Frontier FM1012, FM1015, FM1017 Operator's Manual

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OPERATOR’S MANUAL

FM1012

FM1015

FM1017

REAR DISCHARGE

GROOMING MOWERS

5WPMAN0183 (Rev. 7/9/2008)

TO THE DEALER:

Assembly and proper installation of this product is the responsibility of the Frontier dealer. Read manual instructions and safety rules. Make sure all items on the Dealer’s Pre-Delivery and Delivery Check Lists in the Operator’s Manual are completed before releasing equipment to the owner.

The dealer must complete the Product Registration form, located on the Frontier website. Failure to complete and

return the form does not diminish customer’s warranty rights.

TO THE OWNER:

Read this manual before operating your Frontier equipment. The information presented will prepare you to do a better and safer job. Keep this manual handy for ready reference. Require all operators to read this manual carefully and become acquainted with all the adjustment and operating procedures before attempting to operate. Replacement manuals can be obtained from your selling dealer.

The equipment you have purchased has been carefully engineered and manufactured to provide dependable and satisfactory use. Like all mechanical products, it will require cleaning and upkeep. Lubricate the unit as specified. Observe all safety information in this manual and safety decals on the equipment.

For service, your authorized Frontier dealer has trained mechanics, genuine Frontier service parts, and the necessary tools and equipment to handle all your needs.

Use only genuine Frontier service parts. Substitute parts will void the warranty and may not meet standards required for safe and satisfactory operation. Record the model number and serial number of your equipment in the spaces provided:

Model: ______________________________ Date of Purchase: _____________________

Serial Number: (see Safety Decal section for location) ____________________________________

Provide this information to your dealer to obtain correct repair parts.

Throughout this manual, the term NOTICE is used to indicate that failure to observe can cause damage to equipment. The terms CAUTION, WARNING and DANGER are used in conjunction with the Safety-Alert Symbol, (a triangle with an exclamation mark), to indicate the degree of hazard for items of personal safety.

2 Introduction

Frontier (Rev. 7/20/2007)

Si no lee Ingles, pida ayuda a

alguien que si lo lea para que le

traduzca las medidas de seguridad.

LEA EL INSTRUCTIVO!

TABLE OF CONTENTS

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7

SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 12

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

OWNER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

DEALER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

DEALER CHECK LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

PARTS LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

BOLT TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

BOLT SIZE CHART & ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 61

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

PRODUCT WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

REPLACEMENT PARTS WARRANTY . . . . . . . . . . . . INSIDE BACK COVER

5WPMAN0183 (Rev. 7/9/2008)

Introduction 3

SPECIFICATIONS

WARNING

MODEL FM1012 FM1015 FM1017

Cutting Width 12' (3.66 m) 15' (4.57 m) 17' (5.18 m)

Cutting Height Range 1.0" - 5.0" 1.0" - 5.0" 1.0" - 5.0"

(25 - 127 mm) (25 - 127 mm) (25 - 127 mm)

Shipping Weight (Approximately) 2,900 lbs. 3,200 lbs. 3,340 lbs.

(1315 kg) (1452 kg) (1515 kg)

Blade Speed (feet per minute) 16,950 16,950 16,950

Blade Spindles 7 9 9

Number of Blades 7 9 9

Universal Drive Series (Input: ASAE Cat 4; Wing: ASAE Cat 3)

Transport Wheels 20.5" x 8.0" - 10 20.5" x 8.0" - 10 20.5" x 8.0" - 10

Caster Wheels 15" x 6.00" - 6 15" x 6.00" - 6 15" x 6.00" - 6

Tractor PTO Speed 540 rpm 540 rpm 540 rpm

Recommended Minimum Tractor Horsepower 30 hp 35 hp 40 hp

GENERAL INFORMATION

 Some illustrations in this manual show the equipment with safety shields removed to provide a better view. This equipment should never be operated with any necessary safety shielding removed.

The purpose of this manual is to assist you in operating and maintaining your Flex Wing Mower. Read it carefully. It furnishes information and instructions that will help you achieve years of dependable performance.

These instructions have been compiled from extensive field experience and engineering data. Some information may be general in nature, due to unknown and varying operating conditions. However, through experience and these instructions, you should be able to develop procedures suitable to your particular situation.

Throughout this manual, references are made to right and left direction. These are determined by standing behind the tractor facing the direction of forward travel. Blade rotation is counter-clockwise as viewed from the top of the mower.

4 Introduction

5WPMAN0183 (Rev. 7/9/2008)

TRAINING

Safety is a primary concern in the design and manufacture of our products. Unfortunately, our efforts to provide safe equipment can be wiped out by an operator’s single careless act.

In addition to the design and configuration of equipment, hazard control and accident prevention are dependent upon the awareness, concern, judgement, and proper training of personnel involved in the operation, transport, maintenance and storage of equipment.

It has been said “The best safety device is an informed, careful operator.” We ask you to be that kind of operator.

SAFETY RULES

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

 Safety instructions are important! Read all attachment and power unit manuals; follow all safety rules and safety decal information. (Replacement manuals and safety decals are available from your dealer.) Failure to follow instructions or safety rules can result in serious injury or death.

 If you do not understand any part of this manual and need assistance, see your dealer.

 Know your controls and how to stop engine and attachment quickly in an emergency.

 Operators must be instructed in and be capable of the safe operation of the equipment, its attachments, and all controls. Do not allow anyone to operate this equipment without proper instructions.

 Keep hands and body away from pressurized lines. Use paper or cardboard, not hands or other body parts to check for leaks. Wear safety goggles. Hydraulic fluid under pressure can easily penetrate skin and will cause serious injury or death.

 Make sure that all operating and service person-

nel know that if hydraulic fluid penetrates skin, it must be surgically removed as soon as possible by a doctor familiar with this form of injury or gangrene, serious injury, or death will result. CONTACT A PHYSICIAN IMMEDIATELY IF FLUID ENTERS SKIN OR EYES. DO NOT DELAY.

 Never allow children or untrained persons to operate equipment.

Frontier FM (Rev. 1/31/2007)

PREPARATION

 Check that all hardware is properly installed. Always tighten to torque chart specifications unless instructed otherwise in this manual.

 Air in hydraulic systems can cause erratic operation and allows loads or equipment components to drop unexpectedly. When connecting equipment or hoses or performing any hydraulic maintenance, purge any air in hydraulic system by operating all hydraulic functions several times. Do this before putting into service or allowing anyone to approach the equipment.

 Make sure all hydraulic hoses, fittings, and valves are in good condition and not leaking before starting power unit or using equipment. Check and route hoses carefully to prevent damage. Hoses must not be twisted, bent sharply, kinked, frayed, pinched, or come into contact with any moving parts. Operate moveable components through full operational range to check clearances. Replace any damaged hoses immediately.

 Always wear relatively tight and belted clothing to avoid entanglement in moving parts. Wear sturdy, rough-soled work shoes and protective equipment for eyes, hair, hands, hearing, and head; and respirator or filter mask where appropriate.

 When attaching a pull-type unit to the tractor drawbar, always use a high-strength drawbar pin. The drawbar pin must have a device that will lock it into position. Secure safety chain to attachment and tractor.

 Make sure attachment is properly secured, adjusted, and in good operating condition.

 Make sure spring-activated locking pin or collar slides freely and is seated firmly in tractor PTO spline groove.

 Make sure driveline guard tether chains are attached to the tractor and equipment as shown in the pamphlet that accompanies the driveline. Replace if damaged or broken. Check that driveline guards rotate freely on driveline before putting equipment into service.

 Before starting the power unit, check all equipment driveline guards for damage. Replace any damaged guards. Make sure all guards rotate freely on all drivelines. If guards do not rotate freely on drivelines, repair and replace bearings before putting equipment into service.

(Safety Rules continued on next page)

Safety 5

(Safety Rules continued from previous page)

SAFETY RULES

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

 Power unit must be equipped with ROPS or ROPS cab and seat belt. Keep seat belt securely fastened. Falling off power unit can result in death from being run over or crushed. Keep foldable ROPS systems in “locked up” position at all times.

 Inspect chain shielding before each use. Replace if damaged.

 Remove accumulated debris from this equipment, power unit, and engine to avoid fire hazard.

 Make sure all safety decals are installed. Replace if damaged. (See Safety Decals section for location.)

 Make sure shields and guards are properly installed and in good condition. Replace if damaged.

 A minimum 20% of tractor and equipment weight must be on the tractor front wheels when attachments are in transport position. Without this weight, tractor could tip over, causing personal injury or death. The weight may be attained with front wheel weights, ballast in tires or front tractor weights. Weigh the tractor and equipment. Do not estimate.

 Inspect and clear area of stones, branches, or other hard objects that might be thrown, causing injury or damage.

 Never attach the mower release rope to the operator, the operator's clothing, or the tractor seat.

 Make test turns, both left and right. Check that both the hydraulic hose and the mower transport lock release rope do not become taut or caught on any parts of the tractor or mower.

 Never tow this implement with a motor vehicle.

OPERATION

 Only engage power when equipment is at ground operating level. Always disengage power when equipment is raised off the ground.

 Do not allow bystanders in the area when operating, attaching, removing, assembling, or servicing equipment.

 Never walk, stand, or place yourself or others under a raised wing or in the path of a lowering wing. Hydraulic system leak-down, hydraulic system failures, mechanical failures, or movement of control levers can cause wings to drop unexpectedly and cause severe injury or death.

 Full chain shielding must be installed when operating in populated areas or other areas where thrown objects could injure people or damage property.

• If this machine is not equipped with full chain shielding, operation must be stopped when anyone comes within 300 feet (92 m).

• This shielding is designed to reduce the risk of thrown objects. The mower deck and protective devices cannot prevent all objects from escaping the blade enclosure in every mowing condition. and escape, traveling as much as 300 feet (92 m).

 Never direct discharge toward people, animals, or property.

 Do not operate or transport equipment while under the influence of alcohol or drugs.

It is possible for objects to ricochet

TRANSPORTATION

 The maximum transport speed for towed and semi-mounted machines is 20 mph (32 km/h). Regardless of the maximum speed capability of the towing tractor, do not exceed the implement’s maximum transport speed. Doing so could result in:

• Loss of control of the implement and tractor

• Reduced or no ability to stop during braking

• Implement tire failure

• Damage to the implement or its components.

 Use additional caution and reduce speed when under adverse surface conditions, turning, or on inclines.

 Do not operate PTO during transport.

6 Safety

 Operate only in daylight or good artificial light.

 Keep hands, feet, hair, and clothing away from

equipment while engine is running. Stay clear of all moving parts.

 Always comply with all state and local lighting and marking requirements.

 Never allow riders on power unit or attachment.

 Power unit must be equipped with ROPS or

ROPS cab and seat belt. Keep seat belt securely fastened. Falling off power unit can result in death from being run over or crushed. Keep foldable ROPS systems in “locked up” position at all times.

(Safety Rules continued on next page)

Frontier FM (Rev. 1/31/2007)

(Safety Rules continued from previous page)

SAFETY RULES

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

 Always sit in power unit seat when operating controls or starting engine. Securely fasten seat belt, place transmission in neutral, engage brake, and ensure all other controls are disengaged before starting power unit engine.

 Operate tractor PTO at 540 RPM. Do not exceed.

 Do not modify or alter or permit anyone else to

modify or alter the equipment or any of its components in any way.

 Your dealer can supply original equipment hydraulic accessories and repair parts. Substitute parts may not meet original equipment specifications and may be dangerous.

 Do not operate mowers on terrain that raises mowers beyond 25 degrees. Exceeding this design limit will result in U-joint “knocking noise” and potential driveline failure and could cause driveline to pull apart.

 Before raising or lowering wings, front hitch/lift and rear wheel/lift cylinders must be fully extended and all four cylinder locks installed. This prevents rotor and bearing support damage that can result from ground contact.

 Look down and to the rear and make sure area is clear before operating in reverse.

 Do not operate or transport on steep slopes.

 Do not stop, start, or change directions sud-

denly on slopes.

 Use extreme care and reduce ground speed on slopes and rough terrain.

 Watch for hidden hazards on the terrain during operation.

 Stop power unit and implement immediately upon striking an obstruction. Dismount power unit, using proper procedure. Inspect and repair any damage before resuming operation.

 Always connect safety chain from equipment to towing vehicle when transporting.

MAINTENANCE

 Before dismounting power unit or performing any service or maintenance, follow these steps: disengage power to equipment, lower the 3-point hitch and all raised components to the ground, operate valve levers to release any hydraulic pressure, set parking brake, stop engine, remove key, and unfasten seat belt.

 Before working underneath, carefully read Operator’s Manual instructions, disconnect driveline, raise mower, securely block up all corners with jackstands, and check stability. Secure blocking prevents equipment from dropping due to hydraulic leak down, hydraulic system failures, or mechanical component failures.

