip clutch.

tractor” in Section 2 of the 780GC Flex Wing Rotary
PTO Shaft Removal (Divider Gearbox)
1. In order to remove the three PTO shafts from the
divider gearbox, remove the four 1/2 X 1-1/2 inch
cap screws, 1, and four 1/2 inch flat washers, 2,
and then remove the gearbox shield, 3, from the
top of the divider gearbox. 1 2
1 2
86086778
6
2. In order to remove the tapered pins from the two
outer PTO shafts, 1 and 2, the PTO shaft shields,
1
3, will need to be moved back.
NOTE: The threaded tapered pin, 4, on the center 3
PTO shaft can be accessed without sliding the PTO 4
shield back.
NOTE: The main PTO shaft does not need to be

removed from the divider gearbox in order to remove 2
the other PTO shafts.
86086797
58-4
3. To slide the PTO shields, 1, back depress the
plastic bearing tabs, 2, located on the two outer
PTO shaft shields.
NOTE: The figure is shown for reference only. 1
86086779
8
4. Remove the 1/2 inch nylock nut, and 1/2 inch flat
washer, 1 and 2, from each PTO shaft then use 1 2
a punch and hammer to drive the 1/2 inch
threaded tapered pins, 3, out.
5. The PTO shafts, 4, can now be removed from the
output shafts, 5, on the divider gearbox. 3
NOTE: The figure is shown for reference only.
4
86086781
9
PTO Shaft Removal (Deck Gearboxes)
1. To remove the PTO shafts from the three deck
2 3
gearboxes, remove the access covers from both 6
sides of the PTO shield, 1.
2. Remove the 1/2 inch nylock nut, and 1/2 inch
flat washer, 2 and 3, from each PTO shaft
1
then use a punch and hammer to drive the 1/2
inch threaded tapered pin, 4, out from the PTO
shafts, 5.
4
3. The PTO shafts can now be removed from each
gearbox input shaft, 6. 5
86086798
10
58-5
Adjustment
1. Check the length of the springs, 1, assembled on
the slip clutch. The length of each spring should
be 28.5 mm (1.12 in).
2. If the springs are not at the proper length,
2
adjustment is required.
1
or gearboxes.
36085862
3. Tighten each M10 nut, 2, evenly half a turn at a 11
of 28.5 mm (1.12 in).
PTO Shaft Installation (Deck Gearboxes)
1. Align the spines of each PTO shaft, 1, with those 2
PTO shaft onto the gearbox input shaft until the
hole in the PTO shaft lines up with the groove on
the gearbox input shaft.
1
86086798
12
2, and a 1/2 inch nylock nut, 3.
3 1
86084325
13
58-6
IMPORTANT: Make sure the tapered pins on the
PTO shafts are securely fastened to each gearbox 4 5
input shaft prior to operating the cutter. 2

the groove in the gearbox input shaft, 2, the 1/2 6
3
the tapered side of the pin facing the gearbox
input shaft.
NOTE: Apply a small amount grease to the tapered 1
pin prior to installing it. 86086798
NOTE: The tapered pin can only be installed from 14

one side of the PTO shaft.

using the 1/2 inch flat washer, 4, and 1/2 inch
5. Reattached the access covers to the sides of the
PTO shield, 6.
PTO Shaft Installation (Divider Gearbox)

1. Align the spines of each PTO shaft, 1, with those
of the divider gearbox output shafts, 2, and then 3
slide each PTO shaft onto the output shafts until
the hole, 3, in each PTO shaft lines up with the
groove on the each of the output shafts on the
divider gearbox.
1
NOTE: The figure is shown for reference only. 2
86086780
15
58-7
2, and a 1/2 inch nylock nut, 3.
3 1
86084325
16
IMPORTANT: Make sure the tapered pins on the
PTO shafts are securely fastened to each gearbox 4 5
output shaft prior to operating the cutter.

the groove in the gearbox input shaft, 2, the 1/2
3

1
input shaft. 2
NOTE: Apply a small amount grease to the tapered
pin prior to installing it. 86086781

side of the PTO shaft.

58-8
5. Align the plastic tabs, 1, on the plastic bearing
with both outer PTO shaft shields, 2.
6. Once the tabs are aligned, slide the outer PTO
shields onto the tabs until they lock in place. 2
86086779
18
7. Reinstall the gearbox shield, 1, onto the top of
divider gearbox. Secure the PTO shield to the
gearbox using the four 1/2 X 1-1/2 inch cap
screws, 2, and four 1/2 inch flat washers, 3, that
8. To reconnect the rotary cutter to the tractor refer; 2 3
to “Connecting the Flex Wing Rotary Cutter to the 2 3
Tractor” in Section 2 of the 780GC Flex Wing
Rotary Cutter Operator’s Manual.
1
86086778
19
58-9
SEASONAL CLUTCH MAINTENANCE

(770GC)
It is important that the clutch slips when an obstacle
or load heavier than the clutch setting is
encountered. Before using the cutter each season,
use the following procedure to make sure the clutch
will slip and give the overload protection required.
NOTE: If the cutter sits outside longer than 30 days

and it is exposed to rain and humid air, the clutches
should be removed from the machine and stored in
a dry area. The clutch friction plates will soak up
moisture and cause the metal plates to rust. When
this occurs, the break away torque increases greatly
and damage to the gearbox, driveline, or tractor PTO
can occur.
1. To gain access to the slip clutch the PTO shaft will

2. To remove the PTO shaft refer to “Slip Clutch
Adjustment (770GC), Removal” found earlier in
this chapter.
3. Loosen each M10 nut, 1, until the spring, 2, is
free, and then retighten approximately one turn.
4. Reattach the PTO shaft to the cutter, refer to “Slip
Clutch Adjustment (770GC), Installation” found
earlier in this chapter. 1
5. Connect the cutter to the tractor, to connect the 2
cutter to the tractor refer to “Connecting the
Rotary Cutter to the Tractor” in Section 2 of the
770GC Rotary Cutter Operator’s Manual.
86085857
20
58-10
DANGER
Never engage the PTO while the center section or
wings of a rotary cutter are in the raised transport
position. Failure to comply will result in death or
serious injury.
M1360
6. Start the engine of the tractor and set the engine

at approximately half throttle and quickly engage
the PTO.
NOTE: This procedure will break the clutch facings
loose and allow the proper torque to be maintained.
7. Disconnect the cutter from the tractor and

remove the PTO shaft from the center gearbox
on the cutter.
8. To disconnect the cutter from the tractor refer to
“Disconnecting the Rotary Cutter from the
Tractor” in Section 2 of the 770GC Rotary Cutter
Operator’s Manual. To remove the PTO shaft
from the center gearbox on the cutter refer to
“Slip Clutch Adjustment (770GC), Removal”
found earlier in this chapter.
or gearboxes.
9. After the PTO shaft is removed, tighten each M10
nut, 1, evenly half a turn at a time, until each
spring, 2, has a compressed length of 28.5 mm
(1.12 in).
10. The PTO shaft can now be reattached to the 1
center gearbox on the cutter. Refer to “Slip Clutch
Adjustment (770GC), Installation” found earlier 2
in this chapter.
86085857
21
58-11
SEASONAL CLUTCH MAINTENANCE

(780GC)
It is important that the clutch slips when an obstacle
or load heavier than the clutch setting is
encountered. Before using the cutter each season,
use the following procedure to make sure the clutch
will slip and give the overload protection required.
NOTE: If the cutter sits outside longer than 30 days

and it is exposed to rain and humid air, the clutches
should be removed from the machine and stored in
a dry area. The clutch friction plates will soak up
moisture and cause the metal plates to rust. When
this occurs, the break away torque increases greatly
and damage to the gearbox, driveline, or tractor PTO
can occur.
1. To gain access to each slip clutch, each PTO

shaft will need to be removed from the divider
gearbox and deck gearboxes.
2. To remove the PTO shafts from the divider
gearbox and each deck gearbox refer to “Slip
Clutch Adjustment (780GC), PTO Shaft Remov-
al (Divider Gearbox)” and “PTO Shaft Removal
(Deck Gearboxes)” found earlier in this chapter.
NOTE: The main PTO shaft does not need to be
removed from the divider gearbox in order to remove
the other PTO shafts.
3. Loosen each M10 nut, 1, until the spring, 2, is
free, and then retighten approximately one turn.
4. Reattach the PTO shafts to the deck gearboxes
and divider gearbox; refer to “Slip Clutch
Adjustment (780GC), “PTO Shaft Installation
(Deck Gearboxes)” and “PTO Shaft Installation 1
(Divider Gearbox) found earlier in this chapter. 2
5. Connect the cutter to the tractor, to connect the
cutter to the tractor refer to “Connecting the Flex
Wing Rotary Cutter to the Tractor” in Section 2 of
the 780GC Flex Wing Rotary Cutter Operator’s
Manual. 36085862
22
58-12
DANGER
Never engage the PTO while the center section or
wings of a rotary cutter are in the raised transport
position. Failure to comply will result in death or
serious injury.
M1360
6. Start the engine of the tractor and set the engine

at approximately half throttle and quickly engage
the PTO.
NOTE: This procedure will break the clutch facings
loose and allow the proper torque to be maintained.
7. Disconnect the cutter from the tractor and

remove the PTO shafts from the divider gearbox
and each deck gearbox.
“Disconnecting the Flex Wing Rotary Cutter from
the Tractor” in Section 2 of the 780GC Flex Wing
Rotary Cutter Operator’s Manual. To remove the
PTO shafts from the divider gearbox and each
deck gearbox refer to “Slip Clutch Adjustment
(780GC), “PTO Shaft Removal (Divider Gear-
box)” and “PTO Shaft Removal (Deck Gear-
boxes)” found earlier in this chapter.
or gearboxes.
9. Once the PTO shafts are removed, tighten each
M10 nut, 1, evenly half a turn at a time, until each
spring, 2, has a compressed length 28.5 mm
(1.12 in).
10. The PTO shafts can now be reattached to the
divider gearbox and each deck gearbox. Refer to 1
“Slip Clutch, Adjustment (780GC)”, “PTO Shaft 2
Installation (Deck Gearboxes)” and “ PTO Shaft
Installation (Divider Gearbox)” found earlier in
this chapter.
36085862
23
58-13
SLIP CLUTCH REPAIR (770GC)

In order to repair the slip clutch the cutter will need
disconnected from the tractor, and the PTO shaft will

Manual.
Removal
1. To remove the PTO shaft from the cutter refer to
“Slip Clutch Adjustment (770GC), Removal”
found earlier in this chapter.
SLIP CLUTCH COMPONENTS (770GC)
1 9
5
6
2 3 4 4 7 8
L
36085892 L = 28.5 mm (1.12 in)
24
1. Cap Screw, M10 x 85 CL 8.8 6. Collar/Bushing
2. Pressure Plate 7. Flange Yoke
3. Inner Plate 8. Spring
4. Friction Plate – 770GC – (2) 162 x 85 mm 9. Nut, M10
5. Clutch Hub
Disassembly
1. Remove the eight M10 nuts, 1, eight springs, 2,
and eight M10 x 85 cap screws, 3.
NOTE: Loosen each of the M10 nuts evenly. 1 2

2. Remove the slip clutch assembly, 4, from the 3
flange yoke on the end of the PTO shaft.
86085857
4
25
58-14
3. Remove the pressure plate, 1, inner plate, 2, and
friction plates, 3, from the clutch hub, 4. 4
1 2
3
86085858
26
4. Remove the collar/bushing, 1, from the flange
yoke, 2.
1
2
86085859
27
Inspection
1. Inspect the surface of the inner plate, clutch hub,
and flange yoke for any signs of scoring,
excessive wear, or any other damage. Replace
as necessary.
2. Inspect the friction plates for wear, damage, or oil
contamination. Replace as necessary.
NOTE: Any rust or glazing found on the friction plates
or hub can be removed by using a piece of emery
paper.
NOTE: The lining of the friction plates are 3.1 mm

(0.12 in) thick when new. Replace after 0.79 mm
(0.03 in) of wear.
3. Inspect the collar/bushing for wear or damage.

Replace as necessary.
58-15
Assembly
1. Insert the collar/bushing, 1, into the flange yoke,
2.
1
2
86085859
28
2. Reassemble the slip clutch assembly by placing
one of the fiction plates, 1, onto the clutch hub, 2.
4 1 5
3. Place the inner plate, 3, on top of the friction
plate, 1.
NOTE: If the inner plate was not replaced, one side
of the inner plate will be worn from the friction plate;
this side of the inner plate goes toward the friction
plate.
4. Place the pressure plate, 4, on top of the inner

plate, 3. 3 2
86085858
5. Place the remaining friction plate, 5, on the other
end of the clutch hub, 2, which faces the flange 29
yoke on the PTO shaft.
6. Reattach the slip clutch assembly, 1, to the flange
yoke located on the end of the PTO shaft. Secure
using the eight M10 x 85 cap screws, 2, eight
springs, 3, and eight M10 nuts, 4. Do not tighten
at this time.
3 4
NOTE: The one end of the clutch hub will be inserted
into the collar/bushing located on the flange yoke 2
when the slip clutch assembly is reattached.
NOTE: Make sure all the plates are properly aligned

with the clutch hub when reattached to the flange
yoke. 1
86085857
IMPORTANT: Do not tighten the M10 nuts over half 30

or gearbox.
7. Tighten each M10 nut, 4, evenly half a turn at a

of 28.5 mm (1.12 in).
58-16
Installation
To reattach the PTO shaft to the cutter refer to “Slip
Clutch Adjustment (770GC), Installation” found
earlier in this chapter.
To reattach the cutter to the tractor refer to

Manual.
SLIP CLUTCH REPAIR (780GC)

In order to repair the slip clutch the cutter will need
disconnected from the tractor, and each PTO shaft
will need to be removed from divider gearbox and
deck gearboxes.
NOTE: The 780GC Flex Wing Rotary Cutter has

three slip clutches.

Removal
1. To remove the PTO shafts from the divider
gearbox and each deck gearbox refer to “Slip
Clutch Adjustment (780GC)”, “PTO Shaft
Removal (Divider Gearbox)” and “PTO Shaft
Removal (Deck Gearboxes)” listed at the
beginning of this chapter.
58-17
SLIP CLUTCH COMPONENTS (780GC)
4 4 6 7 8
10
1
5 4 4 11
2 3 9
L = 28.5 mm (1.12 in)
36085856
31
1. Cap Screw, M10 x 100 CL 8.8 7. Driving Plate
2. Pressure Plate 8. Collar/Bushing
3. Inner Plate 9. Flange Yoke
4. Friction Plate – 780GC – (4) 140 x 85 mm 10. Spring
5. Clutch Hub 11. Nut, M10
6. Inner Plate
Disassembly
1. Remove the eight M10 nuts, 1, eight springs, 2,
and eight M10 x 100 cap screws, 3.
NOTE: Loosen each of the M10 nuts evenly.
1 2
2. Remove the slip clutch assembly, 4, from the
flange yoke on the end of the PTO shaft. 3
4
36085862
32
58-18
3. Remove the pressure plate, 1, inner plates, 2,
friction plates, 3, and driving plate, 4, from the 5
clutch hub, 5. 1 2
3
3 4
2
36085863
33
4. Remove the collar/bushing, 1, from the flange
yoke, 2.
1
2
86085859
34
Inspection
1. Inspect the surface of the inner plates, clutch
hub, and flange yoke for any signs of scoring,
excessive wear, or any other damage. Replace
as necessary.
2. Inspect the friction plates for wear, damage, or oil
contamination. Replace as necessary.
NOTE: Any rust or glazing found on the plates or hub
can be removed by using a piece of emery paper.
NOTE: The lining of the friction plates are 3.1 mm

(0.12 in) thick when new. Replace after 0.79 mm
(0.03 in) of wear.
3. Inspect the collar/bushing for wear. Replace as

necessary.
58-19
Assembly
1. Insert the collar/bushing, 1, into the flange
yoke, 2.
1
2
86085859
35
2. Reassemble the slip clutch assembly by placing
one of the friction plates, 1, onto the clutch 2
hub, 2. 4 3 5
7
3. Place the inner plate, 3, on top of the friction
plate, 1.
NOTE: If the inner plate was not replaced, one side
of the inner plate will be worn from the friction plate;
this side of the inner plate goes toward the friction
plate.
1 8
6
4. Place the pressure plate, 4, on top of the inner
plate, 3. 36085863
5. Place one of the remaining friction plates, 5, on 36
the other end of the clutch hub, 2.
6. Place the other inner plate, 6, on top of the friction
plate, 5.
7. Place the remaining friction plates, 7, on both
ends of the driving plate, 8, and then place the
driving plate against the inner plate, 6.
58-20
8. Reattach the slip clutch assembly, 1, to the flange
yoke located on the end of the PTO shaft. Secure
using the eight M10 x 100 cap screws, 2, eight
springs, 3, and eight M10 nuts, 4. Do not tighten
at this time.
3 4
NOTE: The one end of the clutch hub will inserted
into the collar/bushing located on the flange yoke 2
when the slip clutch assembly is reattached.
NOTE: Make sure all the plates are properly aligned

with the clutch hub when reattached to the flange
yoke. 1
36085862
IMPORTANT: Do not tighten the M10 nuts over half 37

or gearbox.
9. Tighten each M10 nut, 4, evenly half a turn at a

of 28.5 mm (1.12 in).
Installation
The PTO shafts can now be reattached to the divider
gearbox and each deck gearbox. Refer to “Slip
Clutch, Adjustment (780GC)”, “PTO Shaft Installa-
tion (Deck Gearboxes)” and “ PTO Shaft Installation
(Divider Gearbox)” found earlier in this chapter.
To reattach the cutter to the tractor refer to

Section 2 of the 780GC Flex Wing Rotary Cutter
58-21
58-22

CONTENTS

Skid Shoes (780GC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Leveling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
58-1
SKID SHOES (780GC)

The skid shoes are made of carbon steel to reduce
wear and increase service life. Premature wear can
be caused by the cutter wing sections’ being set too
low which allows the wing skid shoes to drag on the
ground.
Dragging the skid shoes on the ground or running the

skid shoes into solid objects can contribute to early
frame failure on the cutter. Replace worn skid shoes
as required, and tighten hardware regularly.
NOTE: Failure to tighten hardware on the skid shoes

can cause premature failure.
Skid Shoe Replacement (Center Deck)

To replace the skid shoes on the center deck raise the
center deck, then raise the wing decks up and lock
the wing decks in place with the transport lock
braces.
1. To remove the center deck skid shoes, 1, remove
the two 5/8 inch nylock nuts, 2, and two 5/8 inch
flat washers, 3, and then remove the two 5/8 X
1-3/4 inch cap screws, 4.
2. Attach the new skid shoes, 1, to the center deck,
and secure using the two 5/8 X 1-3/4 inch cap 3
screws, 4, two 5/8 inch flat washers, 3, and two
5/8 inch nylock nuts, 2. 4
1
36086799 2
1
58-2
7 8 9
3 4 5
6
36086800
2
Skid Shoe/Side Skirt Replacement (Wing Decks)
To replace the skid shoes or side skirts on the wing
decks raise the wing decks up enough to remove the
related hardware for the skid shoes or side skirts.
1. To remove the wing deck skid shoes, 1, from the

side skirts, 2, remove the four 3/8 inch nuts, 3,
four 3/8 inch lock washers, 4, four 1/2 inch flat
washers, 5, and four 3/8 X 1-1/2 inch plow bolts,
6.
NOTE: If replacing the side skirts, 2, remove the eight
1/2 inch nylock nuts, 7, eight 1/2 inch flat washers, 8
and eight 1/2 X 2 inch cap screws, 9. Install the new
side skirts on the wing decks and secure using the
hardware previously removed.
2. Attach the new skid shoes, 1, to side skirts, 2, and

secure using the four 3/8 X 1-1/2 inch plow bolts,
6, four 1/2 inch flat washers, 5, four 3/8 inch lock
washers, 4, and four 3/8 inch nuts, 3. Torque to
46 N⋅m (34 lb-ft).
58-3
FRONT TONGUE ASSEMBLY (780GC)

Leveling System 3
The 780GC uses a turnbuckle, 1, to adjust the tongue 2
assembly, 2, and hitch clevis, 3, on the cutter. When
adjusted correctly the tongue assembly and hitch
clevis will be level and parallel with the tractor
drawbar, 4.
4
86086786
1
3
The turnbuckle, 1, is connected to the hitch clevis, 2,
and to a wire rope, 3, which is connected to a bracket,
4, on the center section of the cutter. 4
NOTE: The top hole in the bracket is used for tractors

which have a higher drawbar, and the bottom hole is
used for tractors which have a lower drawbar.
2
3 1
86081129
58-4
4 12
11
5
6
3 7
8 7
7 6
9
2
10
86091130
5
FRONT TONGUE ASSEMBLY
COMPONENTS
1. Tongue Assembly 7. Nylock Nut, 1 inch
2. Fold-Up Parking Jack 8. Flat Washer, 1 inch
3. Hitch Clevis 9. Nylock Nut, 3/4 inch
4. Turnbuckle 10. Bolt, 3/4 x 3 GR8
5. Wire Rope 11. Bolt, 3/4 x 3-1/2 inch GR8
6. Bolt, 1 x 6-1/2 inch GR8 12. Bolt, 1 x 3-1/2 inch GR8
NOTE: Periodically inspect the tongue assembly for

any damage parts or hardware. Replace as
necessary.
58-5
58-6
CONTENTS

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
58-1
AXLE COMPRESSION SPRINGS (CENTER

SECTION AXLES)
Before removing the axle suspension caps, lower the
cutter to the ground.
2
WARNING
Do not remove the axle suspension caps until the
tension on the compression springs is relieved.
Failure to comply could result in death or serious
injury.
M1361 1
86091131
Using a jack, 1, raise the center axle beam, 2, to
relieve the tension off the compression springs. 1
Removal
2
1. Using an adjustable wrench, 1, carefully remove
the suspension caps, 2, from the center axle
beam, 3.
86091132
1
2
2. Remove the compression springs, 1, from the
center axle beam, 2.
1
2
86091133
58-2
Inspection
Inspect each compression spring for any cracks or
other damage and replace as necessary.
Assembly
1. Align the new or old compression spring, 1, with
the spring locator, 2, located on top of the axle leg
inside the center axle beam, 3.
IMPORTANT: Do not tighten the caps all the way in, 2
this will collapse the compression springs and the 1
suspension will not work.
86091134
86091133
3
4
2. Screw the axle suspension caps, 1, back into the
center axle beam, 2. 1
NOTE: When the axle suspension caps are screwed
into the center axle beam, the caps should have one
to two threads exposed.
NOTE: The wing axle leg is shown.
2
86086806
58-3
AXLE COMPRESSION SPRINGS (WING

AXLES)
Raise each wing slightly off the ground with the
tractor hydraulic system; this will relieve the tension
off the compression springs.
WARNING
Do not remove the axle suspension caps until the
tension on the compression springs is relieved.
Failure to comply could result in death or serious
injury.
M1361
Removal
1. Using an adjustable wrench, 1, carefully remove 2
the suspension caps, 2, from the wing axle
beam, 3.
NOTE: The center axle beam is shown; the wing axle
beam only has two axle suspension caps.
3
1
86091132
6
2. Remove the compression springs, 1, from the
wing axle beam, 2.
1
NOTE: The center axle beam is shown.
2
86091133
58-4
Inspection
Inspect each compression spring for any cracks or
other damage and replace as necessary.
Assembly/Installation
1. Align the new or old compression spring, 1, with
the spring locator, 2, located on top of the axle leg
inside the wing axle beam, 3.
IMPORTANT: Do not tighten the caps all the way in, 2
this will collapse the compression springs and the 1
suspension will not work.
86091134
86091133 3
8
2. Screw the axle suspension caps, 1, back into the
wing axle beam, 2. 1
NOTE: When the axle suspension caps are screwed
into the center axle beam, the caps should have one
to two threads exposed.
2
86086806
9
EMERGENCY AXLE USAGE
If one of the center axle legs ever fails while the cutter
is in operation, an axle leg from one of the wings can
be installed in the center axle position for emergency
transportation.
NOTE: The axle diameter is the same for both axles
58-5
58-6
CONTENTS

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
58-1
WHEEL HUB ASSEMBLY (770GC AND