 To prevent contamination, clean and then cover hose ends, fittings, and motor ports with tape.

 Do not allow bystanders in the area when operating, attaching, removing, assembling, or servicing equipment.

 Make sure attachment is properly secured, adjusted, and in good operating condition.

 Keep all persons away from operator control area while performing adjustments, service, or maintenance.

 Frequently check blades. They should be sharp, free of nicks and cracks, and securely fastened.

 Do not handle blades with bare hands. Careless or improper handling may result in serious injury.

 Your dealer can supply genuine replacement blades. Substitute blades may not meet original equipment specifications and may be dangerous.

 Tighten all bolts, nuts and screws to torque chart specifications. Check that all cotter pins are installed securely to ensure equipment is in a safe condition before putting unit into service.

 Make sure all safety decals are installed. Replace if damaged. (See Safety Decals section for location.)

 Make sure shields and guards are properly installed and in good condition. Replace if damaged.

 Do not disconnect hydraulic lines until engine is stopped, power unit is properly secured, equipment and all components are lowered to the ground, and system pressure is released by operating all valve control levers.

(Safety Rules continued on next page)

Frontier FM (Rev. 1/31/2007)

Safety 7

(Safety Rules continued from previous page)



SAFETY RULES

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

 When lubricating telescoping PTO drives, keep fingers out of shield access slots to prevent injury.

 Wear gloves when installing belt. Be careful to prevent fingers from being caught between belt and pulley.

extended and, if released suddenly, can cause personal injury.

STORAGE

 Block equipment securely for storage.

 Use care when installing or removing belt from

spring-loaded idler. Springs store energy when

 Keep children and bystanders away from storage area.

8 Safety

Frontier FM (Rev. 1/31/2007)

FM1012 & FM1015 REAR DECK

(FM1017 SIMILAR)

PRODUCT IDENTIFICATION NUMBER

LENEXA, KS, U.S.A.LE NEX A, K S, U .S. A.

5 - Serial Number Plate

SHIELD MISSING

DO NOT OPERATE

PUT SHIELD ON

DANGER

18867--B

1 - 5WP18867

GUARD MISSING.

DO NOT OPERATE.

DANGER

33347E

DANGER

GUARD MISSING.

DO NOT OPERATE.

4 - 5WP33347

CRUSHING AND

PINCHING HAZARD

 Be extremely careful

handling various parts of the machine. They are heavy and hands, fingers, feet, and other body parts could be crushed or pinched between tractor and implement.

 Operate tractor controls from

tractor seat only.

 Do not stand between tractor

and implement when tractor is in gear.

 Make sure parking brake is

engaged before going between tractor and implement.

 Stand clear of machine while

in operation or when it is being raised or lowered.

FAILURE TO FOLLOW THESE

INSTRUCTIONS COULD

RESULT IN SERIOUS INJURY

OR DEATH.

WARNING

1002941-A

18 - 5WP1002941

ROTATING BLADES AND

THROWN OBJECTS

 Do not put hands or feet under or into mower when

engine is running.

 Before mowing, clear area of objects that may be

thrown by blade.

 Keep bystanders away.

 Keep guards in place and in good condition.

BLADE CONTACT OR THROWN OBJECTS CAN

CAUSE SERIOUS INJURY OR DEATH.

DANGER

15503-C

2 - 5WP15503

(Safety Decals continued on next page)

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

SAFETY & INSTRUCTIONAL DECALS

Replace Immediately If Damaged!

5WPMAN0183 (Rev. 7/9/2008)

Safety 9

SAFETY & INSTRUCTIONAL DECALS

IMPORTANT

OPERATING MOWERS AT RAISED ANGLES EXCEEDING 25

•

WILL CREATE U-JOINT KNOCKING NOISE AND DAMAGE DRIVELINE. FAILURES RESULTING FROM THIS OPERATION WILL NOT BE COVERED BY WARRANTY.

38446

16 - 5WP38446

FM1015 & FM1017 WING

(RIGHT WING SHOWN; FM1012 SIMILAR)

3 - 5WP18864

FALLING OFF CAN RESULT IN BEING RUN OVER.



Tractor must be equipped with ROPS (or ROPS CAB) and seat belt. Keep foldable ROPS systems in “locked up” position at all times.



Buckle Up! Keep seat belt securely fastened.



Allow no riders.

RAISED EQUIPMENT CAN DROP AND CRUSH.



Before working underneath, follow all instructions and safety rules in operator’s manual and securely block up all corners of equipment with jack stands.



Securely blocking prevents equipment dropping from hydraulic leakdown, hydraulic system failures or mechanical component failures.

FALLING OFF OR FAILING TO BLOCK SECURELY CAN RESULT IN SERIOUS INJURY OR DEATH.

WARNING

18865--C

9 - 5WP18865

(Safety Decals continued from previous page)

(Safety Decals continued on next page)

DANGER

ROTATING DRIVELINE

CONTACT CAN CAUSE DEATH

KEEP AWAY!

DO NOT OPERATE WITHOUT -

 All driveline guards, tractor and

equipment shields in place

 Drivelines securely attached at both ends

 Driveline guards that turn freely on

driveline

18864-C

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Replace Immediately If Damaged!

10 Safety

5WPMAN0183 (Rev. 7/9/2008)

SAFETY & INSTRUCTIONAL DECALS

WARNING

PIN INSERTED TO LOCK TRANSPORT LATCH

PIN STORAGE POSITION

RAISED MOWER CAN DROP AND CRUSH

Before working underneath rear mower:

Raise rear mower to transport position.

Insert pin to lock transport latch.

Securely block up rear of mower. See manual.

Blocking up prevents mower dropping from transport latch release or failure, hydraulic leak down, or hydraulic system failures.

FAILURE TO FOLLOW INSTRUCTIONS CAN

RESULT IN SERIOUS INJURY OR DEATH.

44650

WARNING

RAISED MOWERS CAN

DROP AND CRUSH

Keep away. Do not go underneath.

When raised, insert pins to lock transport latches.

Lower after transport.

FAILURE TO FOLLOW INSTRUCTIONS CAN

RESULT IN SERIOUS INJURY OR DEATH.

SIDE MOWER TRANSPORT LATCHES

44651

PIN STORAGE POSITION

PIN INSERTED TO LOCK TRANSPORT LATCH

WARNING

RAISED MOWERS EXPOSE

BLADES AND INCREASE

THROWN OBJECT HAZARDS

Only raise for transport.

Stop mowers before raising.

FAILURE TO FOLLOW INSTRUCTIONS CAN RESULT IN SERIOUS INJURY OR DEATH.

44656

17 - 5WP44656

11 - 5WP44651

7 - 5WP44650

6 - 5WP38421

RAISED MOWER CAN

DROP AND CRUSH

1

Before working underneath side mowers, lower side mowers and securely block up. See manual.

1

Blocking up prevents mower dropping from transport latch release or failure, hydraulic leak down or hydraulic system failure.

FAILURE TO FOLLOW INSTRUCTIONS CAN

RESULT IN SERIOUS INJURY OR DEATH.

WARNING

38421-A

DO NOT EXCEED PTO SPEED OF

540 RPM

PTO speeds higher than 540 RPM can cause

equipment failure and personal injury.

WARNING

18866-D

8 - 5WP18866

(Safety Decals continued on next page)

(Safety Decals continued from previous page)

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Replace Immediately If Damaged!

5WPMAN0183 (Rev. 7/9/2008)

Safety 11

CD5593A

FM1012, FM1015 & FM1017 TRAILER

13 - 5WP20105 Amber

Front Reflector

14 - 5WP57123 Red

Rear Reflector

HIGH-PRESSURE HYDRAULIC OIL LEAKS CAN PENETRATE SKIN

RESULTING IN SERIOUS INJURY, GANGRENE OR DEATH.

Check for leaks with cardboard; never use hand.

Before loosening fittings: lower load, release pressure, and be sure oil is cool.

Consult physician immediately if skin penetration occurs.

WARNING

19924-B

15 - 5WP19924

10 - 5WP1002423

12 - 5WP18869

BE CAREFUL!

Use a clean, damp cloth to clean safety decals.

Avoid spraying too close to decals when using a pressure washer; high-pressure water can enter through very small scratches or under edges of decals causing them to peel or come off.

Replacement safety decals can be ordered free from your dealer.

WARNING

TO AVOID SERIOUS INJURY OR DEATH:

 Read Operator's Manual before operating,

servicing or repairing equipment. Follow all safety rules and instructions. (Manuals are available from your selling dealer.)

 Never allow riders.  Keep bystanders away from equipment during

operation.

 Operate from tractor seat only.  Keep all shields in place and in good condition.  Lower equipment to ground, stop engine,

remove key and set brake before dismounting tractor.

 Never allow children or untrained persons to

operate equipment.

 Do not transport towed or semi-mounted units

over 20 MPH.

FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN INJURY OR DEATH.

1002423-B

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

SAFETY & INSTRUCTIONAL DECALS

Replace Immediately If Damaged!

12 Safety

SHIELD MISSING

DO NOT OPERATE - PUT SHIELD ON

5WPMAN0183 (Rev. 7/9/2008)

DANGER

18869-B

OPERATION

DANGER

WARNING

CAUTION

WARNING

(229 mm)

The operator is responsible for the safe operation of the cutter. The operator must be properly trained. Operators should be familiar with the cutter, the tractor, and all safety practices before starting operation. Read the safety rules and safety decals on pages 5 to 12.

This mower is designed for lawn and grass mowing. It is not designed for rough conditions or heavy weed mowing. It is equipped with suction type blades for best results in lawn mowing.

Recommended mowing speed for most conditions is from 2 to 5 mph (3 - 8 km/h).

 Full chain shielding must be installed when operating in populated areas or other areas where thrown objects could injure people or damage property.

• If this machine is not equipped with full chain shielding, operation must be stopped when anyone comes within 300 feet (92 m).

 Never allow children or untrained persons to operate equipment.

 Keep bystanders away from equipment.

 Make sure spring-activated locking pin or collar

slides freely and is seated firmly in tractor PTO spline groove.

It is possible for objects to ricochet

ATTACHING MOWER TO TRACTOR

 Make sure spring-activated locking pin or collar slides freely and is seated firmly in tractor PTO spline groove.

 Make sure shields and guards are properly installed and in good condition. Replace if damaged.

 Never attach the mower release rope to the operator, the operator's clothing, or the tractor seat.

1. Park the mower and tractor on a level, hard-sur-

faced area.

2. Adjust tractor hitch bracket on trailer frame so the trailer is level when attached to the tractor. Pin the mower to the tractor.

NOTE: When attaching mower to tractor drawbar, make sure the correct drawbar pin is used. A Category 1 drawbar is 1" (25.4 mm); Category 2 is 1.25" (31.75 mm). Failure to use the correct pin size will result in premature wear of hitch and drawbar hole. If the hitch on the mower doesn't match your tractor drawbar, contact your dealer to order the correct size hitch for your tractor. If not removing mower from tractor on a regular basis, a bolt, locknut, and washers assembled tightly will reduce wear on drawbar and hitch.

A 1-3/8" 6B spline PTO shaft is used for connecting the mower to the tractor. This mower is designed for 540 rpm PTO only.

The PTO drive shaft is intended for use with tractors that have 14 inches (356 mm) between the end of the PTO shaft and the tractor's drawbar hitch pin hole.

3. Attach the safety chain to the tractor as shown in Figure 1.

 Operate tractor PTO at 540 RPM. Do not exceed.

 Stop power unit and implement immediately

upon striking an obstruction. Dismount power unit, using proper procedure. Inspect and repair any damage before resuming operation.

5WPMAN0183 (Rev. 4/25/2008)

Figure 1. Tow Chain Installation

Operation 13

4. Attach the mower drive shaft to tractor PTO. Make

WARNING

sure the lock collar engages securely.

5. Attach the end of the mower transport's lock release rope to a location on the tractor within easy reach of the operator.

NOTE: When routing the rope, do not route through the hydraulic hose guide and do not allow rope slack to drop between the driveline shields and the gearbox rotating shafts.

CV DRIVELINE TURNING LIMITS

NOTICE

 Do not exceed turning angle of 80 degrees at the head of the Constant Velocity (CV) driveline or damage will occur.

Check for excessive turn angle:

1. Disconnect the driveline from the tractor.

2. Start engine and turn as far right or left as possible.

3. Shut off the engine and connect the CV driveline to

the tractor. If it cannot be connected, the turn angle is too severe.

4. Restart the tractor and straighten the angle slightly.

5. Shut off the engine and connect the CV driveline to

tractor.

6. Repeat the process until the driveline can be connected. The point at which the driveline can be connected is the maximum turn that can be made.

LEVELING MOWER

NOTE: To ensure satisfactory mower performance, the

trailer frame and decks must be leveled before operating the mower. During normal operation the mower should be leveled twice each season. The mower must be leveled each time a tractor with a different drawbar height is used.

Follow this procedure to level the flex mower for operation:

1. Park the tractor and mower on a flat level surface with the decks in mowing position.

2. Inflate all tires to the recommended pressure: 70 psi (483 kPa) for trailer tires and 30 psi (207 kPa) for deck gauge tires.

3. Level the trailer frame by adjusting the hitch. (See Figure 2.)

4. Remove the hitch clevis from the trailer frame and pin to the tractor drawbar.

5. Use the parking jack to adjust the trailer frame to the level position. Align the nearest hitch adjustment hole in the hitch clevis with a hole in the trailer frame.

6. Tighten the hardware to specifications in the Bolt Torque Chart on page 57. Frame level must be readjusted each time the drawbar height changes.

7. Attach the mower and the driveline to the tractor. Level the driveline by placing a bolt through the carrier bearing and the driveline height adjustment holes.

Figure 2. Level Trailer Frame

CUTTING HEIGHT ADJUSTMENT

 Keep all persons away from operator control area while performing adjustments, service, or maintenance.

NOTICE

 Avoid low cutting heights. Striking the ground with blades produces one of the most damaging shock loads a mower can encounter. Allowing blades to contact ground repeatedly will cause damage to mower and drive.

1. Level mower from side to side. Check by measur-

ing from mower frame to the ground at each deck rail.

2. Verify that the same amount of spacers are under all caster arms.

3. Loosen cap screws that attach caster arm assembly to deck.

4. Set mower on the ground.

14 Operation

5WPMAN0183 (Rev. 4/25/2008)

5. Retighten cap screws. This equalizes the clear-

Table 1: Cutting Height Chart

Spacers Required Under

Caster Arm Pivot Tube

Cut Height 1/2"

Spacer

3/4"

Spacer

1" (25 mm)

1-1/2" (38 mm)

2" (51 mm)

2-1/2" (64 mm)

3" (76 mm)

3-1/2" (89 mm)

4" (102 mm)

121

4-1/2" (114 mm)

5" (127 mm)

122

ance in the bolt holes.

6. Best mowing results will be obtained with front of mower level with, or slightly lower than, the rear.

7. Cutting height is controlled with front and rear caster wheel adjustment.

8. To raise rear of mower, move caster adjustment spacers under caster arms.

9. To raise front of mower, move spacers under front caster wheel arms.

TRANSPORTING

When transporting the mower short distances, raise the wings and the rear deck until all three transport locks engage automatically.

Install locking pins to secure the mower wings for transport as shown in Figure 4 and Figure 5.

To lower the wings and the rear deck:

1. Remove the locking pins and store in holes provided.

2. Slightly raise the wings and rear deck to take pressure off the locking mechanisms.

3. Pull the transport lock release rope to disengage the locks. Lower the wings and rear deck and release the rope.

Remember, measurement at location A, Figure 3, should not be less than location B and should not be

Figure 3. Cutting Height Adjustment

over 1/2" (13 mm) greater than location B.

5WPMAN0183 (Rev. 4/25/2008)

Figure 4. Lock Pin Installed (Right Wing)

Figure 5. Lock Pin Installed (Rear Deck)

Operation 15

STARTING AND STOPPING MOWER

WARNING

CAUTION

WARNING

CAUTION

WARNING

 Do not operate PTO during transport.

 Never direct discharge toward people, animals,

or property.

 Keep hands, feet, hair, and clothing away from equipment while engine is running. Stay clear of all moving parts.

 Stop power unit and implement immediately upon striking an obstruction. Dismount power unit, using proper procedure. Inspect and repair any damage before resuming operation.

Power for operating the mower is supplied from the tractor PTO. Refer to your tractor manual for instructions on engaging and disengaging the PTO.

Operate PTO at 540 rpm. Know how to stop tractor and mower quickly in case of an emergency.

If the mower becomes plugged causing the belt to slip for over two seconds, follow these steps:

1. Raise mower just enough to clear accumulated material.

2. Continue running at least two minutes, allowing pulleys to cool.

NOTICE

 Stopping the mower with belt in contact with a very hot pulley will bake and ruin belt.

To reduce the risk of thrown objects, do not raise the mower higher than necessary.

Mower vibration tends to loosen bolts. All hardware should be checked regularly to maintain proper torque. Each time the mower is used, check all hardware to be sure it is secure.

The condition of the terrain will determine cutting results. For best results, mower blades should be kept sharp at all times and the platform as level as possible. When mower blades show excessive wear, they should be replaced.

Operating Technique

 Stop power unit and implement immediately upon striking an obstruction. Dismount power unit, using proper procedure. Inspect and repair any damage before resuming operation.

Proper ground speed will depend upon the terrain, the height, type, and density of material to be cut.

Normally, ground speed will range from two to five mph. Tall dense material should be cut at a low speed; thin medium-height material can be cut at a faster ground speed.

Always operate tractor PTO at 540 rpm to maintain proper blade speed and produce a clean cut.

Under certain conditions, tractor tires may roll some grass down and prevent it from being cut at the same height as the surrounding area. When this occurs, reduce your ground speed, but maintain PTO at 540 rpm. The lower ground speed will permit grass to partially rebound.

In general, lower cutting heights give a more even cut with less tendency to leave tire tracks. However, it is better to cut grass frequently rather than too short. Short grass deteriorates rapidly in hot weather and invites weed growth during growing seasons. Follow local recommendations for the suitable cutting height in your area.

OPERATING

When engaging the PTO, engine rpm should always be low. Once engaged and ready for mowing, increase PTO speed to 540 rpm and maintain speed throughout the cutting operation.

16 Operation

Operating Tips

 Inspect and clear area of stones, branches, or other hard objects that might be thrown, causing injury or damage.

Extremely tall material should be cut twice. Set mower at a higher cutting height for the first pass. Then cut at desired height 90 degrees to the first pass.

Remember, sharp blades produce cleaner cuts and require less power.

5WPMAN0183 (Rev. 4/25/2008)

Analyze area to be cut to determine the best proce-

WARNING

dure. Consider height and type of grass and terrain type: hilly, level, or rough.

Plan your mowing pattern to travel straight forward whenever possible. Mow with uncut grass to the right. This will distribute the clippings over the cut area.

Uneven Terrain

OWNER PRE-OPERATION CHECK LIST

(OWNER'S RESPONSIBILITY)

___ Review and follow all safety rules and safety

decal instructions on pages 5 through 12.

___ Check that all safety decals are installed and in

good condition. Replace if damaged.

___ Check that all shields and guards are properly

installed and in good condition. Replace if damaged.

 Do not operate or transport on steep slopes.

 Do not stop, start, or change directions sud-

denly on slopes.

 Use extreme care and reduce ground speed on slopes and rough terrain.

 Watch for hidden hazards on the terrain during operation.

In extremely uneven terrain, rear wheel weights, front tractor weights and/or front tire ballast should be used to improve stability.

Pass diagonally through sharp dips and avoid sharp drops to prevent hanging up the tractor and the mower. Practice will improve your skills in maneuvering rough terrain.

Avoid sudden starts and stops when traveling up or down hill.

Always mow down slopes, never up or across the face. Avoid operating on steep slopes.

Slow down on sharp turns and slopes to prevent tipping and losing control.

REMOVING MOWER FROM TRACTOR

___ Check that chain shielding is in good condition

and replace any damaged chain links.

___ Check that all hardware and cotter pins are prop-

erly installed and secured.

___ Check to ensure blades are sharp, in good condi-

tion, and installed correctly. Replace if damaged.

___ Check that equipment is properly and securely

attached to tractor.

___ Make sure driveline spring-activated locking pin

or collar slides freely and is seated firmly in tractor PTO spline groove.

___ Make sure the driveline guards and tether chains

are in good condition. Guards must rotate freely on driveline. Fasten tether chains, as instructed, to the tractor and the equipment.

___ Inspect area and remove stones, branches or

other hard objects that might be thrown, causing injury or damage.

___ Do not allow riders.

___ Check all lubrication points and grease as

instructed in Lubrication Information, page 20. Make sure the PTO slip joint is lubricated and that the gearbox fluid levels are correct.

1. Park the unit on a level, hard surface with the wings and rear deck fully lowered to the ground.

2. Block the wheels to keep the mower from rolling when unhitched from tractor.

3. Attach the jack to the side of the tongue and adjust the height to take the weight off the tractor hitch.

4. Disconnect the PTO shaft and the hydraulic hose, untie the mower transport lock release rope from the tractor, and remove the hitch pin.

5. Store the PTO shaft end and the hydraulic hose couplings off the ground and keep them clean.

5WPMAN0183 (Rev. 4/25/2008)

___ Check that all hydraulic hoses and fittings are in

good condition and not leaking before starting tractor. Check that hoses are not twisted, bent sharply, kinked, frayed or pulled tight. Replace any damaged hoses immediately.

___ Make sure tractor ROPS or ROPS CAB and seat

belt are in good condition. Keep seat belt securely fastened during operation.

___ Before starting engine, operator must be in trac-

tor seat with seat belt fastened. Place transmission in neutral or park, engage brake and disengage tractor PTO.

Operation 17

NOTES

18 Operation

5WPMAN0183 (Rev. 4/25/2008)

OWNER SERVICE

WARNING

DANGER

CAUTION

The information in this section is written for operators who possess basic mechanical skills. If you need help, your dealer has trained service technicians available. For your protection, read and follow the safety information in this manual.

 Make sure that all operating and service personnel know that if hydraulic fluid penetrates skin, it must be surgically removed as soon as possible by a doctor familiar with this form of injury or gangrene, serious injury, or death will result. CONTACT A PHYSICIAN IMMEDIATELY IF FLUID ENTERS SKIN OR EYES. DO NOT DELAY.

 Keep all persons away from operator control area while performing adjustments, service, or maintenance.

condition. and escape, traveling as much as 300 feet (92 m).

 Always wear relatively tight and belted clothing to avoid getting caught in moving parts. Wear sturdy, rough-soled work shoes and protective equipment for eyes, hair, hands, hearing, and head; and respirator or filter mask where appropriate.

It is possible for objects to ricochet

BLOCKING METHOD

The only approved blocking devices for this mower are jackstands with a load rating of 1,000 pounds (454 kg) or more. Twelve jackstands, located as shown in Figure 6, must be installed before working underneath this unit.

 Full chain shielding must be installed when operating in populated areas or other areas where thrown objects could injure people or damage property.

• If this machine is not equipped with full chain shielding, operation must be stopped when anyone comes within 300 feet (92 m).

• This shielding is designed to reduce the risk of thrown objects. The mower deck and protective devices cannot prevent all objects from escaping the blade enclosure in every mowing

Figure 6. Jackstand Placement

Do not work underneath mower unless it is properly attached to tractor and blocked securely. When properly attached, the unit will be anchored to minimize front to rear movement.

Before blocking, be sure that the mower is securely attached to the tractor. Lower mower units to the ground. Raise the mower units as needed for working room and securely block them. Set tractor brakes, turn engine off and remove key, then disconnect mower driveline.

When blocking, you must consider the overall stability of the unit. Just placing jack stands under the unit will not ensure your safety. The working surface must be level and solid to support the loaded weight of the jack stands. Ensure that jackstands are stable at both top and bottom. Before working under any portion of the mower, test the stability of your blocking with the full weight of the mower units lowered onto the jackstands.

5WPMAN0183 (Rev. 4/25/2008)

Owner Service 19

LUBRICATION INFORMATION

CAUTION

REF DESCRIPTION FREQUENCY

1 Front U-Joint 8 Hours 2 Center U-Joint 8 Hours 3 CV Body 8 Hours 4 Slip Joint Grease Fitting 8 Hours 5 Rear U-Joint 8 Hours 6 Transport Wheel Hub 8 Hours 7 Shield Bearing 8 Hours 8 Splitter Gearbox (Fill 1/2 full Check

with SAE 80W or 90W gear lube) Daily

9 Rear Deck Pivot Arm 8 Hours

10 Drive Carrier Bearing 8 Hours

 When lubricating telescoping PTO drives, keep fingers out of shield access slots to prevent injury.

Remove belt shields and clean out all accumulated grass, dirt and other debris. Heat created by grass build-up can cause belt failure or fires to ignite.

Do not let excess grease collect on or around parts, particularly when operating in sandy areas.

Figure 7 and Figure 8 show lubrication points. The accompanying charts give the frequency of lubrication in operating hours, based on normal operating conditions. Severe or unusual conditions may require more frequent lubrication.