780GC)
3
Using a jack, 1, raise the center axle beam, 2, until
the wheels, 3, on the side being removed are off the
ground.
2
NOTE: The 780GC Flex Wing Rotary Cutter is
shown, on the 770GC Rotary Cutter place the jack
under the axle weldment to raise the laminated tires
off the ground.
1
NOTE: To remove the wheels from the 780GC Flex
86091131
Wing Rotary Cutter wings; slightly raise the wings up
with the tractors hydraulic system. 1
Removal
1. Remove the wheel, 1, from the wheel hub by
removing the five nuts, 2.
1
NOTE: The 770GC Rotary Cutter has a total of two

wheels and the 780GC Flex Wing Rotary Cutter has
a total of six wheels. 2
2
NOTE: The procedure for removing each wheel and
wheel hub is the same for the 770GC Rotary Cutter
and the 780GC Flex Wing Rotary Cutter.
86091135
2
2. Remove the dust cap, 1, from the wheel hub, 2,
by using a hammer and a screwdriver to tap the
dust cover out of the wheel hub.
86091136 1
3
58-2
3. Remove the cotter pin, 1, castle nut, 2, and flat
washer, 3, from the spindle, 4.
3
1
86091137
4
4
4. Remove the wheel hub, 1, from the wheel
spindle, 2, by hitting the wheel hub with a dead
blow hammer until it slides off the wheel spindle.
NOTE: When removing the wheel hub remove the 1
outer tapered bearing when it becomes loose.
NOTE: The seal on the back of the wheel hub will be

removed when the hub is hit off the wheel spindle.
5. Remove the inner tapered bearing from the

wheel hub. 2
NOTE: The inner and outer tapered bearings are two 86091138
different size bearings.
5
58-3
7
8
3 4
2
9
12 6
13 5
10
11
1 14
7 8
86091139
6
WHEEL HUB COMPONENTS
1. Wheel Hub 8. Wheel Stud
2. Tapered Bearing, Outer 9. Spindle
3. Bearing Race, Outer 10. Dust Cap
4. Bearing Race, Inner 11. Castle Nut
5. Tapered Bearing, Inner 12. Flat Washer
6. Seal 13. Cotter Pin
7. Nut 14. Grease Fitting
Disassembly
1. Remove the two bearing races, 1, from the wheel
hub, 2, by using a punch, 3, and hammer.
2
NOTE: The inner and outer bearing races are two 3
different sizes.
86091140
58-4
Inspection
1. Clean and inspect the wheel hub housing for any
damage and replace as necessary.
2. Clean and inspect the tapered bearings, and
bearing races for any scoring, pitting or other
wear or damage. Replace as necessary.
Assembly
IMPORTANT: Apply a generous amount of grease to
the inside of the wheel hub prior to assembly.
1. Install the bearing races back into the wheel hub

by using a hammer and a suitable seal/bearing
driver to hit each bearing race back into the wheel
hub until seated.
NOTE: The inner and outer bearing races are two
different sizes.
IMPORTANT: Repack the tapered bearings with

grease before installing them into the wheel hub.
2. Place the inner tapered bearing, 1, into the wheel
hub, 2.
NOTE: The inner and outer tapered bearings are two
different size bearings.
2
3. Install the new seal, 3, into the back of the wheel
hub, 2, using a suitable seal driver.
3 1
86091141
8
Installation
1. Slide the wheel hub, 1, back onto the wheel
spindle, 2.
1
2
86091138
58-5
2. Slide the outer tapered bearing, 1, onto the wheel
spindle, 2.
86091142 2
10
3. Slide the flat washer, 1, onto the wheel spindle,
2, and screw the castle nut, 3, onto the spindle.
Torque to 81.3 N⋅m (60 lb-ft).
NOTE: When the castle nut is tightened it will press 3
the outer bearing onto the wheel spindle.
1
4
4. Install a new cotter pin, 4.
86091137
2
11
5. Reinstall the dust cap, 1, onto the wheel hub, 2,
by tapping it on with a soft jaw hammer.
2
1
86091136
12
58-6
6. Reinstall the wheel, 1, onto the wheel hub and
secure using the five nuts, 2, that were previously
removed. Torque to 101.6 N⋅m (75 lb-ft). 1
7. The cutter can now be lowered to the ground and
the jack can be removed.
2
2
86091135
13
58-7
58-8
CONTENTS

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Output Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Through Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
58-1

Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Output Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Final Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Divider Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
58-2

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Output Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Final Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
58-3
OUTER GEARBOXES (770GC)

Removal
In order to remove the outer gearboxes from the
rotary cutter, the cutter will need to be disconnected
from the tractor, the PTO shaft removed from the
center gearbox; the blade carriers will need removed
from the outer gearboxes, and the PTO shield and
flex coupler assemblies will need removed from the
gearboxes.

Tractor” in Section 2 of the 770GC Rotary Cutter
2. For blade carrier removal refer to “Blade Carrier
Removal and Installation (770GC)” in Section
58, Chapter 1 of this manual.
3. Remove the 1/2 inch nylock nut, 1, and 1/2 inch
flat washer, 2. Use a hammer and a punch to 1 2
drive the 1/2 inch threaded tapered pin, 3, out
from the PTO shaft, 4.
shaft, 5.
5
4
3
86086747
1
5. In order to gain access to and remove the outer
gearboxes, the PTO shield will need to be
removed.
1
6. To remove the PTO shield, 1, remove the four 5/8

x 1-3/4 inch cap screws, 2, and 3/4 inch flat
washers, 3. 2 3 2 3
86086744
58-4
7. The 770GC Rotary Cutter has four flex coupler
assemblies, 1, located between the center 1
gearbox, 2, and the outer gearboxes, 3.
NOTE: The flex couplers on either side of the cen-

ter gearbox consist of a shaft flex coupler and a
flex coupler with a hub. The flex coupler with a hub
slides onto the shaft flex coupler. 2
8. In order to remove one or both of the outer
gearboxes for repair. One or both of the shaft flex 3
couplers will need to slide into the flex couplers 3
that have a hub.
86091143
NOTE: If both outer gearboxes are to be removed,
repeat instructions 9 through 13 for the other 3
gearbox.
9. Remove the 5/16 inch nylock nut, 1, from the 5/16
x 3 inch cap screw, 2, located on the shaft flex
coupler, 3. 3 1
10. Remove the 5/16 x 3 inch cap screw, 2, from the
shaft flex coupler, 3.
2
86091144
58-5
11. Slide the shaft flex coupler, 1, into the flex coupler
hub, 2, until the shaft flex coupler is off the outer 3
1
gearbox input shaft, 3.
12. Remove the gearbox, 4, from the rotary cutter 4
deck, 2, by removing the four 3/4 inch nylock
nuts, 5.
2
5
86091145
5
13. After the gearbox, 1, is removed; drain the gear
oil out of the gearbox by removing oil level/drain
plug, 2, and oil fill plug, 3. After the plugs are
removed lift the gearbox up to drain the gear oil
out. 3
NOTE: The gearbox is shown attached to the rotary
cutter. 1
86091146
58-6
GEARBOX COMPONENTS
16 24 25
17
11 20
14 23 22
15
1
18
12 21
13 19
9
8
7
3
9 6
2 4 5
36085887
7
1. Housing, Gearbox 13. Shim
2. Cover, Bearing Retainer 14. Bearing, Tapered
3. Gasket 15. Bearing Race
4. Seal, Output Shaft 16. Shim
5. Cap Screw, 1/2 x 1-1/2 inch 17. Snap Ring
6. Flat Washer, 1/2 inch 18. Shaft, Input
7. Shaft, Output 19. Gear, Input
8. Bearing, Tapered 20. Spacer
9. Bearing Race 21. Bearing Housing, Input Shaft
10. Plug, Oil Level/Drain (NOT SHOWN, Located on the 22. Seal, Input Shaft
back of the Gearbox Housing.) 23. Gasket
11. Plug, Oil Fill 24. Cap Screw, 3/8 x 1-1/4 inch
12. Gear, Output 25. Lock Washer, 3/8 inch
58-7
4
1 2
16
5
6
3
12
11
15
13
14
10
8
9
17 7
36085887
8
Disassembly
1. Remove the eight 3/8 x 1-1/4 inch cap screws, 1, NOTE: When the output shaft is driven out, it will also
and 3/8 inch lock washers, 2, from the input shaft force the lower bearing race, 14, out of the gearbox
bearing housing, 3. housing.
2. Tap around the circumference of the bearing
housing, 3, with a hammer to loosen the housing NOTE: The upper and lower bearing races are
and gasket, 4. different. Take notice which one is on the bottom and
which one is on the top for reassembly.
3. Then pull the complete input shaft, 5, and bearing
housing, 3, out of the gearbox housing, 6, and 7. Remove the upper bearing race, 15, for the
remove the gasket, 4. output shaft, 13, from the gearbox housing, 6, by
4. Remove the four 1/2 x 1-1/2 inch cap screws, 7, using a slide hammer and puller.
and 1/2 inch flat washers, 8. Then remove the 8. Remove the input shaft rear bearing race, 16,
lower bearing retaining cover, 9, and gasket, 10. from the gearbox housing, 6, by using a slide
5. Remove the output gear, 11, and any shims, 12, hammer and puller.
from the top of the output shaft, 13. 9. Remove the oil seal, 17, from the lower bearing
6. Remove the output shaft, 13, from the gearbox retaining cover, 9, by using a seal puller.
housing, 6, by using a punch and hammer to
drive the output shaft out. Inspection
NOTE: Place the punch on top of the output shaft, 1. Clean and inspect the gearbox housing for any
then hit the punch with a hammer to drive the output damage and replace as necessary.
shaft out.
58-8
INPUT SHAFT
4
10
5
3
9
7 1
2
8
36085888
9
Disassembly NOTE: The bearing splitter will rest on the press
1. Remove the input shaft, 1, from the bearing plates of the hydraulic press.
housing, 2.
9. To remove the tapered bearing, 7, from the input
2. To remove the tapered bearing, 3, from the input shaft, 1, carefully press the input shaft, 1, down
shaft, 1, place a bearing splitter between the through the tapered bearing, 7.
tapered bearing, 3, and the input gear, 4.
10. Use a seal puller to remove the input shaft oil
3. Place the input shaft, 1, in a hydraulic press with seal, 9, from the bearing housing, 2.
the tapered bearing, 3, on the top.
11. Use a punch and hammer to drive the bearing
NOTE: The bearing splitter will rest on the press race, 10, out of the bearing housing, 2.
plates on the hydraulic press.
4. Carefully press the input shaft, 1, down through Inspection
the tapered bearing, 3.
1. Clean and inspect the input shaft, tapered
5. Remove the snap ring, 5, and shim, 6, from the bearings, and bearing races for any scoring,
input shaft, 1. pitting, wear or damage. Replace as necessary.
6. Slide the input gear, 4, off the input shaft, 1. 2. Inspect the input gear for any wear or damage
and replace as necessary.
7. Slide the spacer, 8, off the input shaft, 1.
8. Place a bearing splitter under the tapered

bearing, 7, and then place the input shaft, 1, in a
hydraulic press with the tapered bearing, 7, on
the top.
58-9
4
8 2
7 6
10
9
5 3
36085888
10
Assembly 7. Place the tapered bearing, 7, onto the gear end
of the input shaft, 2, and then put the input shaft
1. Place the tapered bearing, 1, onto the input shaft,
in a hydraulic press with the tapered bearing, 7,
2.
on the bottom.
NOTE: The tapered end of the bearing will face away
from the larger diameter end of the input shaft.
from the input gear.
2. Place the input shaft, 2, onto a hydraulic press
8. Carefully press the input shaft, 2, down into the
with the tapered bearing, 1, on the bottom.
tapered bearing, 7, until the bearing is seated on
3. Carefully press the input shaft, 2, down through the input shaft.
the tapered bearing, 1, until the tapered bearing,
9. Drive the bearing race, 8, into the bearing
1, is seated on the input shaft, 2.
housing, 9, using a hammer and a suitable
4. Slide the spacer, 3, onto the input shaft, 2, bearing race/seal driver.
5. Slide the input gear, 4, onto input shaft, 2. 10. Install a new oil seal, 10, into the bearing
housing, 9, using a hammer and a suitable seal
NOTE: Make sure the input gear is facing the correct
driver.
direction as shown, before sliding the input gear onto
the input shaft. NOTE: Lubricate the inside diameter of the oil seal.
6. Install the shim, 5, onto the input shaft, 2, and

secure using a new snap ring, 6.
58-10
OUTPUT SHAFT
1 3 2
36085889
11
Disassembly 4. Remove the bottom tapered bearing, 3, from the
output shaft, 1, by carefully pressing the output
1. Place the output shaft, 1, in a hydraulic press with
shaft down through the tapered bearing.
the top tapered bearing, 2, on top.
NOTE: Place a bearing splitter under the tapered
2. Remove the top tapered bearing, 2, from the
bearing.
output shaft, 1, by carefully pressing the output
shaft down through the tapered bearing.
Inspection
NOTE: Place a bearing splitter under the tapered
bearing. 1. Clean and inspect the output shaft, gear, and
bearings for any scoring, pitting, wear or
damage. Replace as necessary.
3. Place the output shaft, 1, in a hydraulic press with
the bottom tapered bearing, 3, on the top.
58-11
2 1 3
36085889
12
Assembly
1. Place the bottom tapered bearing, 1, onto the 4. Place the top tapered bearing, 3, onto the
output shaft, 2, with the tapered end of the opposite end of the output shaft, 2, with the
bearing facing away from the output shaft. tapered end of the bearing facing away from the
output shaft.
2. Place the bearing end of the output shaft, 2, down
onto a hydraulic press. 5. Carefully press the output shaft, 2, down through
the tapered bearing, 3, until the bearing is seated
3. Carefully press the output shaft, 2, down through
down on the output shaft.
down on the output shaft.
58-12
GEARBOX COMPONENTS
17 16 24 25
11 20
14 23 22
15
1
18
12 21
13 19
9
8
7
3
9
6
2 4 5
36085887
13
1. Housing, Gearbox 13. Shim
2. Cover, Bearing Retainer 14. Bearing, Tapered
3. Gasket 15. Bearing Race
4. Seal, Output Shaft 16. Shim
5. Cap Screw, 1/2 x 1-1/2 inch 17. Snap Ring
6. Flat Washer, 1/2 inch 18. Shaft, Input
7. Shaft, Output 19. Gear, Input
8. Bearing, Tapered 20. Spacer
9. Bearing Race 21. Bearing Housing, Input Shaft
10. Plug, Oil Level/Drain (NOT SHOWN, Located on the 22. Seal, Input Shaft
back of the Gearbox Housing.) 23. Gasket
11. Plug, Oil Fill 24. Cap Screw, 3/8 x 1-1/4 inch
12. Gear, Output 25. Lock Washer, 3/8 inch
58-13
GEARBOX
3
4
9
8
11
7
10
36085887
14
Assembly NOTE: Install the same number/thickness of shims
that were removed during disassembly.
IMPORTANT: Soak all the bearings in clean gear oil
before installing them in the gearbox housing.
5. Reinstall the output gear, 6, onto the top of the
output shaft, 3.
1. Drive the upper bearing race, 1, into the gearbox
housing, 2, until seated by using a hammer and 6. Install a new output shaft oil seal, 7, into the
a suitable bearing race/seal driver. bearing retaining cover, 8, using a hammer and
suitable seal driver.
NOTE: The upper and lower bearing races are
different; make sure they are installed in the correct NOTE: Lubricate the inside diameter of the oil seal.
location.
7. Install a new gasket, 9, and then install the
2. Insert the output shaft, 3, into the gearbox bearing retaining cover, 8, down onto the output
housing, 2. shaft, 3.
3. Insert the bottom bearing race, 4, down onto the NOTE: Apply a small bead of sealant on top of the
output shaft, 3, until the race is seated on the gasket and around the flange of the cover.
tapered bearing.
NOTE: Use a punch and a hammer to drive the 8. Secure the bearing retaining cover, 8; with the
bearing race into place. four 1/2 x 1-1/2 inch cap screws, 10, and 1/2 inch
flat washers, 11, that were removed during
disassembly. Torque to 113 N⋅m (83 lb ft).
4. Reinstall the shims, 5, that were removed during
disassembly.
58-14
15
12
13
2
18
14
16 17
36085887
15
9. Drive the rear input shaft bearing race, 12, into 14. Check the gear tooth wear marks to see where
the gearbox housing, 2, until seated using a the input and output gears engaged each other.
hammer and suitable bearing race/seal driver.
NOTE: If the tooth contact is too high towards Toe,
10. To check the Heal to Toe contact of the input and add shims, 18. If the tooth contact is too low towards
output gears, apply Prussian Blue to the teeth of Heal, remove shims, 18.
the input gear.
11. Install a new gasket, 13, onto the bearing 15. Once the gears are properly set with each other,
housing, 14. remove the bearing housing, 14, and apply a
small bead of sealant on top of the gasket and
12. Install the input shaft, 15, into the gearbox around the flange of the housing.
housing, 2, and secure the housing with two of
the 3/8 x 1-1/4 inch cap screws, 16, and two 3/8 16. Reinstall the input shaft, 15, and bearing
inch lock washers, 17. housing, 14, into the gearbox housing, 2, and
secure using the eight 3/8 x 1-1/4 inch cap
NOTE: It may be necessary to rotate the input shaft screws, 16, and eight 3/8 inch lock washers, 17.
to align the gears. Torque to 46 N⋅m (34 lb ft).
13. Rotate the input shaft, 15, several times, then