Raise and lower mower after applying grease so that it spreads over the slip joint working area.

Use a lithium grease of #2 consistency with a MOLY (molybdenum disulfide) additive for all locations unless otherwise noted. Be sure to clean fittings thoroughly before attaching grease gun. When applied according to the lubrication chart, one good pump of most guns is sufficient. Use SAE 80W or 90W gear lube in gearboxes.

Daily lubrication of PTO slip joints is necessary. Failure to maintain proper lubrication can result in damage to U-joints, gearboxes and/or drive shafts. Raise or lower mower until grease fittings in PTO shields are exposed. Insert grease gun through slots and apply grease to all sides of shafts. Always stand clear of mower and wing arm mechanism to avoid being pinched or crushed should the mower or wing suddenly lower.

20 Owner Service

Figure 7. Lubrication Points - Trailer

(Rev. 7/9/2008)

5WPMAN0183 (Rev. 4/25/2008)

REF DESCRIPTION FREQUENCY

1 Caster Wheel Pivots 8 Hours 2 Caster Wheel Hubs 8 Hours 3 Blade Spindles 8 Hours 4 Gearbox (Fill 1/2 full with Check

SAE 80W or 90W gear Daily

lube) 5 Rear U-Joint 8 Hours 6 Front U-Joint 8 Hours 7Wing Pivot 8 Hours 8 Slip Joint Grease Fitting 8 Hours 9 Shield Bearing 8 Hours

10 Carrier Bearing 8 Hours

CAUTION

Figure 8. Lubrication Points - Deck

BELT Belt Replacement

One of the major causes of belt failure is improper installation. Before installing a new belt, check the following:

1. Check pulley shafts and bearings for wear.

2. Check pulley grooves for cleanliness.

3. Make sure spindles turn freely and without wobble.

If grooves require cleaning, moisten a cloth with a nonflammable, non-toxic degreasing agent or commercial detergent and water.

(Rev. 7/9/2008) 5WPMAN0183 (Rev. 4/25/2008)

Avoid excessive force during installation. Do not use tools to pry belt into pulley groove. Do not roll belt over pulleys to install. This can cause hidden damage and premature belt failure.

Belt Installation

WING DECK - FM1012

 Use care when installing or removing belt from spring-loaded idler. Springs store energy when extended and, if released suddenly, can cause personal injury.

Owner Service 21

Figure 9. Belt Routing Right Wing

(3 mm)

CAUTION

(3 mm)

WARNING

REAR DECK - FM1012 ALL DECKS - FM1015 & FM1017

 Use care when installing or removing belt from spring-loaded idler. Springs store energy when extended and, if released suddenly, can cause personal injury.

Figure 11. Belt Routing

Figure 10. Belt Routing Left Wing

1. Slide Belt under drive pulley A and over idler arm.

Position the belt around drive pulley A.

2. Loosen the bolt holding belt guide G and swing it away from pulley B. Route the belt around pulley D as shown.

3. Make sure the belt is on drive pulley A; route around idler F.

4. Grasp the belt between spindle pulley B and spindle pulley D. Drive pulley A. Pull spring loaded idler with belt to obtain enough belt length to route it over pulley B. Make sure spring loaded idler pivots freely with belt installed.

5. Adjust belt guide G to provide 1/16" to 1/8" (2 - 3 mm) clearance from belt. Tighten the bolt to 85 lbs/ft. (115 N-m).

1. Slide the belt under drive pulley A and over idler arm. Position the belt around drive pulley A.

2. Loosen the bolt holding belt guide G and swing it away from pulley B. Route the belt around pulley B, idler C, and pulley D as shown.

3. Make sure the belt is on drive pulley A; route around idler F.

4. Grasp the belt between spindle pulley E, spring loaded idler F, and spindle pulley D. Pull spring loaded idler with belt to obtain enough belt length to route it over pulley E. Make sure spring loaded idler pivots freely with belt installed.

5. Adjust belt guide G to provide 1/16" to 1/8" (2 - 3 mm) clearance from belt. Tighten bolt to 85 lbs/ft. (115 N-m).

BLADE Blade Servicing

 Keep all persons away from operator control area while performing adjustments, service, or maintenance.

22 Owner Service

(Rev. 7/9/2008)

5WPMAN0183 (Rev. 4/25/2008)

 Make sure shields and guards are properly

WARNING

CAUTION

(0.8 mm)

installed and in good condition. Replace if damaged.

Blade Installation

vibration which can damage blade spindle bearings. Vibration may also cause structural cracks in mower components.

1. Remove blades.

2. Always sharpen both ends at the same time to

maintain balance.

3. Follow original sharpening pattern.

4. Do not sharpen blade to a razor edge. Leave from

1/32" to 1/16" (0.8 - 2 mm) blunt edge.

 Your dealer can supply genuine replacement blades. Substitute blades may not meet original equipment specifications and may be dangerous.

Inspect blades before each use to determine that they are mounted tightly and are in good condition. Replace any blade that is bent, excessively nicked, worn, or has any other damage. Small nicks can be ground out when sharpening.

1. Place cap screws (3) through outer holes in blade and spindle shaft.

2. Make sure blade cutting edge is positioned to lead in a clockwise rotation, as viewed from top of mower.

3. Place locknuts (4) on screws and torque to 84 lbs/ft. (114 N-m).

5. Do not sharpen back side.

Figure 13. Blade Sharpening

CLEANING

After Each Use

● Remove large debris such as clumps of dirt, grass,

crop residue, etc. from machine.

● Inspect machine and replace worn or damaged

parts.

● Replace any safety decals that are missing or not

readable.

1. Spindle assembly

2. Blade

3. Screw, HHCS 1/2 NC x 1-1/2 GR5

4. Nut, flange lock 1/2 NC

Figure 12. Blade Assembly

Blade Sharpening

NOTICE

 When sharpening blades, be sure to balance them. Unbalanced blades will cause excessive

5WPMAN0183 (Rev. 4/25/2008)

Periodically or Before Extended Storage

● Clean large debris such as clumps of dirt, grass,

crop residue, etc. from machine.

● Remove the remainder using a low-pressure water

spray.

1. Be careful when spraying near scratched or torn safety decals or near edges of decals as water spray can peel decal off surface.

2. Be careful when spraying near chipped or scratched paint as water spray can lift paint.

3. If a pressure washer is used, follow the advice of the pressure washer manufacturer.

● Inspect machine and replace worn or damaged

parts.

● Sand down scratches and the edges of areas of

missing paint and coat with spray paint of matching color (purchase from your dealer).

● Replace any safety decals that are missing or not

readable (supplied free by your dealer). See Safety Decals section for location drawing.

Owner Service 23

TROUBLESHOOTING

MOWING CONDITIONS

PROBLEM POSSIBLE CAUSE SOLUTION

Grass cut higher in center of swath than at edge

Grass cut lower in center of swath than at edge

Streaking conditions in swath Conditions too wet for mowing Allow grass to dry before mowing.

Height of mower higher at front than at rear

Loose blade Check blade hardware.

Height of mower lower at front than at rear

Loose blade Check blade hardware.

Blades unable to cut that part of grass pressed down by path of tractor tires

Dull blades Sharpen or replace blades.

Loose blade Check blade hardware.

Adjust mower height and attitude so that mower rear and front are within 1/2 inch (13 mm) of same height. See instructions on page 14.

Slow ground speed of tractor but keep engine running at full PTO rpm. Cutting lower will help.

Adjust tractor tire spacing if possible.

Material discharges from mower unevenly; bunches of material along swath

Material too high and too much material

Grass wet Allow grass to dry before mowing.

Reduce ground speed but maintain 540 rpm at tractor PTO, or make two passes over material. Raise mower for the first pass and lower for the second and cut 90 degrees to first pass.

Raise rear of mower high enough to permit material discharge.

Slow ground speed of tractor but keep engine running at full PTO rpm.

24 Owner Service

5WPMAN0183 (Rev. 4/25/2008)

TROUBLESHOOTING

BELT CONDITIONS

PROBLEM POSSIBLE CAUSE SOLUTION

Belt slippage Mower overloading; material too tall

or heavy

Oil on belt from over lubrication Be careful not to over lubricate.

Belt hung up or rubbing Check belt position in pulleys and

Frayed edges on belt cover Belt misaligned Re-align belt. Be sure belt does not rub

Pulley misaligned Inspect to ensure belt is running in

Reduce tractor ground speed but maintain full PTO rpm.

Cut material twice, one high pass and then mow at desired height. Cut 90 degrees to first pass.

Clean lubricant from belt and pulleys with clean rag. Replace oil-soaked belt.

idlers.

Check belt for free travel in pulleys.

Check under mower and around blade spindle shaft for wire, rags, or other foreign material.

Clean all material from under mower.

any other part while running.

center of backside idler. Shim idler as necessary to align.

Belt rollover Pulley misaligned Re-align.

Damaged belt Replace belt.*

Foreign object in pulley groove Inspect all pulley grooves for rust, paint,

or weld spots and remove.

Worn pulley groove Replace pulley.

Damaged belt Rollover, high shock loads or instal-

lation damaged

Belt breakage High shock loads Avoid abusive mowing.

Belt came off drive Check pulleys for foreign material in

* Check belt for damage by laying it flat on the floor. A belt that does not lie flat (has humps or twists, indicating broken

or stretched cords) must be replaced.

Replace belt.*

Avoid hitting the ground or large obstructions.

grooves.

Avoid hitting solid objects or ground.

5WPMAN0183 (Rev. 4/25/2008)

Owner Service 25

DEALER SERVICE

WARNING

CAUTION

The information in this section is written for dealer service personnel. The repair described here requires special skills and tools. If your shop is not properly equipped or your mechanics are not properly trained in this type of repair, you may be time and money ahead to replace complete assemblies.

 Before working underneath, read manual instructions, securely block up, and check stability. Secure blocking prevents equipment from dropping due to hydraulic leak down, hydraulic system failure, or mechanical component failure.

 Keep all persons away from operator control area while performing adjustments, service, or maintenance.

BLOCKING METHOD

Do not work underneath mower unless it is properly attached to the tractor and blocked securely. When properly attached, the unit will be anchored to minimize front to rear movement.

The only approved blocking device for this mower is a jackstand with a load rating of 1000 pounds (454 kg) or more. One jackstand under each corner of each deck (12 total) must be installed before working underneath this unit.

When blocking, you must consider the overall stability of the unit. Just placing jackstands under the unit will not ensure your safety. The working surface must be level and solid to support the loaded weight of the jackstands. Ensure that jackstands are stable at both top and bottom. Before working under any portion of the mower, test the stability of your blocking with the full weight of the mower units lowered onto the jackstands.

Figure 14. Jackstand Placement

BLADE SPINDLE

Servicing

Spindle repair requires special skills and tools. If your shop is not properly equipped or your mechanics are not trained in this type of repair, you may be time and money ahead to use a new spindle assembly.

For reference, the grease fitting is in the top of the spindle shaft.

Per m atex is recommended as a sealant.

®1

3D Aviation Form-A-Gasket or equivalent

Spindle Removal

1. Remove blade from spindle.

2. Remove belt from pulleys.

3. Remove jam nut (1) and washer (3) from top of

spindle shaft.

4. Disassemble split taper bushing (5) (located on top of pulley) by removing the two bolts (2) and washers (4).

5. Insert bolts (2) into the threaded holes of bushing flange.

6. Tighten bolts alternately to remove split taper bushing.

7. Remove pulley (6).

8. Remove bolts (19) that attach spindle to mower

frame and remove spindle.

9. Remove grease fitting (21) from top of shaft.

1. Permatex is a registered trademark of the Permatex Corporation.

26 Dealer Service

5WPMAN0183 (Rev. 4/25/2008)

1. Nut, Jam 7/8 NF

2. Screw, HHCS 1/4 NC x 1 GR5

3. Washer, Lock .929 x 1.66

4. Washer, Lock 1/4

5. Bushing, H 1 Strt bore w/key

6. Sheave, H 1 BK

19. Screw, HHCS 1/2 NF x 1-1/4 GR5

21. Grease fitting

Figure 15. Sheave and Blade Assembly

Spindle Disassembly

1. Place spindle assembly in press and press shaft

down through housing.

2. Remove seals from housing.

3. Remove bearing cups from housing by placing a

punch in the slots provided and driving them out. Alternate punch positions from side to side. Take care to prevent housing damage.

1. Grease fitting

2. Seal, 1.50 x 2.12 x .31

3. Sleeve, 1.14 x 1.50 x .55

4. Bearing cone

5. Bearing cup

6. Spindle, Housing

7. Shaft, Blade spindle

Figure 16. Spindle and Shaft Assembly

Spindle Assembly

Refer to Figure 16 or Figure 17.

Bearing cones and cups are designed to work together. It is important to position them so bearing cone taper mates with cup taper.

1. Lubricate new cups with a light oil. Place them in spindle housing so they will mate with bearing cones. Cups and cones are a press fit to minimize wear.

2. Seat cups securely with a press or place a large drift in the flat lip and drive them into housing until cup seats against machined shoulder of housing.

3. Place bottom bearing cone into spindle with taper positioned to mate with cup.

4. Identify the open side of the seal containing the spring.

5WPMAN0183 (Rev. 4/25/2008)

Dealer Service 27

NOTICE

 Improper positioning of seals can cause seal damage. An improperly installed seal will leak and could cause bearing failure.

5. Apply a thin coat of Permatex to the area of hous-

ing where seals seat.

6. Install bottom seal with spring up toward center of housing.

7. Place seal squarely on housing and select a piece of pipe or tubing with an OD that will set on outside edge of seal. A tubing with an OD that is too small will bow seal cage.

8. Carefully press seal into housing to prevent distortion to metal seal cage. Bottom seal should seat firmly and squarely against machined shoulder in housing.

9. Make sure seal lip did not roll under. Distortion to seal cage or damage to seal lip will cause seal to leak. Damaged seals must be replaced.

10. Insert shaft and bearing through bottom of housing.

1. Install spindle through bottom of mower and secure

with four mounting bolts.

2. Install pulley and split taper bushing with integral key on spindle shaft. Make sure bushing is in contact with sleeve on spindle shaft.

3. Alternately tighten split taper bushing cap screws to 12 lbs/ft. (16 N-m).

4. Install toothed lock washer and nut on spindle shaft. Tighten nut until snug. Bend up edge of lock washer against a flat side on nut.

11. Fill housing cavity with a medium grade grease.

12. Install top bearing on shaft to mate with top cone.

13. Apply a thin coat of Permatex to shaft area where

sleeve will seat.

14. Install sleeve on shaft and press sleeve and bearing into housing until all free play is removed and there is a very light drag on bearings (similar to adjusting front wheel bearings on an automobile). Check by spinning spindle. It should turn freely.

15. Be careful not to overtighten bearings. Proper bearing adjustment is essential to good bearing life.

16. If you overtighten bearings, hold spindle housing and rap spindle shaft with a lead hammer.

17. Carefully press top seal in with spring up. Top seal should be flush with or to within 1/16" (2 mm) above the housing.

18. Rotate housing on spindle shaft, checking for free movement.

19. Install grease fitting in spindle shaft.

1. Grease fitting

2. Seal, 1.50 x 2.12 x .31

3. Sleeve, 1.14 x 1.50 x .55

4. Bearing cone

Spindle Installation

NOTICE

 Pulley installation sequence is very important for bearing life. Follow the sequence exactly.

28 Dealer Service

5. Bearing cup

6. Spindle, Housing

7. Shaft, Blade spindle

Figure 17. Spindle and Shaft Assembly

5WPMAN0183 (Rev. 4/25/2008)

GEARBOX REPAIR

1. Seal

2. Pipe or tube

3. Seal seat

4. Casting

Pipe or tube must press at outer edge of seal

Incorrect Installation

Read this entire section before starting any repair. Many steps are dependent on each other.

Fill gearbox with SAE 80W or 90W gear lube until it runs out the side level plug.

Repair to this gearbox is limited to replacing bearings, seals, and gaskets. Replacing gears, shafts, and a housing is not cost effective. It is more economical to purchase a complete gearbox if repair to anything other than replacement of bearings, seals or gaskets is required.

Inspect gearbox for leakage and bad bearings.

Leakage is a very serious problem and must be corrected immediately.

NOTE: Proper seal installation is important. An improperly installed seal will leak.

1. Clean area in housing where seal outer diameter (OD) seats. Apply a thin coat of Permatex.

2. Inspect area of shaft where seal seats. Remove any burrs or nicks with an emery cloth.

3. Lubricate gear shaft and seal lips.

4. Place seal squarely on housing, spring-loaded lip

toward housing. Select a piece of pipe or tubing with an OD that will sit on the outside edge of the seal but will clear the housing. Tubing with an OD that is too small will bow seal cage and ruin seal.

5. Carefully press seal into housing, avoiding distortion to the metal seal cage.

Bearing failure is indicated by excessive noise and side-to-side or end play in gear shafts.

Seal Replacement

Recommended sealant for gearbox repair is Permatex Aviation 3D Form-A-Gasket or equivalent.

Leakage can occur at the vertical or horizontal gaskets and shaft seals.

Leakage at the horizontal gasket or seal can be repaired without removing the gearbox from the cutter.

Seal Installation

Vertical Shaft Repair (Figure 20)

1. Disconnect and remove the driveline from the

gearbox.

2. Remove vent plug (24) and siphon gear lube from housing through this opening.

3. Remove gearbox stand from mower deck.

4. Remove gearbox and pulley from gearbox stand.

5. Remove vertical shaft seal (18). Replace with new

seal (see Seal Replacement, page 29).

Vertical seal should be recessed in housing. Horizontal seal should be pressed flush with outside of housing.

NOTE: Distortion to seal cage or damage to seal lip will cause seal to leak.

6. Fill gearbox with SAE 80W or 90W gear lube until it runs out the level plug.

7. Assemble gearbox and pulley to gearbox stand. Attach gearbox stand to mower deck.

Figure 18. Seal Installation

5WPMAN0183 (Rev. 4/25/2008)

Horizontal Leak Repair (Figure 20)

1. Disconnect and remove the driveline from the

gearbox.

2. Remove vent plug (24) and siphon gear lube from housing through this opening.

3. If the leak occurred at either end of horizontal shaft, remove oil cap (20) and/or oil seal (19). Replace with new one (refer to Seal Replacement, page

29).

4. Fill gearbox with SAE 80W or 90W gear lube until it runs out the level plug.

Dealer Service 29

Gearbox Removal from Mower (Figure 19)

1. Disconnect and remove the rear driveline from the

gearbox.

2. Remove vent plug and siphon gear lube from housing through this opening.

3. Remove gearbox stand (20) from mower deck by removing four flanged lock nuts (56).

4. Remove four cap screws (43) and washers (42) and remove shield (22) from gearbox.

5. Remove castle nut and hardware from output shaft of gearbox.

6. Remove sheave (19) from gearbox.

19. Sheave, Offset 12.4 PD

20. Gearbox Stand

22. Shield, Counter Cone

42. Washer, Flat Standard 5/16

43. Screw, HHCS 8mm x 1.25P x 16mm

56. Nut, Flanged Lock 1/2 NC

59. Nut, Flanged Lock 5/8 NC

63. Screw, Flanged Hex Head 5/8 NC x 1-3/4

Figure 19. Gearbox Stand Assembly

Gearbox Disassembly

1. Remove top cover (22) from housing. Turn gearbox

upside down and pour out remaining gear oil from gearbox.

2. Remove oil cap (20) (to be replaced).

3. Remove snap ring (10) and shim (13) from input

shaft (3).

4. Support gearbox in hand press and push on input shaft (3) to remove bearing (7) and spacer (11).

5. Remove gear (1) from inside housing.

6. Remove oil seal (19) from front of housing (to be

replaced).

7. Remove snap ring (10) and shim (13) from front of housing (2).

8. Remove input bearing (7) by using a punch and hammer from outside of housing.

9. Support housing in vise in a horizontal position.

10. The castle nut (15) and cotter pin (25) are already

removed with the drive sheave. Remove snap ring (21), washer (8), and seal (18).

11. Remove cotter pin (9), castle nut (14), and washer (17) from output shaft (4).

12. Remove output shaft (4) by using a punch and hammer and tap on top to drive down.

13. Remove gear (5) and shim (16) from inside housing.

14. Remove bearing (26) by using a punch and hammer from the top, outside the housing.

15. Support housing upside down (top cover surface) and remove bearing (6) by using a punch and hammer from the bottom side of the housing.

16. Inspect gears for broken teeth and wear. Some wear is normal and will show on loaded side. Forged gear surfaces are rough when new. Check that wear pattern is smooth.

17. Inspect vertical and horizontal shafts for grooves, nicks, or bumps in the areas where the seals seat. Resurface any damage with emery cloth.

18. Inspect housing and caps for cracks or other damage.

Gearbox Reassembly (Figure 20)

NOTE: Repair to this gearbox is limited to replacing

bearings, seals, and gaskets. Replacing gears, shafts, and a housing is not cost effective. Purchasing a complete gearbox is more economical.

1. Clean housing, paying specific attention to areas where gaskets will be installed.

2. Wash housing and all components thoroughly. Select a clean area for gearbox assembly. Replace all seals, bearings, and gaskets. All parts must be clean and lightly oiled before reassembling.

3. Insert output bearings (6 & 26) in the housing, using a round tube of the correct diameter and a hand press.

4. Slide output shaft (4) through both bearings (6 &

26) until it rests against bearing (6).

5. Slide shim (16) over output shaft (4).

6. Press gear (5) onto output shaft (4) and secure

with washer (17), castle nut (14), and cotter pin (9).

7. Apply grease to lower seal lips (18) and press seal over output shaft (4), using a tube of the correct

30 Dealer Service

5WPMAN0183 (Rev. 4/25/2008)

diameter. Be sure not to damage the seal lip. Press

1. Crown gear

2. Gearbox housing

3. Input shaft

4. Output shaft

5. Gear pinion

6. Bearing

7. Bearing

8. Protective flat washer

9. Cotter pin

10. Snap ring

11. Snap ring

12. Spacer

13. Shim kit

14. Castle nut

15. Castle nut M24 x 2

16. Shim Kit

17. Flat washer

18. Oil seal (40 x 80 x 12)

19. Oil seal (35 x 72 x 10)

20. Cap

21. Snap ring

22. Top Cover

23. Bolt M8 x 14mm

24. Breather level plug

25. Cotter pin

26. Bearing

27. Ball Bearing

in housing so that seal is recessed.

8. Insert protective washer (8) by hand. Install snap ring (21) and position it together with dual lip seal (18) by pressing it into position. Verify that snap ring is seated correctly.

9. Press bearing (7) into the housing, using a round tube of the correct diameter and a hand press. Secure with shim (13) and snap ring (10).

10. Secure snap ring (11) on input shaft (3) if not already secure.

11. Place gear (1) through top of housing and align gear (1) and gear (5) so that gear teeth are a match.

12. While holding gear (1) in place, slide input shaft (3) through gear (1) and bearing (7). Align splines on shaft (3) and gear (1).

13. Slide spacer (12) over input shaft (3) and press bearing onto input shaft (3), using a round tube of the correct diameter and a hand press.

14. Slide shim (13) over input shaft (3) and secure with snap ring (10).

15. Check input shaft end float by moving the input shaft (3) by hand. If end float is higher than 0.012" (0.305 mm), insert shim between input shaft (3) and rear bearing (7). Repeat until end float is less than 0.012" (0.305 mm). Check rotational torque by hand. The torque should be less than 2.2 lbs.-inch (0.25 N-m).

16. Check that the gear backlash is between 0.006" and 0.016" (0.152 mm - 0.406 mm). You should not have to adjust the backlash.

17. Press in input oil seal (19), using tube of correct diameter. Be careful not to damage seal lip.

18. Press oil cap (20) on to cover the rear of housing, using a tube of the correct diameter.

19. Check gearbox housing for leaks by plugging all holes except one. Apply 4 psi (28 kPa) compressed air and immerse the gearbox in water to verify that there are no leaks.

20. Remove gearbox from water and dry off with compressed air. Add SAE 80W or 90W EP oil until it runs out of side level hole. Tighten all plugs.

5WPMAN0183 (Rev. 4/25/2008)

Figure 20. Gearbox Assembly

Dealer Service 31

Gearbox Installation

1. Shim

2. Idler Arm

3. Idler Pulley

4. Drive Sheave

5. Castle nut & Cotter pin

6. Gearbox Stand

1. Yoke

2. Cup and bearings

3. Snap ring

4. Journal cross

NOTE: Gearbox is heavy: do not attempt to move without mechanical assistance.

1. Set gearbox on gearbox stand and fasten with bolts and nuts. Torque bolts to 175 lbs.-ft. (237 Nm).

2. Attach drive sheave to output shaft. Secure using castle nut and hardware previously removed.

3. Attach Gearbox stand to mower using four flanged lock nuts.

UNIVERSAL JOINT REPAIR

DRIVE SHEAVE INSTALLATION

1. When gear stand is installed on mower, dimension

A (from the top of the mower deck to the center line of the drive pulley) must be 2-7/16" (61.913 mm) [±1/32" (±0.794 mm)]. This is a critical dimension and must be carefully adjusted for proper belt life. Add or subtract shim washers under idler pulley to align with drive pulley.