remove the two 3/8 x 1-1/4 inch cap screws, 16,
and two 3/8 inch lock washers, 17, and then
remove the bearing housing, 14.
58-15
Backlash Measurement
1. Place a dial indicator, 1, against the side of the
input shaft, 2.
1
NOTE: The gearbox shown is for reference only.
2. With the dial indicator, 1, set at zero, rotate the

input shaft, 2, back and forth noting the extreme
indicator reading. The input shaft should only 2
have a backlash measurement of 0.152--0.457
mm (0.006--0.018 in).
NOTE: If the backlash measurement is not correct
the shims between the snap ring and the gear on the 86082523
input shaft will need added to increase the backlash 16
measurement or subtracted to decrease the
backlash measurement.
NOTE: The input shaft must rotate smoothly, if the

binds up at all during rotation, the gearbox will need
to be rechecked.
58-16
Installation
1. Install the gearbox, 1, onto the rotary cutter deck, 2
2, and secure using the four 3/4 inch nylock nuts,
3. Torque to 271 N⋅m (200 lb ft). 1
NOTE: If both outer gearboxes were removed,
repeat instructions 1 through 6 for the other gearbox.
2. Reinstall the blade carrier; refer to “Blade Carrier

3
86091145
17
3. Align the splines on the gearbox input shaft, 1,
with the spines in the shaft flex coupler, 2. 1
86091145
18
4. Slide the shaft flex coupler, 1, onto the gearbox
input shaft, 2. 1 2
86091144
19
58-17
5. Align the hole in the shaft flex coupler, 1, with the
groove on the input shaft, 2, of the outer gearbox.
1 4
6. Reinstall the 5/16 x 3 inch cap screw, 3, in the
shaft flex coupler, 1, and secure using the 5/16
inch nylock nut, 4. Torque to 28 N.m (250 lb in).
2
3
86091144
20
7. Reinstall the PTO shield, 1, on top of the center
gearbox. Secure using the four 5/8 x 1--3/4 inch
cap screws, 2, and 3/4 inch flat washers, 3, that
1
2 3 2 3
86086744
21
shaft is securely locked onto the gearbox input shaft 1

center gearbox, 2.
9. Align the splines of the PTO shaft, 1, with those 2
of the gearbox input shaft, 3. Slide the PTO shaft
onto the gearbox input shaft until the hole, 4, in
the PTO shaft lines up with the groove on the 3
gearbox input shaft. 4
22
58-18
one side. The pin is secured by a 1/2 inch flat
washers, 2, and 1/2 inch nylock nut, 3. 3 1
2
86084325
23
the groove on the gearbox input shaft, 2, the 1/2 4 5
2
NOTE: The threaded pin will only go in from one side 1
of the PTO shaft. 3
86086747
13. Refill the gearbox, 1, with gear oil.
IMPORTANT: When checking the oil level or filling
the gearbox, the cutter must be level.
NOTE: It may be necessary to jack one end of the 2

cutter up to level out the gearbox. 1
14. To fill the gearbox, 1, remove the fill plug, 2, and
oil level check/drain plug, 3. Add SAE 80--90W 3
gear oil until oil exits the check hole, then screw
the oil level/drain plug and oil fill plug back into
the gearbox.
86091146
NOTE: The gearbox is shown with the PTO shield
removed. 25
58-19
CENTER GEARBOX (770GC)

Removal
In order to remove the center gearbox from the rotary
cutter, the cutter will need to be disconnected from
the tractor, the PTO shaft removed from the center
gearbox, and the PTO shield and flex coupler
assemblies will need to be removed fro the center
gearbox.

Tractor” in Section 2 of the 770GC Operator’s
Manual.
2. For blade carrier removal refer to “Blade Carrier

flat washer, 2. Use a hammer and a punch to 1 2
shaft, 5.
5
4
3
86086747
26
5. In order to gain access to and remove the outer
gearboxes, the PTO shield will need to be
removed.
1

x 1-3/4 inch cap screws, 2, and 3/4 inch flat
washers, 3. 2 3 2 3
86086744
27
58-20
7. The 770GC Rotary Cutter has four flex coupler
assemblies, 1, located between the center 1
gearbox, 2, and the outer gearboxes, 3.
NOTE: The flex couplers on either side of the center
gearbox consist of a shaft flex coupler and a flex
coupler with a hub. The flex coupler with a hub slides
onto the shaft flex coupler.
2
8. In order to remove the center gearbox, 2, for 3
repair both flex coupler hubs will need to slide
3
back on the shaft flex couplers.
86091143
28
9. Remove the 5/16 inch nylock nut, 1, from the 5/16
x 3 inch cap screw, 2, located on both flex coupler
hubs, 3. 2
10. Remove the 5/16 x 3 inch cap screw, 2, from each
flex coupler hub, 3.
3
86091147
29
11. Slide both flex coupler hubs, 1, off the center
gearbox through shaft, 2, and onto the shaft flex 1
couplers, 3, attached to the outer gearboxes. 3
2
86091148
30
58-21
WARNING
M1340
12. To remove the center gearbox, the cutter will

need to be raised off the ground enough to
access the bottom of the cutter.
13. Use a jack or hoist to lift the cutter, and support
the cutter using jack stands.
14. Remove the four 5/8 x 1-1/2 inch cap screws, 1,
and four 5/8 inch flat washers, 2.
2 1
1 2
86085885
31
15. The center gearbox, 1, and eight spacers, 2, can
be removed from the cutter deck, 3.
3
86091148 2
32
58-22
16. Once the gearbox, 1, is removed, drain the gear
oil out of the gearbox by removing the oil drain
plug, 2, and oil fill plug, 3.
3
2
86085946
33
58-23
GEARBOX COMPONENTS
15
14 16
17
18
13
19
11
9 20
10
21
6 8 22 23
7
5
12
24 25
30
29
26
4
27 28
3
2
1
36091149
34
1. Cap Screw, 1/2 x 1-1/2 inch 16. Gearbox Housing
2. Lock Washer, 1/2 inch 17. Oil Level Plug, 1/8 inch
3. Input Shaft Cap 18. Bearing Race
4. Gaskets 19. Tapered Bearing
5. Oil Seal 20. Through Shaft
6. Bearing Race 21. Snap Ring
7. Tapered Bearing 22. Spacer, 7.4 mm (0.291 in)
8. Input Shaft 23. Gear, 17T
9. Tapered Bearing 24. Tapered Bearing
10. Bearing Race 25. Bearing Race
11. Spacer, 8.6 mm (0.338 in) 26. Gaskets
12. Gear, 17T 27. Side Cover
13. Drain Plug, 1/2 inch 28. Oil Seal
14. Oil Seal 29. Lock Washer, 3/8 inch
15. Oil Fill Plug/Pressure Relief 30. Cap Screw, 3/8 x 1-1/4 inch
58-24

Disassembly 3
1. Remove the eight 3/8 x 1-1/4 inch cap screws, 1,
and 3/8 inch lock washers, 2, from the side cover,
3.
2. Loosen the side cover by using a screwdriver and 5
1 2
hammer. Remove the through shaft, 4, and side
cover, 3, from the gearbox housing, 5.
3. Remove any gaskets from the side cover.
86085920
4
35
4. Remove the oil seal, 1, from the side cover, 2, by
using a seal puller. 2
86085921
36
5. Remove the bearing race, 1, from the side cover,
2, by using a slide hammer. 2 1
NOTE: The side cover is shown with the oil seal
installed.
86085922
37
58-25
and 1/2 inch lock washers, 2, from the input shaft 4
cap, 3.
3
7. Loosen the input cap, 3, by using a screwdriver
and hammer. Remove the input shaft cap, 3, from
the gearbox housing, 4. 1 2 1 2
8. Remove any gaskets from the input shaft cap.
86085924
38
9. Remove the oil seal, 1, from the input shaft cap,
2, by using a seal puller.
1
2
86085944
39
10. Slide the gear, 1, off the input shaft, 2.
86085925
40
58-26
11. Slide the 8.6 mm (0.338 in) spacer, 1, off the input
shaft, 2.
1
86085926
41
12. Use a hammer and punch, 1, to drive the input
shaft, 2, out of the gearbox housing, 3.
1
NOTE: Drive the input shaft out until the outer
bearing race is driven out of the gearbox housing.
Remove the bearing race and pull the input shaft out
of the gearbox housing. 3
2
86085927
42
13. Remove the oil seal, 1, from the gearbox
housing, 2, by using a seal puller.
86085928
43
58-27
14. Use a slide hammer and puller to remove the two
remaining bearing races, 1, from the gearbox
housing, 2.
NOTE: A punch and hammer can also be used to 2
remove the two bearing races from the gearbox
housing.
NOTE: The gearbox housing is shown with the oil

seal installed.
1
86085929
44
Inspection
1. Clean and inspect the gearbox housing for any
INPUT SHAFT
Disassembly
1. To remove the inner tapered bearing, 1, from the
input shaft, 2, place a bearing splitter, 3, under
the tapered bearing.
1
2. Place the input shaft, 2, in a hydraulic press with
2
the inner tapered bearing, 1, on the top.
NOTE: The bearing splitter will rest on the press

plates located on the hydraulic press.
3
3. Carefully press the input shaft, 2, down through 86085930
the inner tapered bearing, 1.
45
4. To remove the outer tapered bearing, 1, from the
input shaft, 2, place a bearing splitter, 3, under
the outer tapered bearing on the top.
NOTE: The bearing splitter will rest on the press 2
plates located on the hydraulic press. 1
6. Carefully press the input shaft, 2, down through

the outer tapered bearing, 1.
3
86085931
46
58-28
Inspection
1. Clean and inspect the input shaft, bearings, and
bearing races for any scoring, pitting, wear or
damage. Replace as necessary.
Assembly
1. Place the outer tapered bearing, 1, onto the input
shaft, 2, with the tapered end of the bearing
facing away from the input shaft.
2. Place the bearing end of the input shaft, 2, onto 2
a hydraulic press with the tapered bearing on the
bottom. 1
NOTE: If the press plates under the tapered bearing
are not level, use a bearing splitter, 3, to properly
align the bearing on the input shaft. 3
86085932
the tapered bearing, 1, until the bearing is seated 47
on the input shaft.
4. Place the inner tapered bearing, 1, onto the
opposite end of the input shaft, 2, with the
tapered end of the bearing facing away from the
input shaft.
5. Place the end of the input shaft, 2, with the inner
tapered bearing onto a hydraulic press with the 2
inner tapered bearing on the bottom.
NOTE: If the press plates under the tapered bearing 1
align the bearing on the input shaft.
3
6. Carefully press the input shaft, 2, down through 86085933
on the input shaft. 48
58-29
THROUGH SHAFT
Disassembly
1. To remove the left tapered bearing, 1, from the
through shaft, 2, place a bearing splitter, 3,
between the tapered bearing and the gear.
2. Place the through shaft, 2, in a hydraulic press 2 1
with the tapered bearing, 1, on the top.
plates located on the hydraulic press. 3
3. Carefully press the through shaft, 2, down 86085934

through the tapered bearing, 1.
49
4. Slide the gear, 1, and 7.4 mm (0.291 in) spacer,
2, off the through shaft, 3. 1 3
5. Remove the snap ring, 4, from the through 4
shaft, 3.
NOTE: Use a paint pen or marker to mark this end of
the through shaft for reassembly.
2
36091150
50
6. To remove the right tapered bearing, 1, from the
through shaft, 2, place a bearing splitter, 3, under
7. Place the through shaft, 2, in a hydraulic press
with the tapered bearing, 1, on the top.
1
2
8. Carefully press the through shaft, 2, down 3

through the tapered bearing, 1.
86085936
51
58-30
Inspection
1. Clean and inspect the through shaft, bearings,
and bearing races for any scoring, pitting, wear
or damage. Replace as necessary.
2. Inspect the gear for any wear or damage and
replace as necessary.
Assembly
1. Install a new snap ring, 1, in the middle ring 1
groove located on the through shaft, 2.
NOTE: The new snap ring will be installed on the side
of the through shaft previously marked with a paint
pen or marker.
2
36091151
52
2. Place the right tapered bearing, 1, onto the
through shaft, 2, with the tapered end of the
bearing facing away from the through shaft.
3. Place the bearing end of the through shaft, 2,
onto a hydraulic press with the tapered bearing
on the bottom.
2
align the bearing on the through shaft.
3
4. Carefully press the through shaft, 2, down
through the tapered bearing, 1, until the bearing 36091152
is seated on the through shaft.
53
58-31
5. Slide the 7.4 mm (0.291 in) spacer, 1, onto the
through shaft, 2, until it’s seated against the snap 4
2
ring, 3.
3
6. Align the splines of the gear, 4, with those on the
through shaft, 2, slide the gear onto the through
shaft until it’s seated against the 7.4 mm (0.291
in) spacer, 1.
NOTE: The tapered side of the gear will face towards
the through shaft.
1
36091150
54
7. Place the left tapered bearing, 1, onto the
through shaft, 2, with the tapered bearing facing
away from the through shaft.
8. Place the end of the through shaft, 2, with the left
tapered bearing, 1, onto a hydraulic press with
the left tapered bearing on the bottom.
are not level, use a bearing splitter, 3, to properly 4
align the bearing on the through shaft.
9. Carefully press the through shaft, 2, down

3
through the tapered bearing, 1, until the bearing 1
36091153
is seated against the gear, 4.
55
NOTE: When pressing the through shaft down
through the tapered bearing, make sure the splines
of the gear are aligned with the splines on the through
shaft. The gear will be seated against the spacer,
once the bearing is seated.
58-32
GEARBOX COMPONENTS
15
14 16
17
18
13
19
11
9 20
10
21
6 8 22 23
7
5
12
24 25
30
29
26
4
27 28
3
2
1
36091149
56
1. Cap Screw, 1/2 x 1--1/2 inch 16. Gearbox Housing
2. Lock Washer, 1/2 inch 17. Oil Level Plug, 1/8 inch
3. Input Shaft Cap 18. Bearing Race
4. Gaskets 19. Tapered Bearing
5. Oil Seal 20. Through Shaft
7. Tapered Bearing 22. Spacer, 7.4 mm (0.291 in)
8. Input Shaft 23. Gear, 17T
9. Tapered Bearing 24. Tapered Bearing
10. Bearing Race 25. Bearing Race
11. Spacer, 8.6 mm (0.338 in) 26. Gaskets
12. Gear, 17T 27. Side Cover
13. Drain Plug, 1/2 inch 28. Oil Seal
14. Oil Seal 29. Lock Washer, 3/8 inch
15. Oil Fill Plug/Pressure Relief 30. Cap Screw, 3/8 x 1--1/4 inch
58-33
GEARBOX
Assembly
IMPORTANT: Soak all the bearings in clean gear oil
before installing them in the gearbox housing.
1. Install the through shaft bearing race, 1, and
input shaft bearing race, 2, in the gearbox
housing, 3, using a suitable bearing race/seal 3
driver.
NOTE: Before installing the bearing races, apply a
small amount of Loctite 271 to the outer surface of
both bearing races.
1 2
86085929
57
2. Install a new through shaft oil seal, 1, in the
gearbox housing, 2.
NOTE: Lubricate the inside diameter of the oil seal.
2
86085928
58
3. Insert the input shaft, 1, into the gearbox housing,
2.
86085940
59
58-34
4. Insert the outer input shaft bearing race, 1, into
the gearbox housing, 2.
NOTE: Before installing the bearing race, apply a
small amount of Loctite 271 to the outer surface of the
bearing race. 1
5. Use a deal blow hammer to drive the bearing
race, 1, down into the gearbox housing, 2, until
its flush with the housing. 2
NOTE: Once the bearing race is flush with the
gearbox housing, use a dead blow hammer and a
punch to drive the bearing race into the housing until 86085941
the proper rolling torque is achieved.
60
6. Place a 1-5/16 inch socket, 1, on the end of the
input shaft, 2, and then use an inch pound torque
wrench, 3, to check the rolling torque of the input 1 2
shaft.
NOTE: The 1-5/16 inch socket is not an exact fit for
the input shaft. The socket will have to be tilted to the
side in order to engage the splines on the input shaft.
NOTE: The rolling torque should be 1.12 -- 1.69 N⋅m

(10--15 lb in).
NOTE: If the rolling torque is not correct use a punch 3

86085942
and hammer to drive the bearing race further in the
gearbox housing until the correct rolling torque is 61
achieved.
7. Install a new oil seal, 1, into the input shaft cap,
2, using a hammer and suitable seal driver.
NOTE: Lubricate the inside diameter of the oil seal. 2
86085944
62
58-35
8. Place the input shaft cap, 1, onto the input shaft,
2, and gearbox housing, 3, and then use a feeler 1 2
gauge, 4, to measure the gap between the
gearbox housing, 3, and the cap to see how
many gaskets will be required. 3
9. Once the measurement is obtained, remove the
input shaft cap.
86085943
4
63
10. Stack the gaskets, 1; together until the correct
thickness is obtained then place the gaskets on
the input shaft cap, 2.
NOTE: Part No. MAG501D0249D1 is the gasket set
used for the input shaft. Each set will have 3 gaskets
consisting of the following sizes 0.1 mm (0.004 in),
0.15 mm (0.006 in) and 0.3 mm (0.012 in).
11. Place a small bead of sealant on top of the

gaskets and around the flange of the cap.
1
86085945 2
64
12. Reinstall the input shaft cap, 1, onto the gearbox
housing, 2, and secure using the four 1/2 X 1-1/2
inch cap screws, 3, and 1/2 inch lock washers, 4, 2
1
that were previously removed. Torque to 100 N⋅m
(74 lb ft).
3 4 3 4
NOTE: Apply Loctite 243 on the threads of the cap
screws.
86085924
65
58-36
13. Once the rolling torque is set, slide the spacer, 1,
onto the input shaft, 2.
1
86085926
66
14. Slide the input gear, 1, onto the input shaft, 2, with
the tapered side of the gear facing in. 1
86085925
67
15. Insert the through shaft, 1, into the gearbox
housing, 2.
NOTE: While inserting the through shaft, align the
two gears with each other.
1
86086729
68
58-37
16. Place the side cover, 1, onto the through shaft, 2,
and the gearbox housing, 3, and then use a feeler
gauge, 4, to measure the gap between the
gearbox housing, 3, and the side cover to see 3
how many gaskets will be required.
4
side cover. 1
2
86086730
69
18. Stack the gaskets, 1; together until the correct
the side cover, 2. 1
NOTE: Part No. MAG501D0243D1 is the gasket set
used for the through shaft. Each set will have 3
gaskets consisting of the following sizes 0.1 mm
(0.004 in), 0.15 mm (0.006 in) and 0.3 mm (0.012 in).
2
86086731
70
19. Install the side cover, 1, onto the gearbox
housing, 2, and secure using two 3/8 X 1-1/14 1
inch cap screws and 3/8 inch lock washers that
4 2
20. Place a 1-5/16 inch socket, 3, on the end of the
input shaft, 4, and then use an inch pound torque
wrench, 5, to check the rolling torque of the input
3
shaft.
NOTE: The 1-5/16 inch socket is not an exact fit for
the input shaft. The socket will have to be tilted to the
side in order to engage the splines on the input shaft. 5
86086732
NOTE: The rolling torque should be 2.25 -- 2.82 N⋅m
(20--25 lb in). 71
NOTE: If the rolling torque is not correct, remove the

side cover and remove the through shaft, then
recheck the rolling torque of the input shaft. If the
rolling torque of the input shaft is not correct, recheck
the assembly of the input shaft.
58-38
21. If the rolling torque is correct remove the two cap
screws and remove the side cover, 1, from the 1
gearbox housing, 2.
22. Place a small bead of sealant on top of the
gaskets and around the flange of the cover.
23. Reinstall the side cover, 1, onto the gearbox 3 4
housing, 2, and secure using the eight 3/8 X
1-1/14 inch cap screws, 3, and 3/8 inch lock
2
washers, 4, that were previously removed.
Torque to 46 N⋅m (34 lb ft).
NOTE: Apply Loctite 243 on the threads of the cap
86085920
screws.
72
NOTE: Use a star pattern when tightening the cap
screws.
NOTE: Check to make sure the through shaft and

input shaft rotate smoothly. If either shaft binds up at
all during rotation, the gearbox will need to be
rechecked.
through shaft, 2. 1
2. With the dial indicator, 1, set at zero, use a pair
of slip--joint pliers to hold the input shaft, and then
rotate the input shaft, 2, back and forth noting the
extreme indicator reading. The input shaft should
only have a backlash measurement of
0.152--0.457 mm (0.006--0.018 in).
NOTE: There is no adjustment for the for backlash
measurement. If the backlash is not correct, recheck
86086733
2
the assembly of the gearbox.
73
58-39

Installation 3
1. Install the center gearbox, 1, and eight spacers,
2, onto the cutter deck, 3.
NOTE: Two spacers go under each corner of the 1
gearbox.
86091148 2
74
WARNING
Always stop engine and remove key before 1 2
starting repairs. Always use suitable jacks or 1 2
M1340
2. Secure the center gearbox to the cutter deck

using the four 5/8 x 1-1/2 inch cap screws, 1, and 86085885
four 5/8 inch flat washers, 2. Torque to 224 N⋅m 75
(165 lb ft).
3. Align the splines on the center gearbox through
shaft, 1, with the splines in both the flex coupler 2
hubs, 2.
1
86091148
76
58-40
4. Slide both the flex coupler hubs, 1, onto the
center gearbox through shaft, 2.
3
5. Align the hole in each flex coupler hub, 1, with the 2
groove on the through shaft, 2, of the center
gearbox.
6. Reinstall the 5/16 x 3 inch cap screw, 3, in both 1
flex coupler hubs, 1, and secure using the 5/16
inch nylock nut, 4. Torque to 28 N.m (250 lb in).
4
86091147
77
7. Refill the gearbox, 1, with gear oil by removing
the fill plug, 2, and the oil level check plug, 3. Add
SAE 80--90W gear oil until oil exits the check
hole, then screw the oil level plug and oil fill plug 2 1
back into the gearbox.
the gearboxes, the cutter must be level.
NOTE: It may be necessary to jack one end of the

cutter up to level out the center gearbox.
3
86091154
78
gearbox. Secure using the four 5/8 x 1--3/4 inch
1
2 3 2 3
86086744
79
58-41
shaft is securely locked onto the gearbox input shaft 1

center gearbox, 2.
10. Align the splines of the PTO shaft, 1, with those 2
of the gearbox input shaft, 3. Slide the PTO shaft
onto the gearbox input shaft until the hole, 4, in
the PTO shaft lines up with the groove on the 3
gearbox input shaft. 4
80
2
86084325
81
the groove on the gearbox input shaft, 2, the 1/2 4 5
2
NOTE: The threaded pin will only go in from one side 1
of the PTO shaft. 3
86086747
58-42
FLEX COUPLER REPAIR (770GC ONLY)

Periodically inspect the flex coupler assemblies for
any damage. Repair as necessary.
Rubber Disc Replacement
1. To gain access to the flex couplers, the PTO 1
shield will need to be removed from the center
gearbox.
x 1-3/4 inch cap screws, 2, and 3/4 inch flat 2 3 2 3
washers, 3.
86086744
83
NOTE: The flex couplers on either side of the center
gearbox, 1, consist of a shaft flex coupler, 2, and a 3
flex coupler with a hub, 3. The flex coupler with a hub
slides onto the shaft flex coupler.
2 2
86091143
84
3. To remove the rubber disc’s, 1, from the flex
couplers, 2, remove the six 5/8 inch lock nuts, 3, 5 2 1
and six 5/8--18 x 2-3/4 inch cap screws, 4, from
each flex coupler.
NOTE: To remove the rubber disc’s from the shaft
flex coupler; slide the shaft flex coupler into the flex
coupler hub, 5.
NOTE: To remove the rubber disc’s from the flex

coupler hub, 5, slide the hub onto the shaft flex
coupler, 2.
86091144 3 4
NOTE: The rubber discs have a 5/8 inch beaded
washer between each disc and one on each 5/8--18 85
x 2-3/4 inch cap screw.
58-43
4. Install the new rubber disc’s, 1, onto the flex
coupler, 2, and secure using the six 5/8--18 x 1
2-3/4 inch cap screws, 3, and six 5/8 inch lock
nuts, 4, previously removed. Torque to 174 N⋅m 2
(128 lb ft).
NOTE: Use new 5/8 inch beaded washers between
each rubber disc, and place a new 5/8 inch beaded
washer on each 5/8--18 x 2-3/4 inch cap screw.
NOTE: When installing the rubber disc’s for shaft flex

coupler, slide the shaft flex coupler back towards the
outer gearbox. 4
86091144 3
NOTE: When installing the rubber disc’s for flex 86
coupler hub, slide the hub back towards the center
gearbox.
gearbox. Secure using the four 5/8 x 1-3/4 inch
1
2 3 2 3
86086744
87
58-44
DIVIDER GEARBOX (780GC)

Preparation
In order to dissemble the divider gearbox from the
flex wing rotary cutter, the cutter will need to be
disconnected from the tractor, the main PTO shaft
removed from the divider gearbox, and the center
and wing gearbox PTO shafts will need to be
removed from divider gearbox.