2. Tighten gear stand hardware.

3. Fill gearbox half full with SAE 80W or 90W gear

lube.

4. Check level after waiting five minutes to permit lube to work through bearings. Add lube, if necessary, until gearbox is half full.

5. Replace driveline shield. Attach driveline to gearbox.

Figure 22. U-Joint Exploded View

U-Joint Disassembly

1. Remove external snap rings from yokes in four

locations as shown in Figure 23.

Figure 23

2. With snap rings removed, support drive in vise,

hold yoke in hand and tap on yoke to drive cup up out of yoke. See Figure 24.

32 Dealer Service

Figure 21. Drive Sheave Installation

Figure 24

3. Clamp cup in vise as shown in Figure 25 and tap

on yoke to completely remove cup from yoke. Repeat Step 2 and Step 3 for opposite cup.

(Rev. 7/9/2008)

5WPMAN0183 (Rev. 4/25/2008)

Figure 25

4. Place universal cross in vise as shown in Figure 26

and tap on yoke to remove cup. Repeat Step 3 for final removal. Drive remaining cup out with a drift and hammer.

U-Joint Assembly

1. Place seals securely on bearing cups. Insert cup

into yoke from outside and press in with hand pressure as far as possible. Insert journal cross into bearing cup with grease fitting away from shaft. Be careful not to disturb needle bearings. Insert another bearing cup directly across from first cup and press in as far as possible with hand pressure.

2. Trap cups in vise and apply pressure. Be sure journal cross is started into bearings and continue pressure with vise, squeezing in as far as possible. Tapping the yoke will help.

3. Seat cups by placing a drift or socket (slightly smaller than the cup) on cup and rap with a hammer. See Figure 27. Install snap ring and repeat on opposite cup

4. Repeat Step 1 and Step 2 to install remaining cups in remaining yoke.

5. Move both yokes in all directions to check for free movement. If movement is restricted, rap on yokes sharply with a hammer to relieve any tension. Repeat until both yokes move in all directions without restriction.

Figure 26

5WPMAN0183 (Rev. 4/25/2008)

Figure 27

Dealer Service 33

ASSEMBLY INSTRUCTIONS

WARNING

CAUTION

WARNING

Remove Hardware

Remove 5/8 Lock nut

DEALER SET-UP INSTRUCTIONS

The mower is shipped mostly assembled but requires dealer set-up. The Frontier dealer should deliver the mower to the owner completely assembled, lubricated, and adjusted for normal conditions.

Recommended torque values for hardware are located on page 57.

Complete the Dealer Check Lists on page 36 when assembly is complete.

slides freely and is seated firmly in tractor PTO spline groove.

1. Remove front drive from between wing frames.

2. Attach to splitter gearbox.

3. Lift rear deck to take tension off rear lift chains.

4. Remove 3/8 bolts, washers, and nuts from both

rear lift chains. See Figure 28. This hardware is for factory shipping purposes only and can be discarded.

5. Gently lower deck until the deck is supported by the lift chains.

 Make sure spring-activated locking pin or collar

Figure 28. Remove Shipping Hardware

6. Remove 5/8 lock nuts and remove shipping strap

from between right and left decks.

Figure 29. Remove Shipping Strap (Right Wing)

Attach Mower to Tractor

1. Park the mower on a hard level surfaced with park-

ing jack securely fastened to trailer.

2. Align tractor with hitch bracket on trailer frame.

3. Set tractor parking brake and block mower trans-

port wheels.

34 Assembly

5WPMAN0183 (Rev. 4/25/2008)

4. Adjust tractor hitch bracket on trailer frame so the

(229 mm)

WARNING

trailer is level when attached to the tractor.

5. Pin the mower to the tractor with a locking type hitch pin.

6. Attach drive shaft to tractor PTO. Make sure lock collar engages securely.

7. Attach end of transport lock release rope to a location on the tractor within easy reach of the operator and away from driveline.

NOTE: When routing the rope, do not route through the hydraulic hose guide and do not allow rope slack to drop between the driveline shields and the gearbox rotating shafts.

8. Attach towing safety chain to tractor drawbar as shown in Figure 30.

Lighting Kit Installation

1. Install electronic module to rear cylinder mount

using #10 screws (8).

2. Route wires as shown. Do not install wire ties at this time. Be sure wire labeled “Left” is routed to left light. Pass wires over axles, under deck support platform, and up the outside rear corner.

3. Install left and right light brackets as shown using 3/8" bolts (11), washers (13), and nuts (12). If more clearance is desired between light brackets and tires, add more 3/8" flat washers. Be sure wires pass through the corners before tightening light brackets.

4. Connect lights to wiring harness.

5. Starting at each light, pull the wire tight and install

wire ties as shown. Any extra slack in the wiring harness should be located at the center of machine near the electronic module. Route main wire along hydraulic hose and secure to hose using wire ties.

Figure 30. Tow Chain Installation

Attach Hydraulic Hoses

Attach the mower hydraulic hose to the tractor port. Hydraulic quick coupler is not supplied.

NOTE: The mower hydraulic system should have been filled at the factory. Always assume it is empty. Fully purge air and fill the hydraulic system by raising and lowering wings several times while hooked to a tractor hydraulic supply. Keep all personnel away while raising and lowering.

1. Left hand light (not shown)

2. Right hand light

3. Left light bracket (not shown)

4. Right light bracket

5. Wire harness

6. 14" Tie strap

7. 7" Tie strap

8. #10 x 1/2" Tapping screw

9. 1/4 NC x 1" Hex head cap screw GR5

10. 1/4 NC Lock nut

11. 3/8 NC x 1" Hex head cap screw flanged GR5

12. 3/8 NC Flange lock nut

13. 3/8" Standard flat washer

Figure 31. Lighting Kit Installation

5WPMAN0183 (Rev. 4/25/2008)

Assembly 35

DEALER CHECK LISTS

PRE-DELIVERY CHECK LIST

(DEALER’S RESPONSIBILITY)

Inspect the equipment thoroughly after assembly to ensure it is set up properly before delivering it to the customer.

The following check lists are a reminder of points to inspect. Check off each item as it is found satisfactory or after proper adjustment is made.

___ Check that all safety decals are installed and in

good condition. Replace if damaged.

___ Check that shields and guards are properly

installed and in good condition. Replace if damaged.

DELIVERY CHECK LIST

(DEALER’S RESPONSIBILITY)

___ Show customer how to make adjustments and

select proper PTO speed.

___ Show customer how to make sure driveline is

properly installed and that spring-activated locking pin or collar slides freely and is seated in groove on tractor PTO shaft.

___ Show customer how to determine the turning

limits of the CV PTO driveline.

___ Show customer the safe, proper procedures to

be used when mounting, dismounting, and storing equipment.

___ Make customer aware of optional equipment

available so that customer can make proper choices as required.

___ Instruct customer how to lubricate and explain

importance of lubrication.

___ Point out the safety decals. Explain their mean-

ing and the need to keep them in place and in good condition. Emphasize the increased safety hazards when instructions are not followed.

___ Check all bolts to be sure they are properly

torqued.

___ Check that all cotter pins and safety pins are

properly installed. Replace if damaged.

___ Check that blades have been properly installed.

___ Check mower attitude and belt alignment

___ Check and grease all lubrication points as iden-

tified in lubrication information on page 20.

___ Check the level of gearbox fluids before deliv-

ery. Service, if required, as specified in the lubrication information on page 20.

___ Present Operator's Manual and request that

customer and all operators read it before operating equipment. Point out the manual safety rules, explain their meanings and emphasize the increased safety hazards that exist when safety rules are not followed.

___ Explain to customer the potential crushing haz-

ards of going underneath raised equipment. Instruct that before going underneath to disconnect the driveline, securely block up all corners with jackstands and to follow all instructions in the “Blocking Method” on page 19 of the operators manual. Explain that blocking up prevents equipment dropping from hydraulic leak down, hydraulic system failures or mechanical component failures.

___ Point out all guards and shields. Explain their

importance and the safety hazards that exist when not kept in place and in good condition.

36 Dealer Check Lists

5WPMAN0183 (Rev. 4/25/2008)

PARTS INDEX

Rear Discharge Grooming Mowers: FM1012, FM1015, FM1017

COMMON PARTS

MAIN FRAME ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 - 39

TRAILER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 - 41

WING FRAME ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

CASTER WHEELS, ROTATING & NON-ROTATING . . . . . . . . . . . . . . . . . . . . . . . . . . 45

HEIGHT ADJUSTMENT POST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

HUB & AXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

WING GEARBOX ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

BLADE AND SPINDLE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

DRIVES

REAR & WING DRIVE (COMER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 - 51

REAR & WING DRIVE (WALTERSCHEID). . . . . . . . . . . . . . . . . . . . . . . . 52 - 53

CV DRIVE ASSEMBLY (WALTERSCHEID) . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

CV DRIVE ASSEMBLY (WEASLER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

JACKSHAFT DRIVE (WALTERSCHEID) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

JACKSHAFT DRIVE (COMER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

LIGHTING KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

REAR CHAIN SHIELDING ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

HYDRAULIC CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

HYDRAULIC HOSE ASSEMBLY PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

FM1012

CENTER DECK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

WING DECK ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

CENTER DECK FRONT ROLLER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

WING DECK ANTI-SCALP ROLLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

FM1015

CENTER & WING DECK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

FRONT ROLLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

FM1017

CENTER & WING DECK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

FRONT ROLLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

5WPMAN0183 (Rev. 7/9/2008)

Parts 37

FM1012, FM1015 & FM1017 MAIN FRAME ASSEMBLY

Refer to page 59 for Hydraulic Hose Parts list.

33 - COMPLETE DECAL SET

38 Parts

5WPMAN0183 (Rev. 7/9/2008)

FM1012, FM1015 & FM1017 MAIN FRAME ASSEMBLY

REF PART QTY DESCRIPTION

1 – – – – – 1 Trailer assembly (See page 40)

2 – – – – – 1 Right wing assembly (See page 42)

3 – – – – – 1 Left wing assembly (See page 42)

4 – – – – – 1 Right deck assembly FM1012

(See page 44) -or-

4 – – – – – 1 Right deck assembly FM1015,

FM1017 (See page 43)

5 – – – – – 1 Left deck assembly FM1012

(See page 44) -or-

5 – – – – – 1 Left deck assembly FM1015,

FM1017 (See page 43)

6 – – – – – 1 Center deck assembly FM1012

(See page 43) -or-

6 – – – – – 1 Center deck assembly FM1015,

FM1017 (See page 43)

7 5WP1023226 2 Drive, Cmpl 40, 21.3 x 32.3 FM1012

(See page 50) -or-

7 5WP1023227 2 Drive, Cmpl 40, 25.6 x 40.9 FM1015

(See page 50) -or-

7 5WP1023228 2 Drive, Cmpl 40, 28.3 x 46.4 FM1017

(See page 50)

8 – – – – – 6 Rotating caster (See page 45)

9 – – – – – 2 Non-rotating caster (See page 45)

10 – – – – – 4 Height adjustment post

(See page 46)

11 5WP58956 6 Caster arm asy w/bearing

5WP31780 12 Bushing, Oilite 1.25 x 1.50 x 1.50

* 6 Grease fitting, 1/4 - 28 Tapered

thread

12 5WP58968 2 Caster arm asy, Non-rotating

13 5WP40947 1 Caster arm asy, FM1012 -or-

13 5WP40944 1 Caster arm asy, Right, FM1015 -or-

13 5WP40942 1 Caster arm asy, Right, FM1017

14 5WP40947 1 Caster arm asy, FM1012

14 5WP40945 1 Caster arm asy, Left, FM1015 -or-

14 5WP40943 1 Caster arm asy, Left, FM1017

REF PART QTY DESCRIPTION

15 5WP58993 1 Caster arm asy, Right, FM1012 -or-

15 5WP58974 1 Caster arm asy, Right, FM1015,

FM1017

16 5WP58994 1 Caster arm asy, Left, FM1012

-or-

16 5WP58978 1 Caster arm asy, Left, FM1015,

FM1017

17 5WP38001 4 Pin, Wing hinge

18 5WP1791 6 Sleeve, HT .63 x 1.00 x .56

19 5WP38296 1 Rope, .25 x 95.0

20 5WP38295 3 Rope clamp

21 5WP38257 3 S-Hook, .25 x 2.25

22 5WP38294 1 Rope, .25 x 46.0

32 5WP1631 2 Pin, Headless 1.00 x 3.63

33 5WP40908 1 Complete decal set

50 * Screw, HHCS 5/8 NC x 2-1/2 GR5

51 * Screw, HHCS 1/2 NC x 1-3/4 GR5

52 * Screw, HHCS 1/2 NC x 3-1/4 GR5

53 5WP11900 Nut, Flanged lock 1/2 NC

54 5WP19025 Nut, Flanged lock 5/8 NC

57 * Washer, Flat 1" standard

60 * Pin, Safety 3/16

61 5WP62789 Screw, HHCS 1/2 NC x 2 FT GR5

62 5WP1003828 1 Manual tube assembly

63 5WP37420 2 Clamp, Hose 3.06 - 4.00

64 5WP1024650 1 Clutch shield kit

(includes items 65 through 68)