1. In order to remove the three PTO shafts from the
divider gearbox, remove the four 1/2 X 1--1/2 inch
cap screws, 1, and four 1/2 inch flat washers, 2,
and then remove the gearbox shield, 3, from the
top of the divider gearbox.
1 2
1 2
86086778
88
2. In order to remove the tapered pin from the main
PTO shaft, the PTO shield, 1, will need to be
moved back.
1
3. To slide the PTO shield, 1, back depress the
plastic bearing tabs, 2, located on the PTO
shield.
86086779
89
58-45
flat washer, 2, then use a punch and hammer to 1 2
drive the 1/2 inch threaded tapered pin, 3, out. 5
5. Once the 1/2 inch threaded tapered pin is
removed the main PTO shaft, 4, can removed
from the input shaft, 5, on the divider gearbox. 3
4
86086781
90
6. The other three PTO shafts, 1, are removed from
the divider gearbox, 2, in the same manner as the
main PTO shaft, 3. 4 1
NOTE: The threaded tapered pin, 4, on the center
PTO shaft can be accessed without removing the
PTO shield.
2
NOTE: The main PTO shaft will be removed; figure
is shown for reference only. 3
86086797
91
7. Remove the gear oil from the divider gearbox, 1.
In order to remove the gear oil from the divider 2
gearbox an oil suction gun must be used.
8. Remove the oil fill plug/dip stick, 2, from the top
of the divider gearbox, 1, and insert the tube from
the suction gun down into the oil fill hole, then 1
suction the oil out of the gearbox.
86086782
92
58-46
Removal
IMPORTANT: To disassemble the divider gearbox,
it’s recommended not to remove the gearbox from
the flex wing rotary cutter.
If the divider gearbox must be removed from the

cutter follow the following steps.
WARNING
M1340
1. To remove the divider gearbox, the cutter will

need to be raised off the ground enough to
access the bottom of the cutter.
2. Use a jack or hoist to lift the front of the cutter, and
support the cutter using jack stands.
NOTE: The cap screws have anti-rotation bars
welded to them to keep the cap screws from
loosening. 2 3
3. Remove the anti-rotation bars, 1, by turning the

four 3/4 x 1-3/4 inch cap screws, 2, with a wrench
until the welds break loose, and then remove the 1
anti-rotation bars.
and four 3/4 inch flat washers, 3.
5. The divider gearbox can now be removed from
the cutter deck. 86091159
93
58-47
GEARBOX COMPONENTS
9 12 19 20
1 5
7 9 12
3
14
23
22 21
26
6
4
8
2
15
13 9 15
10 11
16 18
17
5
14
9 12
3
7 17
9 12
86091155
94
1. Gearbox Housing 14. Oil Seal, Output Shafts
2. Input Cap 15. Oil Seal, Input Shaft
3. Output Shaft Housing 16. Gaskets
4. Output Cap 17. Gaskets
5. Gear, 20T 18. Spacer, 16 mm (0.63 in)
6. Gear, 24T 19. Cap Screw, 3/8 x 1-1/4 inch
7. Output Shaft 20. Lock Washer, 3/8 inch
8. Input Shaft 21. Spanner Nut
9. Tapered Bearing 22. Tab Lock Washer
10. Tapered Bearing 23. Tongued Washer
11. Bearing Race 24. Oil Fill Plug/Dip Stick (Pressure Relief) (Not Shown)
12. Bearing Race 25. Oil Level Plug, 1/8 inch (Not Shown)
58-48

4 5 3
Disassembly
2
1. Using a hammer drive a screwdriver, 1, or similar
device through both oil seals, 2, and force them
out of the shaft housings, 3.
2. Remove the eight 3/8 x 1-1/4 inch cap screws, 4, 1
and eight 3/8 inch lock washers, 5, from each
shaft housing, 3.
86091156
95
3. Remove the shaft housings, 1, and gaskets from
the divider gearbox housing, 2.
1
86091157
96
4. Remove the eight 3/8 x 1-1/4 inch cap screws, 1,
and eight 3/8 inch lock washers, 2, from the input
cap, 3.
1 2

is shown for reference only.
86086782
97
58-49
5. Remove the input shaft, 1, from the gearbox
housing, 2, by hitting the output end of the input
shaft with a dead blow hammer.
86091160
98
6. Remove the input cap, 1, and gaskets, 2, from
the input shaft, 3.
2
86091163 1
99
7. Remove the output cap, 1, from the gearbox
housing, 2, by removing the four 3/8 x 1--1/4 inch
cap screws, 3, and four 3/8 inch lock washers, 4.
NOTE: The figure is shown for reference only; the 1
shaft housing’s and PTO shafts will be removed. 2
8. Remove the oil seals from the input and output

caps by using a seal removal tool.
3 4
9. Remove the bearing races from the input and 3 4
output caps by using a punch and hammer to
drive the bearing races out of the cap.
86091161
100
Inspection
2. Inspect the bearing races for any scoring, pitting,
wear or damage and replace as necessary.
58-50
INPUT SHAFT
6
1
3 2
86091162
101
Disassembly 5. Remove the snap ring, 5, from the input shaft, 2.
1. To remove the tapered bearing, 1, from the 6. To remove the other tapered bearing, 6, from the
output end of the input shaft, 2, place a bearing input shaft, 2, place a bearing splitter under the
splitter between the tapered bearing and the tapered bearing.
spacer, 3.
2. Place the input shaft, 2, in a hydraulic press with the tapered bearing on the top.
the tapered bearing, 1, on the output end of input
shaft on the top. NOTE: The bearing splitter will rest on the press
NOTE: The bearing splitter will rest on the press plates located on the hydraulic press.
plates located on the hydraulic press. 8. Carefully press the input shaft, 2, down through
the tapered bearing, 1. Inspection
1. Clean and inspect the input shaft and tapered
NOTE: The tapered bearings on the input shaft are bearings for any scoring, pitting, wear or
two different sizes. damage. Replace as necessary.
4. Slide the spacer, 3, and gear, 4, off the input
2. Inspect the gear for any wear or damage and
shaft, 2.
58-51
5
3 1
6 2
86091162
102
Assembly 5. Slide the gear, 4, onto the input shaft, 2, with the
tapered end of the gear facing towards the input
1. Place the tapered bearing, 1, onto the input end
end of the input shaft until it’s seated against the
of the input shaft, 2.
snap ring, 3.
NOTE: Soak the bearings in clean gear oil prior to
6. Slide the spacer, 5, onto the input shaft, 2, until
assembly.
seated against the gear, 4.
NOTE: The tapered bearings on the input shaft are 7. Place the tapered bearing, 6, onto the output end
two different sizes. of the input shaft, 2.
NOTE: The tapered end of the bearing will face from the gear.
towards the shorter end of the input shaft.
2. Place the input shaft, 2, onto a hydraulic press the tapered bearing, 6, on the bottom.
3. Carefully press the input shaft, 2, down through the tapered bearing, 6, until the bearing is seated
the tapered bearing, 1, until the tapered bearing on the input shaft.
is seated on the input shaft, 2.
NOTE: When pressing the input shaft down through
NOTE: If the press plates under the tapered bearing the tapered bearing, make sure the splines of the
are not level, use a bearing splitter to properly align gear are aligned with the splines on the input shaft.
the bearing on the input shaft. The gear will be seated against the snap ring once
the bearing is seated.
4. Install a new snap ring, 3, on the input shaft, 2,
where shown.
58-52
OUTPUT SHAFT
6
7 1 2 4
5
3
86091158
103
Disassembly 7. Place the output shaft, 5, in a hydraulic press with
the tapered bearing, 8, on the top.
1. Unlock the tabs on the tab lock washer, 1, from
the spanner nut, 2, on both shaft housings, 3. NOTE: The bearing splitter will rest on the press
2. Remove the spanner nut, 2; tab lock washer, 1,
and tongued washer, 4, from the output shaft, 5,
on both shaft housings, 3. 8. Carefully press the output shaft, 5, down through
NOTE: To remove the spanner nut, use a punch a
hammer. NOTE: Repeat steps 7 and 8 for the other shaft
housing.
3. Slide the gear, 6, off the output shaft, 5, on both 9. Remove the two bearing races from both shaft
shaft housings, 3. housings by using a punch and a hammer.
4. Remove the output shaft, 5, from the shaft
housings, 3, by using a dead blow hammer to hit Inspection
the gear end of the output shaft, 5, through the
1. Clean and inspect the output shafts and tapered
tapered bearing, 7.
bearings for any scoring, pitting, wear or
5. Once the output shaft, 5, has cleared the tapered damage. Replace as necessary.
bearing, 7, the output shaft and tapered bearing,
2. Inspect the gears for any wear or damage and
7, can be removed from the shaft housing, 3.
6. Remove the tapered bearing, 8, from the other
end of the output shaft, 5, by placing a bearing
splitter under the tapered bearing.
58-53
6
1 7 8 9
3
1
4
2
86091158
104
Assembly 7. Use a brass drift and a hammer to drive the
tapered bearing, 5, down onto the output shaft,
1. Install the bearing races, 1, in both shaft
4, until the bearing is seated in the bearing race
housings, 2, by using a suitable bearing
in the shaft housing, 2.
race/seal driver and hammer.
8. Slide the gear, 6, down onto the output shaft, 4,
with the tapered side of the gear facing away
from the shaft housing, 2.
bearing races.
9. Place the tongued washer, 7, tab lock washer, 8,
2. Place the tapered bearing, 3, on the gear end of onto the output shaft, 4, and secure using the
the output shaft, 4. spanner nut, 9.
NOTE: The tapered end of the bearing will face away NOTE: Apply Loctite 271 to the threads of the
from the output end of the output shaft, 4. spanner nut.
NOTE: Soak the bearings in clean gear oil prior to NOTE: Tighten the spanner nut by using a punch and
assembly. hammer, until there is no end play in the output shaft.
Bend the tab on the lock washer over against the
3. Place the output shaft, 4, onto a hydraulic press
grooves in the spanner nut.
4. Carefully press the output shaft, 4, down through NOTE: Strike each end of the output shaft with a
the tapered bearing, 3, until the tapered bearing hammer to seat all parts, recheck the end play.
is seated on the output shaft, 4.
10. Install a new oil seal into the shaft housing, 2, by
NOTE: If the press plates under the tapered bearing using a soft face hammer to tap the seal into
are not level, use a bearing splitter to properly align place.
the bearing on the output shaft.
NOTE: Apply a small amount of silicone sealant to
5. Insert the gear end of the output shaft, 4, into the the outside edge of the oil seal prior to installation.
shaft housing, 2.
NOTE: Make sure the seal is level with shaft housing
6. Place the other tapered bearing, 5, onto the when seated.
output shaft, 4.
NOTE: Repeat steps 2 through 10 for the other shaft
NOTE: The tapered end of the bearing will face housing.
towards the shaft housing, 2, on the output shaft, 4.
58-54
GEARBOX COMPONENTS
9 12 19 20
1 5
7 9 12
3
14
23
22 21
26
6
4
8
2
15
13 9 15
10 11
16 18
17
5
14
9 12
3
7 17
9 12
86091155
105
1. Gearbox Housing 14. Oil Seal, Output Shafts
2. Input Cap 15. Oil Seal, Input Shaft
3. Output Shaft Housing 16. Gaskets
4. Output Cap 17. Gaskets
5. Gear, 20T 18. Spacer, 16 mm (0.63 in)
6. Gear, 24T 19. Cap Screw, 3/8 x 1--1/4 inch
8. Input Shaft 21. Spanner Nut
9. Tapered Bearing 22. Tab Lock Washer
10. Tapered Bearing 23. Tongued Washer
11. Bearing Race 24. Oil Fill Plug/Dip Stick (Pressure Relief) (Not Shown)
58-55

Assembly
1. Install the bearing races into the output and input
caps using a suitable bearing race/seal driver
and hammer.
bearing races.
2. Install new oil seals in the output and input caps

using a suitable seal driver and hammer.
NOTE: Apply a small amount of silicone sealant to
the outside edge of the oil seal prior to installation.
3. Install the output cap, 1, onto the gearbox
housing, 2, and secure using the four 3/8 x 1--1/4
inch cap screws, 3, and four 3/8 inch lock
washers, 4. Torque to 46 N⋅m (34 lb ft).
1
NOTE: The figure is shown for reference only; the 2
shaft housing’s and PTO shafts will be removed.
3 4
3 4
86091161
106
4. Install the input shaft, 1, into the gearbox
housing, 2. 4
3
5. Slide the input cap, 3, onto the input shaft and
use a feeler gauge to measure the gap between 2
the gearbox housing, 2, and the input cap, 3, to
determine the approximate amount of gaskets
that will be required. 1
input cap, 3.
7. Stack the gaskets, 4, together until the correct
thickness is obtained then place the gaskets, 4,
on the input cap, 3. 86091163
107
58-56
8. Reinstall the input cap, 1, and secure using four
3/8 x 1-1/4 inch cap screws, 2, and four 3/8 inch
lock washers, 3.
2 3
NOTE: Tighten the four cap screws evenly.
NOTE: The main PTO shaft will be removed, figure

is shown for reference. 1 4
9. Turn the input shaft, the input shaft should turn

freely but should not move from side to side in the
gearbox housing, 4.
NOTE: If the input shaft is tight when turned, 86086782
additional gaskets are needed. If the input shaft is
loose when turned and the shaft can be moved from 108
side to side, gaskets need to be removed.
10. Install one of the shaft housings, 1, into the
gearbox housing, 2, and use a feeler gauge to
measure the gap between the shaft housing, 1, 1
and the gearbox housing, 2.
shaft housing, 1, from the gearbox. 2
12. Stack the gaskets together until the correct
the shaft housing, 1.
13. Reinstall the shaft housing, 1, and secure using
four 3/8 x 1-1/4 inch cap screws and four 3/8 inch
lock washers. 86091157
NOTE: Tighten the four cap screws evenly. 109
14. Turn the output shaft in the shaft housing; it

should turn smoothly with little gear mesh noise.
NOTE: After the backlash measurement is set with
the first output shaft, install the second shaft housing
and repeat steps 10 though 14. To check and adjust
the backlash measurement of the second output
shaft follow the instructions listed under “Backlash
Measurement”.
58-57
BACKLASH MEASUREMENT
1. Place a dial indicator against the side of the outer
output shaft.
2. With the dial indicator set to zero, use a pair of
slip-joint pliers to hold the input shaft, rotate the
output shaft back and forth noting the extreme
indicator reading. The output shaft should have
a backlash measurement of 0.431--0.558 mm
(0.017--0.022 in).
NOTE: If the backlash measurement is not correct
adjust the gaskets as follows. To increase the
backlash measurement add gaskets to the shaft
housing. To reduce the backlash measurement
remove gaskets from the shaft housing.
NOTE: The output shafts must rotate smoothly, and

with little gear mesh noise. If the output shafts still do
not rotate smoothly or make a lot of noise, recheck
the assembly of the gearbox.
Final Assembly
1. After the backlash adjustment is made the input
cap and shaft housings should be removed from
the gearbox housing by removing the 3/8 x 1-1/4
inch cap screws, and 3/8 inch lock washers.
2. Apply a small bead of silicone sealant, 1, on the
gaskets and flange of the input cap, 2, and shaft 2
housings, 3.
86091164
1
3
86091165
110
3. Reinstall the shaft housings, 1, to the gearbox
housing, 2, secure using the eight 3/8 x 1--1/4 3 4 1
inch cap screws, 3, and eight 3/8 inch lock 3 4
washers, 4 that were previously removed.
2
NOTE: Tighten the eight cap screws evenly on the
shaft housings.
1
86091166
111
58-58
4. Reinstall the input cap, 1, and secure using eight
3/8 x 1-1/4 inch cap screws, 2, and eight 3/8 inch
lock washers, 3. Torque to 46 N⋅m (34 lb ft).
2 3
NOTE: Tighten the eight cap screws evenly.

is shown for reference only. 1
86086782
112
5. The divider gearbox, 1, can now be refilled with
gear oil.
2
the gearboxes, the cutter must be level.
1
cutter up to level out the gearboxes.
6. Remove the oil fill plug/dip stick, 2, and oil level

3
plug, 3, from the gearbox, 1.
7. Add SAE 80--90W gear oil to the gearbox until oil
exits the oil level hole. 86086782
8. Screw the oil level plug, 3, and oil fill plug/dip 113
stick, 2, back into the gearbox, 1.
9. Recheck the oil level using the oil fill plug/dip
stick, 1.
1
10. The oil level should be at the full mark, 2, on the
oil fill plug/dip stick, 1.
11. If the oil level is over the full mark remove the oil
level plug, and allow the oil to drain out until the
proper level is reached on the oil fill plug/dip
stick,1, then screw the oil level plug back into the
gearbox.
12. The oil fill plug/dip stick, 1, can now be screwed
back into the gearbox. 2
86086783
114
58-59
MAIN PTO/GEARBOX PTO SHAFT

Installation
1
1. Reattach the three PTO shafts, 1, and main PTO
shaft, 2, to the divider gearbox, 3.
86086797
115
2. Align the splines of the main PTO shaft, 1, with
those of the gearbox input shaft, 2, and slide the 3 2
hole, 3, in the PTO shaft is lined up with the
groove on the gearbox input shaft.
gearbox input shaft and output shaft before installing
the PTO shafts.
NOTE: The main PTO shaft is shown in the figure,

connecting the other three PTO shafts to the output
shafts on the gearbox is done the same way. 1
86086780
116
2
86084325
117
58-60
shafts are securely fastened to the gearbox input and 4 5
output shafts prior to operating the cutter. 2

groove in the gearbox input shaft, 2, the 1/2 inch
threaded pin, 3, can be installed. 3
4. Slide the 1/2 inch threaded pin, 3, in with the
tapered side of the pin facing the gearbox input
or output shaft.
tapered pins prior to installing them. 86086781

one side of the PTO shafts.

6. Align the plastic tabs, 1, on the plastic bearing
with the PTO shield, 2.
7. Once the tabs are aligned, slide the PTO shield,
2
2, onto the tabs, 1, until they lock in place.
NOTE: The main PTO shaft and outer wing PTO
shafts will need to have the PTO shields put back in
place. 1
86086779
119
8. Reinstall the gearbox shield, 1, onto the top of the
divider gearbox. Secure using the four 1/2 x 1-1/2
inch cap screws, 2, and four 1/2 inch flat
2 3
2 3
86086778
120
58-61
DIVIDER GEARBOX
Installation
If the divider gearbox was removed, follow the
following steps to reinstall the gearbox to the cutter.
WARNING
M1340
1. Reinstall the divider gearbox to the cutter deck

and secure using the four 3/4 x 1--3/4 inch cap
screws, 1, and four 3/4 inch flat washers, 2. 1 2
NOTE: Apply Loctite 271 to the threads of the cap
screws.
3
2. Weld the anti-rotation bars, 3, back onto the
heads of the cap screws, 1.
3. To reattach the gearbox shield and PTO shafts
refer to “Main PTO/Gearbox PTO Shaft,
Installation” found in this chapter. 86091159
121
58-62
LEFT WING, CENTER DECK AND RIGHT

WING GEARBOXES
Removal
In order to remove the left/right wing gearboxes and
the center deck gearbox from the flex wing rotary
cutter, the cutter will need to be disconnected from
the tractor; the center deck and wing gearbox PTO
shafts will need to be removed from divider gearbox
and have the blade carriers removed.

To remove the blade carriers refer to “Blade Carrier

Removal and Installation (780GC)” in Section 58,
Chapter 1 of this service manual.
1. To remove the PTO shafts from the three deck
gearboxes, remove the access covers from both 2 3 6
sides of each PTO shield, 1.
flat washer, 3, then use a punch and hammer to
1
3. The PTO shafts can now slide off each gearbox

input shaft, 6.
4. Remove the PTO shield, 1, from the gearbox, by 5
removing the four 5/16 x 5/8 inch cap screws and 4
four 5/16 inch washers. 86086798
122
5. Remove the PTO shield, 1, from the gearbox, by
removing the four 5/16 x 5/8 inch cap screws and 5
four 5/16 inch washers.
6. Remove the gearbox, 2, by removing the six 3/4
1
inch nylock nuts, 3, and six 3/4 inch flat washers,
4.
6
7. Once the gearbox is removed, drain the gear oil 2
out of the gearbox by removing the oil fill plug/dip
stick, 5, and the oil level plug, 6.
NOTE: The center gearbox is shown. The left wing
gearbox is the same as the center gearbox. 3 4
86086784
NOTE: The oil fill plug/dip stick on the right wing 123
gearbox is located at the opposite corner of the
gearbox.
NOTE: Tilt the gearbox and drain the oil from the side
of the gearbox where the oil fill/dip stick is located.
58-63
GEARBOX COMPONENTS
22 23 14 18
13 16 20 4
11
7 8
15
18
7 8
1
9
12 5
3 2
12 8
7
10
21
6
17
86091167
124
1. Gearbox Housing 13. Cotter Pin
2. Input Cap 14. Cap Screw, 3/8 x 1 inch
3. Output Gear, 13T 15. Cap Screw, 3/8 x 1-1/4 inch
4. Input Gear, 19T 16. Castle Nut, 1-3/8 inch
5. Input Shaft 17. Castle Nut, 1-1/4 inch
8. Tapered Bearing 20. Oil Fill Plug/Dip Stick (Pressure Relief)
9. Oil Seal, Input Shaft 21. Hub
10. Oil Seal, Output Shaft 22. Snap Ring
11. Gaskets 23. Top Cover
12. Shims
58-64

WING GEARBOXES 3 1 2
Disassembly
1. Remove the ten 3/8 x 1-1/4 inch cap screws, 1,
and ten 3/8 inch lock washers, 2, from the input
cap, 3.
36091168
125
2. Loosen the input cap, 1, with a screwdriver, 2,
and hammer, 3. 2
1
36091169
126
3. Remove the input cap, 1, and input shaft
assembly, 2, from the gearbox housing, 3, by 1
lifting up on the end of the input shaft.
36091170
127
58-65
4. Remove the four 3/8 x 1 inch cap screws and 3/8
inch lock washers from the top cover, 1. 3
5. Remove the top cover, 1, with a screwdriver, 2,
and hammer, 3.
2
1
36091171
128
6. Remove the cotter pin, 1, from the 1--3/8 inch
castle nut, 2.
7. Remove the 1-3/8 inch castle nut, 2, from the
4
output shaft, 3. 1
8. Slide the output gear, 4, off the output shaft, 3,
and remove any shims.
3
2
36091172
129
9. Drive a screwdriver, 1, into the output shaft
oil seal, 2, and force it out of the gearbox 1
housing, 3. 3
36091173
130
58-66
10. Insert a long punch, 1, onto the top of the output
shaft, 2. Hit the punch with a hammer, 3, to drive 2
1
out the output shaft, 2, two tapered bearings and 3
lower bearing race.
NOTE: The upper bearing race will remain in the

gearbox housing.
11. Remove the upper bearing race by inserting a
punch in the bottom of the gearbox housing. Use
a hammer to hit the punch against the bearing
race until the bearing race is removed.
12. Remove the rear bearing race for the input shaft 36091174
from the gearbox housing using a slide hammer
and puller. 131
Inspection
58-67
OUTPUT SHAFT
2
86091181
132
Disassembly 2. Inspect the gear for any wear or damage and
1. Remove the remaining tapered bearing, 1, from
the output shaft, 2, by placing a bearing splitter
under the tapered bearing. Assembly
NOTE: The bearing splitter will rest on the press 1. Place the tapered bearing, 1, onto the gear end
plates located on the hydraulic press. of the output shaft, 2.
NOTE: The tapered end of the bearing will face
NOTE: The tapered bearings used on the output towards the gear end of the output shaft.
shaft are different than those used on the input shaft.
2. Place the output shaft, 2, in a hydraulic press with assembly.
the tapered bearing, 1, on the bottom.
3. Carefully press the output shaft, 2, down through NOTE: Apply small amount of Loctite 271 to the
the tapered bearing, 1. tapered bearing bore.
Inspection 2. Place the output shaft, 2, in a hydraulic press with

1. Clean and inspect the output shaft, bearings and
bearing races that were removed from the 3. Carefully press the output shaft, 2, down through
gearbox housing for any scoring, pitting, wear or the tapered bearing, 1, until the tapered bearing
other damage. Replace as necessary. is seated on the output shaft.
58-68
INPUT SHAFT/INPUT CAP

Disassembly
1. Slide the input cap off the input shaft, then
remove the input gear, shims, and tapered
bearing from the input shaft.
NOTE: Remove any shims that are on top or under
the input gear.
2. To remove the input gear, 1, and tapered bearing,