65 5WP1002048 3 Clutch shield

66 * Screw, HHCS M8 x 1.25P x 20 mm

67 * Washer, 5/16 lock

68 * Washer, 5/16 flat

* Standard Hardware, Obtain Locally

5WPMAN0183 (Rev. 7/9/2008)

Parts 39

FM1012, FM1015 & FM1017 TRAILER ASSEMBLY

40 Parts

5WPMAN0183 (Rev. 7/9/2008)

FM1012, FM1015 & FM1017 TRAILER ASSEMBLY

REF PART QTY DESCRIPTION

1 – – – – – 1 Trailer frame

2 5WP1009501 1 Hitch, Category 1 (FM1012)

-or-

2 5WP1009502 1 Hitch, Category 2 (FM1015 &

FM1017

3 5WP1006689 2 Link, Hitch adjustment

4 5WP44639 2 Sleeve, .76 x 1.00 x 4.12

5 5WP40804 1 Lock, Rear deck

6 5WP40880 1 Lever, Rear deck lock release

7 5WP40879 2 Lock, Wing deck

8 5WP40938 1 Lever, Wing deck lock release

9 5WP19201 1 H-Frame, CV drive

10 5WP44641 2 Sleeve, HT .78 x 1.00 x .69

11 5WP31464 2 Sleeve, .38 x .63 x .34

12 5WP23790 1 Jack, Parking

13 5WP21957 3 Spring, Comp .58 x .08 x 2.4 40

14 5WP484 2 Sleeve, HT .63 x 1.00 x .44

15 5WP3502 1 Bearing, Ball

16 – – – – – 1 Housing, Bearing (Not Serviced)

17 5WP1251 1 Bearing holder w/bearing

(Includes ref. 15, 16, 77, 78)

18 5WP44637 1 Shield, Front drive

19 – – – – – 1 Drive, Yoke & shaft Non-tel 2400 x

26.4 (see page 56)

20 5WP19407 1 Chain, Safety 6400 lb

21 5WP62440 2 Bumper pad

22 5WP38264 1 Pin, Lynch chain & cotter asy

23 5WP40933 1 Gearbox, 4-Way splitter

– – 5WP58815 2 Seal, Thru shaft 4-way gearbox

– – 5WP58816 2 Seal, Wing shaft 4-way gearbox

– – 5WP58817 6 Bearing, Cup & cone 4-way box

– – 5WP1009083 1 Plug, Vent w/Washer

24 5WP62626 4 Sleeve, .76 x 1.00 x 1.00

25 5WP44636 1 Shield, Gearbox 4-way

26 5WP1001020 2 Asy, Whl hub & axle (See page 46)

27 5WP38298G 2 Wheel & tire, 20.5 x 8.00 x 10 Gray

– – 5WP38475G Wheel rim, 5-Bolt 8.00 x 10 gray

28 5WP44625 1 Drive, Cmpl CV 2480, 35.8 x 48.4

(See page 54) -or-

28 5WP1021100 1 Drive, Cmpl CV 35R 35.0 x 47.6 (See

page 55)

29 5WP1023225 1 Drive, Cmpl 40, 26.9 x 43.5

(See page 50)

30 5WP58984 2 Pin, Rear wing hinge

31 5WP40805 1 Frame, Rear wWing

32 5WP44638 2 Chain, 16 Link 1/4-proof

REF PART QTY DESCRIPTION

33 5WP3443 1 Hydraulic Hose holder

34 5WP62484 1 Socket, SMV emblem

50 * Screw, HHCS 5/8 NC x 7-1/2 GR5

51 * Screw, HHCS 5/8 NC x 7 GR5

52 * Screw, HHCS 3/4 NC x 2-1/4 GR5

53 * Screw, HHCS 5/8 NC x 2 GR5

54 * Screw, HHCS 5/8 NC x 5 GR5

55 * Screw, HHCS 1/2 NC x 5-1/4 GR5

56 * Screw, HHCS 3/8 NC x 1 GR5

57 * Screw, HHCS 3/8 NC x 1-1/4 GR5

58 * Screw, HHCS 3/8 NC x 3-1/2 GR5

59 * Screw, HHCS 1/2 NC x 1-1/4 GR5

60 * Screw, HHCS 1/2 NC x 3 GR5

61 * Screw, HHCS 1/2 NC x 2 GR5

62 * Nut, Lock 5/8 NC

63 * Nut, Lock 3/4 NC

64 5WP11900 Nut, Flanged lock 1/2 NC

66 5WP14350 Nut, Flanged lock 3/8 NC

67 * Nut, Lock 3/8 NC

68 5WP28873 Washer, Flat .75 x 1.50 x .25

69 5WP44640 Washer, Cup 1.04 x 2.25 x .17

70 5WP34467 Washer, Flat .63 x 2.00 x .38

71 5WP10635 Washer, Cup .63 x 1.75 x 14 Ga

72 * Washer, Flat 3/8 standard

73 * Washer, Flat 1/2 standard

74 5WP57811 8 Washer, Flat 1/2 extra thick hrd

75 * Washer, Lock 3/8

76 5WP1258 Bolt, Wheel 1/2 NF x 1-1/8

77 * Grease fitting, 1/4-28 90° Tapered

thread

78 5WP12128 Ring, Retaining .06 x 72 MM

79 * Pin, Spirol 3/8 x 1-1/2

80 * Grease fitting,1/4-28 Taper thread

81 * Pin, Safety 3/16

82 5WP62789 Screw, HHCS 1/2 NC x 2 FT GR5

83 * Screw, HHCS1/2 NC x 1-3/4 GR5

84 5WP14139 Nut, Flanged lock 5/16 NC

85 * Bolt, Carriage 5/16 NC x 1/2

86 5WP1004251 1 SMV Bracket

87 5WP24611 1 Sign (SMV) Slow moving vehicle

* Standard Hardware, Obtain Locally

5WPMAN0183 (Rev. 7/9/2008)

Parts 41

FM1012, FM1015 & FM1017 WING FRAME

REF PART QTY DESCRIPTION

1 5WP1000610 1 Frame, Right wing (FM1012)

-or-

1 5WP1006340 1 Frame, Right wing (FM1015)

-or-

1 5WP1000614 1 Frame, Right wing (FM1017)

2 5WP1000611 1 Frame, Left wing (FM1012)

-or-

2 5WP1006341 1 Frame, Left wing (FM1015)

-or-

2 5WP1000615 1 Frame, Left wing (FM1017)

3 5WP40907 2 Link, Wing deck lift (FM1012)

-or-

3 5WP40881 2 Link, Wing deck lift (FM1015,

FM1017)

REF PART QTY DESCRIPTION

4 5WP40895 2 Trunnion, Front deck (FM1012,

FM1015)

-or-

4 5WP40887 2 Trunnion, Front deck (FM1017)

5 5WP40896 2 Trunnion, Rear deck (FM1012,

FM1015)

-or-

5 5WP40888 2 Trunnion, Rear deck (FM1017)

6 5WP58980 2 Pin, Wing deck link

7 5WP58982 4 Pin, Deck link trunnion

8 * 6 Pin, Safety 3/16

9 5WP71444 2 Rubber bumper

10 5WP14139 2 Nut, Flanged lock 5/16 NC

11 5WP38264 2 Pin, Lynch chain & cotter asy

* Standard Hardware, Obtain Locally

42 Parts

5WPMAN0183 (Rev. 7/9/2008)

FM1012 CENTER DECK

FM1015 & FM1017 CENTER & WING DECK ASSEMBLY

REF PART QTY DESCRIPTION

1 5WP1000618 1 Deck, Weld asy 6 Foot (FM1015

center, FM1017 all) -or-

1 5WP1000617 1 Deck, Weld assembly 5 Foot

(FM1012 center, FM1015 wings)

2 5WP18879 1 V-Belt W112 (FM1015 center,

FM1017 all) -or-

2 5WP1001244 1 V-Belt W99 (FM1012 center,

FM1015 wings)

3 3 CW Spindle asy (See page 48)

4 5WP44635 2 Shield, Belt (FM1015 center,

FM1017 all) -or-

4 5WP44634 2 Shield, Belt (FM1012 center,

FM1015 wings)

5 5WP53534 1 Gearbox stand

6 5WP1002499 1 Gearbox, 1:1.92 (See page 47)

7 5WP65197 1 Sheave, Offset 12.4 P.D.

8 5WP29792 1 Key, HT 1/4 x 1/4 x 1-1/4

9 5WP53567 1 Guide, Belt 8 Ga formed

10 5WP64555 1 Idler, Flat 5.5 dia.

REF PART QTY DESCRIPTION

11 5WP58989 1 Idler arm assembly

12 5WP53595 1 Idler, Flat 5.0 Dia.

13 5WP67131 1 Spring, Ext .177 x 1.22 x 9.88

14 5WP35193 2 Bearing, Ball

50 5WP35141 Ring, Retaining int .062 x 1.56

51 5WP302178 Nut, Castle 5/8 NF

52 * Pin, Cotter 3/16 x 1-1/2

53 * Screw, HHCS 1/2 NC x 2-1/2 GR5

54 * Washer, Flat 1/2 standard

57 5WP11900 Nut, Flanged lock 1/2 NC

58 5WP19024 Screw, Flngd hex head 5/8 NC x 1-3/4

59 5WP1517 Washer, Flat .63 x 1.38 x 7 Ga

60 5WP19025 Nut, Flanged lock 5/8 NC

61 5WP4358 Screw, HHCS 1/2 NF x 1-1/4 GR5

62 5WP62153 Bolt, Flngd whiz 3/8 NC x 1

* Standard Hardware, Obtain Locally

5WPMAN0183 (Rev. 7/9/2008)

Parts 43

FM1012 WING DECK ASSEMBLY

REF PART QTY DESCRIPTION

1 5WP1000609 1 Deck, Weld asy 4 foot left -or-

1 5WP1000608 1 Deck, Weld asy 4 foot right (NS)

2 5WP40930 1 V-Belt, W80

3 3 CW Spindle asly (See page 48)

4 5WP58953 1 Shield, Belt left -or-

4 5WP58954 1 Shield, Belt right (NS)

5 5WP58295 1 Gearbox stand, Left -or-

5 5WP58294 1 Gearbox stand, Right (NS)

6 5WP1002499 1 Gearbox, 1:1.92 (See page 47)

7 5WP65197 1 Sheave, Offset 12.4 PD

8 5WP29792 1 Key, HT 1/4 x 1/4 x 1-1/4

9 5WP53567 1 Guide, Belt 8 Ga formed

10 5WP58952 2 Shield, Belt inner

11 5WP57939 1 Idler arm assembly

12 5WP57972 1 Idler, Flat 6.0 Dia

44 Parts

REF PART QTY DESCRIPTION

13 5WP67131 1 Spring, Ext .177 x 1.22 x 9.88

14 5WP35193 2 Bearing, Ball

50 5WP35141 Ring, Retaining int .062 x 1.56

51 5WP302178 Nut, Castle 5/8 NF

52 * Pin, Cotter 3/16 x 1-1/2

53 * Screw, HHCS 1/2 NC x 2-1/2 GR5

54 * Washer, Flat 1/2 standard

56 5WP52877 Sleeve, .51 x .63 x .64

57 5WP11900 Nut, Flanged lock 1/2 NC

58 5WP19024 Screw, Flngd hex head 5/8 NC x 1-3/4

60 5WP19025 Nut, Flanged lock 5/8 NC

61 5WP4358 Screw, HHCS 1/2 NF x 1-1/4 GR5

62 5WP62153 Bolt, Flngd whiz 3/8 NC x 1

NS Not Shown

* Standard Hardware, Obtain Locally

5WPMAN0183 (Rev. 7/9/2008)