2, from the input shaft, 3, place the input shaft, 3 3
in a hydraulic press with the gear, 1, on the
bottom. 2
1
the tapered bearing, 2, and input gear, 1.
36091175
133
58-69
3 1
86091182
134
4. Remove the snap ring, 1, from the input shaft, 2. 8. Remove the oil seal from the input cap by using
a seal removal tool.
5. To remove the tapered bearing, 3, from the other
end of the input shaft, 2, place a bearing splitter 9. Remove the bearing race from the input cap by
under the tapered bearing, 3. using a punch and a hammer to drive the bearing
race out.
Inspection
6. Place the input shaft, 2, in a hydraulic press with 1. Clean and inspect the input shaft, tapered
the tapered bearing, 3, on the top. bearings, and bearing races for any scoring,
pitting, wear or damage. Replace as necessary.
the tapered bearing, 3. 2. Inspect the gear for any wear or damage and
NOTE: The tapered bearings used on the input shaft
are different than those used on the output shaft.
58-70
1 3
86091182
135
Assembly NOTE: The tapered end of the bearing will face away
from the input shaft.
1. Install the bearing race into the input cap by using
a suitable bearing race/seal driver and hammer.
NOTE: Before installing the bearing races, apply a assembly.
bearing races. 4. Place the input shaft, 2, in a hydraulic press with
2. Install a new oil seal into the input cap using a
suitable seal driver and hammer. 5. Carefully press the input shaft, 2, down into the
tapered bearing, 1, until the tapered bearing is
NOTE: Lubricate the inside diameter of the oil seal. seated on the input shaft.
6. Install a new snap ring, 3, in the last groove on the
3. Place one of the tapered bearings, 1, on the end
input gear end of the input shaft, 2.
of the input shaft, 2, that will be inserted into the
gearbox housing.
58-71
GEARBOX COMPONENTS
22 23 14 18
13 16 20 4
11
7 8
15
18
7 8
1
9
12 5
3 2
12 8
7
10
21
6
17
86091167
136
1. Gearbox Housing 13. Cotter Pin
2. Input Cap 14. Cap Screw, 3/8 x 1 inch
3. Output Gear, 13T 15. Cap Screw, 3/8 x 1-1/4 inch
4. Input Gear, 19T 16. Castle Nut, 1-3/8 inch
5. Input Shaft 17. Castle Nut, 1-1/4 inch
8. Tapered Bearing 20. Oil Fill Plug/Dip Stick (Pressure Relief)
9. Oil Seal, Input Shaft 21. Hub
10. Oil Seal, Output Shaft 22. Snap Ring
11. Gaskets 23. Top Cover
12. Shims
58-72

WING GEARBOXES
Assembly
4
1. Install the bearing race, 1, in the lower end of the
gearbox housing, 2, using a suitable bearing
race/seal driver, 3, and hammer, 4.
2. Install the upper bearing race into the gearbox 3
housing using a suitable bearing race/seal driver
and hammer. 2 1
small amount of Loctite 271 to the outer surface of
each bearing race.
36091176
NOTE: Make sure the bearing races are facing the
correct direction during installation. 137
3. Install the rear input shaft bearing race in the

gearbox housing using a suitable race/seal
driver and hammer.
4. Insert the output shaft assembly, 1, into the
bottom of the main gearbox housing, 2.
5. Install the other tapered bearing, 3, onto the top 4 2
of the output shaft, 1.
6. Drive the tapered bearing down onto the output
shaft using a punch and a hammer.
3
7. Install any shims, 4, if any were present during
disassembly.
NOTE: Install the same number/thickness of shims

that were removed during disassembly. 1
36091177
138
8. Install the output gear, 1, onto the top of the
output shaft, 2.
1
9. Install the 1-3/8 inch castle nut, 3, onto the top of
the output shaft, 2.
4
NOTE: Tighten the castle nut until there is no end
play in the output shaft.
NOTE: Strike each end of the output shaft with a 2

hammer to seat all parts, recheck the end play.
10. After the end play is set install a new cotter pin,
4, in the 1-3/8 inch castle nut, 3. 3
36091172
139
58-73
11. Insert the input shaft assembly, 1, into the
gearbox housing, 2. 4
3
12. Install the shims, 3, onto the input shaft, 1.
NOTE: Install the same number/thickness of shims
that were removed during disassembly. 1
13. Slide the input gear, 4, onto the input shaft, 1.
2
36091178
140
14. While holding the input shaft, 1, in place check
the back side of the gear tooth surface, 2, where 1
the input and output gears engage each other. 4
15. These two surfaces, 2, should be approximately
flush.
16. If they are not approximately flush, then either
add or subtract shims under the output gear, 3,
or in front of the input gear, 4.
3
2
86091183
141
17. Install the remaining tapered bearing, 1, onto the
input shaft, 2, using a punch, 3, and a hammer, 4
4, until the tapered bearing is seated against the
shims or input gear.
from the input gear. 2
3 1
36091179
142
58-74
18. Install the input cap, 1, onto the input shaft, 2.
19. Using a feeler gauge check the gap between the 2
input cap, 1, and the gearbox housing, 3,
1
input cap, 1, from the gearbox housing, 3.
21. Stack the gaskets together until the correct
3
the input cap, 1.
36091180
143
22. Reinstall the input cap, 1, with gaskets onto the
gearbox housing, 2. Secure using the four 3/8 x 5 3 4
1
1--1/4 inch cap screws, 3, and 3/8 inch lock
NOTE: Insert the cap screws in every other hole in
the input cap. Tighten the four cap screws evenly.
23. Turn the input shaft, 5; the input shaft should turn
freely but should not move in or out of the
gearbox housing, 2. 2
NOTE: If the input shaft is tight when turned,
additional gaskets are needed. If the input shaft is 36091168
loose when turned and the shaft can be move in and
out of the gearbox housing, gaskets need to be 144
removed.
58-75
input shaft, 2.
2. With the dial indicator set to zero, use a pair of 1
slip-joint pliers to hold the output shaft, rotate the 2
input shaft back and forth noting the extreme
indicator reading. The input shaft should have a
backlash measurement of 0.152--0.457 mm
(0.006--0.018 in).
NOTE: The gearbox is shown for reference only.
86082523
NOTE: If the measurement is not correct adjust the
shims as follows. To increase the backlash move the 145
shims from the front side of the input gear to the back
side of the input gear. To decrease the backlash,
move the shims in the opposite direction.
NOTE: The front side of the input gear faces toward

the center of the gearbox.
NOTE: The input shaft must rotate smoothly, if it

binds up at all during rotation, the gearbox will need
to be rechecked.
Final Assembly
3 1 2
1. Once the backlash measurement is set, remove
the four 3/8 x 1--1/4 inch cap screws, 1, and 3/8
inch lock washers, 2, and remove the input cap,
3, and gaskets.
2. Apply a small bead of silicone sealant around the
flange of the input cap and on top of the gaskets.
3. Reinstall the input cap, 3, on the gearbox
housing, 4, and secure using the eight 3/8 x 4
1--1/4 inch cap screws, 1, and eight 3/8 inch lock
washers, 2. Torque to 46 N⋅m (34 lb ft).
36091168
4. Apply a small bead of silicone sealant around the
flange of the top cover. 146
5. Reinstall the top cover on the gearbox housing.
Secure using the four 3/8 x 1 inch cap screws and
3/8 inch lock washers. Torque to 46 N⋅m (34 lb ft).
NOTE: The removal, disassembly and assembly
procedures are the same for all three gearboxes.
58-76

WING GEARBOXES
Installation
1. Install the gearbox, 1, onto the cutter, 2, and
secure using the six 3/4 inch nylock nuts, 3, and
six 3/4 inch flat washers, 4. Torque to 383 N⋅m
5
(282 lb ft).
NOTE: The gearboxes use six 3/4 x 1--3/4 inch cap
screws which are mounted from underneath the 1
cutter.
2. Reinstall the PTO shield, 5, to the gearbox, 1, 2

and secure using the four 5/16 x 5/8 inch cap 3 4
screws and four 5/16 inch washers that were 86086784
previously removed.
147
3. Reinstall the blade carrier, refer to “Blade Carrier
58, Chapter 1 of this service manual.
4. The gearbox, 1, can now be refilled with gear oil.
the gearboxes, the cutter must be level. 2

cutter up to level out the gearboxes.
1
5. Remove the oil fill plug/dip stick, 2, and oil level
plug, 3, from the gearbox, 1.
NOTE: The center gearbox is shown. The left wing
3
gearbox is the same as the center gearbox.
86086784
NOTE: The oil fill plug/dip stick on the right wing
148
gearbox is located at the opposite corner of the
gearbox.
6. Add SAE 80--90W gear oil to the gearbox until oil

exits the oil level hole.
7. Screw the oil level plug, 3, and oil fill plug/dip
stick, 2, back into the gearbox, 1.
58-77
8. Recheck the oil level using the oil fill plug/dip
stick, 1.
1
9. The oil level should be at the full mark, 2, on the
oil fill plug/dip stick, 1.
10. If the oil level is over the full mark remove the oil
level plug, and allow the oil to drain out until the
proper level is reached on the oil fill plug/dip
stick,1, then screw the oil level plug back into the
gearbox.
11. The oil fill plug/dip stick, 1, can now be screwed
back into the gearbox. 2
86086783
149
WING PTO SHAFTS
Installation
2
1. Align the spines of the PTO shaft, 1, with those
hole in the PTO shaft lines up with the groove on
the gearbox input shaft.
1
86086798
150
2
86084325
151
58-78
shaft is securely fastened to the gearbox input shaft 4 5 2

the groove in the gearbox input shaft, 2, the 1/2
inch threaded tapered pin, 3, can be installed. 6
input shaft.
1
NOTE: Apply a small amount of grease to the ta- 3
86086798
pered pin prior to installing it.
152
NOTE: The tapered pin can only be installed from
one side of the PTO shaft.
5. Reattach the access cover to the sides of the
PTO shield, 6.
6. To reattach the main PTO shaft to the tractor refer
to “Connecting the Flex Wing Rotary Cutter to the
Tractor” in Section 2 of the 780GC Flex Wing
Rotary Cutter Operator’s manual.
58-79
58-80
COMPLETE CONTENTS

CONTENTS

General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Chapter 1 -- Hydraulic System (Continued)

CONTENTS

Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

CONTENTS

Blade Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

CONTENTS

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

CONTENTS

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

CONTENTS

Skid Shoes (780GC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Leveling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CONTENTS

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

CONTENTS

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

CONTENTS

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Output Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

CONTENTS

Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Through Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

CONTENTS

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Output Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Final Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Divider Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Output Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

CONTENTS

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Final Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

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COMPLETE CONTENTS

SECTION 35 -- HYDRAULIC SYSTEM

Chapter 1 -- Hydraulic System

Section Description Page

Chapter 1 -- Hydraulic System (Continued)

Section Description Page

Chapter 1 -- Blade Service

Section Description Page

Chapter 2 -- PTO Shaft Lubrication and Maintenance

Section Description Page

Chapter 3 – Slip Clutches

Section Description Page

Chapter 4 – Skid Shoe/Side Skirt (780GC Only) and

Section Description Page

SECTION 58 -- CUTTER COMPONENTS

Chapter 5 -- Axle Suspension (780GC Only)

Section Description Page

Chapter 6 – Wheel Hubs

Section Description Page

SECTION 58 -- CUTTER COMPONENTS

Chapter 7 – Gearbox Repair

Section Description Page

Chapter 7 – Gearbox Repair (Continued)

Section Description Page

Chapter 7 – Gearbox Repair (Continued)

Section Description Page

Chapter 7 – Gearbox Repair (Continued)

Section Description Page

SECTION 35 -- HYDRAULIC SYSTEM

Chapter 1 -- Hydraulic System

Section Description Page

Section Description Page

HYDRAULIC SYSTEM LAYOUT/

Item Description Qty. Part No.

HYDRAULIC CYLINDER (770GC)

HYDRAULIC CYLINDER SPECIFICATIONS

Cylinder Description Rod Closed Mounting Pin PSI Seal Kit

Item Description Qty. Item Description Qty.

HYDRAULIC CYLINDER (770GC)

NOTE: Lubricate all seals and O-rings with clean

5. Once all the air is bled out from the hydraulic

HYDRAULIC SYSTEM LAYOUT/

Item Description Qty. Part No.

CENTER DECK HYDRAULIC CYLINDER

CENTER DECK HYDRAULIC CYLINDER

Item Description Qty. Item Description Qty.

CENTER DECK HYDRAULIC CYLINDER

2. Attach the rod end of the hydraulic cylinder, 1, to

4. With the rotary cutter connected to the tractor. 19

5. Once all the air is bled out from the hydraulic

WING HYDRAULIC CYLINDERS (780GC)

WING HYDRAULIC CYLINDERS

Item Description Qty. Item Description Qty.

WING HYDRAULIC CYLINDERS (780GC)

4. With the rotary cutter connected to the tractor. 24

5. Once all the air is bled out from the hydraulic

HYDRAULIC SYSTEM LAYOUT/COMPO-

6 Phasing Hydraulic Cylinder, 3 1 415--645032 15 Transport Lock Braces 2 116--1572

CENTER DECK HYDRAULIC CYLINDER

NOTE: The center phasing hydraulic cylinder has

CENTER DECK PHASING HYDRAULIC

CENTER DECK PHASING HYDRAULIC