NON-ROTATING

ROTATING

REF PART QTY DESCRIPTION

1 5WP38267G 1 Wheel & hub 15.00 x 6.00 x 6 Gray

5WP38476G Wheel rim & hub, 6.00 x 6 w/Cups

gray

2 * 1 Grease fitting, 1/8 Pipe thread

3 5WP2306 2 Bearing, Cup

4 5WP2304 2 Bearing, Cone

5 5WP5624 2 Seal, 1.13 x 1.78 x .47

6 5WP14318 2 Sleeve, HT .75 x 1.13 x 1.25

7 5WP38111 1 Sleeve, HT .53 x .75 x 6.75

8 5WP58958 1 Caster yoke & shaft asy, Rotating

-or- -or-

8 5WP58961 1 Caster yoke & shaft asy,

Non-rotating

9 5WP35124 1 Pin, Klik 7/16 x 2

10 5WP38107 1 Screw, HHCS 1/2 NC x 9 GR5

11 * 1 Nut, Hex 1/2 NC

12 5WP11900 1 Nut, Flanged lock 1/2 NC

REF PART QTY DESCRIPTION

Non-Rotating:

13A 5WP58987 2 Sleeve, 1.50 x 1.90 x 1.00

14A 5WP58986 2 Sleeve, 1.50 x 1.90 x .75

15A 5WP58985 1 Sleeve, 1.50 x 1.90 x .50

16A 5WP6237 1 Washer, Flat 1.50 x 2.25 x 13 Ga

Rotating:

13B 5WP52855 2 Sleeve, 1.25 x 1.90 x 1.00

14B 5WP52854 2 Sleeve, 1.25 x 1.90 x .75

15B 5WP52853 1 Sleeve, 1.25 x 1.90 x .50

16B 5WP7163 1 Washer, Flat 1.25 standard

* Standard Hardware, Obtain Locally

CASTER WHEELS

5WPMAN0183 (Rev. 7/9/2008)

Parts 45

HEIGHT ADJUSTMENT POST

REF PART QTY DESCRIPTION

1 5WP58998 1 Sleeve, Drld .81 x 1.25 x 8.00

2 5WP58999 1 Wear pad

3 * 1 Pin, Spirol .25 x 1.00

4 5WP35124 1 Pin, Klik 7/16 x 2

5 5WP52855 2 Sleeve, 1.28 x 1.66 x 1.00

6 5WP52854 2 Sleeve, 1.28 x 1.66 x .75

7 5WP52853 1 Sleeve, 1.28 x 1.66 x .50

8 * 1 Washer, Flat 1-1/4 standard

* Standard Hardware, Obtain Locally

HUB & AXLE ASSEMBLY

REF PART QTY DESCRIPTION

1 5WP1001020 1 Wheel hub & axle assembly

2 5WP1001021 1 Axle shaft

3 5WP314 1 Seal, 1.50 x 2.44 x .31

4 5WP2303 2 Bearing, Cone

5 5WP38437 1 Wheel hub, Housing w/cups

6 5WP2305 2 Bearing, Cup

7 * 2 Washer, Flat 3/4 standard

8 5WP5849 1 Nut, Slotted hex 3/4 NF

9 * 1 Pin, Cotter 3/16 x 1

10 5WP14133 1 Hub cap, Assembly w/fitting

11 5WP531 1 Hub cap

12 * 1 Grease fitting, 1/4 Tapered thread

* Standard Hardware, Obtain Locally

46 Parts

5WPMAN0183 (Rev. 7/9/2008)

WING GEARBOX ASSEMBLY

REF PART QTY DESCRIPTION

A 5WP1002499 1 Gearbox asy, complete

1 5WP57458 1 Gear crown Z25 M5.3

2 NS 1 Gearbox housing

3 5WP1005320 1 Shaft, Input 1-3/8 -6

4 5WP1005321 1 Shaft, Output 1-1/4

5 5WP57491 1 Pinion gear Z13 M5.3

6 5WP57476 1 Bearing

7 5WP57462 1 Bearing

8 5WP20888 1 Washer, Protective flat

9 * 1 Pin, Cotter 4 x 50

10 5WP57466 2 Snap ring

11 5WP20895 1 Snap ring

12 5WP57373 1 Spacer 35.5 x 48 x 2.5

13 5WP57328 2 Kit, Shim 60.3 x 71.6

14 5WP57468 1 Nut, Castle

15 5WP51946 1 Nut, Castle M24 x 2

16 5WP57328 1 Kit, Shim 30.3 x 44

17 5WP57473 1 Washer, Flat

18 5WP20900 1 Seal, Oil 40 x 80 x 12

19 5WP57463 1 Seal, Oil 35 x 72 x 10

20 5WP57374 1 Cap

21 5WP20897 1 Snap ring

REF PART QTY DESCRIPTION

22 5WP1005322 1 Cover, Top

23 * 6 Bolt 8 mm x 14 mm

24 5WP57076 1 Plug, Breather level

25 * 1 Pin, Cotter 5 x 50

26 5WP57478 1 Bearing

27 5WP20890 1 Bearing, Ball

NS Not Serviced

* Standard Hardware - Obtain Locally

5WPMAN0183 (Rev. 7/9/2008)

Parts 47

BLADE & SPINDLE ASSEMBLY

REF PART QTY DESCRIPTION

1 5WP37009 Nut, Jam 7/8 NF

2 * Screw HHCS 1/4 NC x 1 GR5

3 5WP52898 Washer, Lock .929 x 1.66

4 * Washer, Lock 1/4

5 5WP34440 Bushing, H 1 Strt bore w/key

6 5WP12622 Sheave, H 1 BK 5.0 PD (FM1012 wing

deck & FM1015 rear deck & FM1017 wWing & rear deck) -or-

6 5WP66694 Sheave, H 1 BK 4.17 PD (FM1012)

rear deck, FM1015 wing deck)

7 5WP52881 Spindle assembly complete

8 5WP52949 Seal 1.50 x 2.12 x .31

9 5WP52872 Sleeve 1.14 x 1.50 x .55

10 5WP29899 Bearing, Cone

11 5WP52882 Spindle, Housing with cups

12 5WP29898 Bearing, Cup

14 5WP52852 Shaft, Blade spindle

19 5WP4358 Screw, HHCS 1/2 NF x 1-1/4 GR5

21 * Grease fitting, 1/4-28 Tapered thread

22 5WP3379 Screw, HHCS 1/2 NC x 1-1/2 GR5

23 5WP11900 Nut, Flanged lock 1/2 NC

* Standard Hardware - Obtain Locally

BLADE KITS

5WP7144BDKT Blade kit, High Lift FM1012 complete 5WP9180BDKT Blade kit, High Lift FM1015 complete 5WP9204BDKT Blade kit, High Lift FM1017 complete

5WP7144BDKT2 Blade kit, Low lift FM1012 complete 5WP9180BDKT2 Blade kit, Low lift FM1015 complete 5WP9204BDKT2 Blade kit, Low lift FM1017 complete

5WP1008199K2 Blade kit, High lift, 48" Decks

5WP1001511K2 Blade kit, Low lift, 48" Decks

5WP1001513KT Blade kit, High lift, 60" Decks 5WP1001510KT Blade kit, Low lift, 60" Decks

5WP1008199KT Blade kit, High lift 72" Decks

5WP1001511KT Blade kit, Low lift 72" Decks

48 Parts

5WPMAN0183 (Rev. 7/9/2008)

FM1012 CENTER DECK AND

REF PART QTY DESCRIPTION

5WP1006417 1 Front roller kit, complete

2 * 1 1/2 NC Flanged lock nut

3 5WP38107 1 1/2 NC x 9 Cap screw GR5

4 * 2 1/2 Flat washer SAE

5 * 4 3/8 NC x 1 Carriage bolt

6 5WP70069 4 3/8 NC Flanged whiz nut

7 5WP1006420 1 Spacer, .75 x 6.62

8 5WP1006419 1 Bracket, Front roller

9 5WP1006418 1 Roller, 4 x 7.37

10 5WP35193 2 Bearing

* Standard Hardware, Obtain Locally

REF PART QTY DESCRIPTION

5WP1006421 Roller kit, Front complete

2 * 1 1/2 NC Flanged lock nut

3 5WP38107 1 1/2 NC x 9 Cap screw GR5

4 * 2 1/2 Flat washer SAE

5 * 4 3/8 NC x 1 Carriage bolt

6 5WP70069 4 3/8 NC Flanged whiz nut

7 5WP1006420 1 Spacer, .75 x 6.62

8 5WP1006422 1 Bracket, Front roller right

9 5WP1006423 1 Bracket, Front roller left

10 5WP1006418 1 Roller, 4 x 7.37

11 5WP35193 2 Bearing

* Standard Hardware, Obtain Locally

FM1015 & FM1017 FRONT ROLLER ASSEMBLY (OPTIONAL)

FM1012 WING DECK ANTI-SCALP ROLLER KIT

5WPMAN0183 (Rev. 7/9/2008)

Parts 49

FM1012, FM1015 & FM1017 REAR & WING DECK DRIVES (COMER)

FM1012 Wing Drive FM1015 Wing Drive

REF PART QTY DESCRIPTION

A 5WP1023226 Drive, Cmpl 40, 21.3 x 32.3

1 5WP1026999 1 Complete collar yoke C12

2 5WP36990 1 U-Joint Repair Kit 50

3 5WP38478 1 U-Joint Repair Kit 2300

4 5WP1001300 1 Complete collar yoke C12 1-3/8 - 6

5 5WP1019442 1 Outer cone fix ring

6 5WP30922 6 Protection fixing screw

7 5WP1019444 1 Inner cone fix ring

8 5WP1026987 1 Complete shield

9 NSS 1 Outer half shaft

10 NSS 1 Inner half shaft

11 5WP1001340 2 Lock collar repair kit

12 5WP1001306 1 Inner tube yoke

13 5WP1001305 1 Flexible pin

14 5WP1026985 1 Outer yoke & tube

15 5WP1026986 1 Inner yoke & tube

REF PART QTY DESCRIPTION

A 5WP1023227 Drive, Cmpl 40, 25.6 x 40.9

1 5WP1026999 1 Complete collar yoke C12

2 5WP36990 1 U-Joint Repair Kit 50

3 5WP38478 1 U-Joint Repair Kit 2300

4 5WP1001300 1 Complete collar yoke C12 1-3/8 - 6

5 5WP1019442 1 Outer cone fix ring

6 5WP30922 6 Protection fixing screw

7 5WP1019444 1 Inner cone fix ring

8 5WP1026990 1 Complete shield

9 NSS 1 Outer half shaft

10 NSS 1 Inner half shaft

11 5WP1001340 2 Lock collar repair kit

12 5WP1001306 1 Inner tube yoke

13 5WP1001305 1 Flexible pin

14 5WP1026988 1 Outer yoke & tube

15 5WP1026989 1 Inner yoke & tube

FM1017 Wing Drive All Rear Wing Drives

REF PART QTY DESCRIPTION

A 5WP1023228 Drive, Cmpl 40, 28.3 x 46.4

1 5WP1026999 1 Complete collar yoke C12

2 5WP36990 1 U-Joint Repair Kit 50

3 5WP38478 1 U-Joint Repair Kit 2300

4 5WP1001300 1 Complete collar yoke C12 1-3/8 - 6

5 5WP1019442 1 Outer cone fix ring

6 5WP30922 6 Protection fixing screw

7 5WP1019444 1 Inner cone fix ring

8 5WP1026998 1 Complete shield

9 NSS 1 Outer half shaft

10 NSS 1 Inner half shaft

11 5WP1001340 2 Lock collar repair kit

12 5WP1001306 1 Inner tube yoke

13 5WP1001305 1 Flexible pin

14 5WP1026991 1 Outer yoke & tube

15 5WP1026992 1 Inner yoke & tube

REF PART QTY DESCRIPTION

A 5WP1023225 Drive, Cmpl 40, 26.9 x 43.5

1 5WP1001300 1 Complete collar yoke C12 1-3/8 - 6

2 5WP38478 1 U-Joint Repair Kit 2300

3 5WP38478 1 U-Joint Repair Kit 2300

4 5WP1001300 1 Complete collar yoke C12 1-3/8 - 6

5 5WP1019442 1 Outer cone fix ring

6 5WP30922 6 Protection fixing screw

7 5WP1019444 1 Inner cone fix ring

8 5WP1026984 1 Complete shield

9 5WP1026978 1 Outer half shaft

(includes outer half of item 8)

10 5WP1026979 1 Inner half shaft

(includes inner half of item 8)

11 5WP1001340 2 Lock collar repair kit

12 5WP1001306 1 Inner tube yoke

13 5WP1001305 1 Flexible pin

14 NSS 1 Outer yoke & tube

15 NSS 1 Inner yoke & tube

50 Parts

NSS Not Serviced Separately

5WPMAN0183 (Rev. 7/9/2008)

FM1012, FM1015 & FM1017 REAR & WING DECK DRIVES (COMER)

Check profile and order from correct parts list.

5WPMAN0183 (Rev. 7/9/2008)

Parts 51

FM1012, FM1015 & FM1017 REAR & WING DECK DRIVES (WALTERSCHEID)

FM1012 Wing Drive FM1015 Wing Drive

REF PART QTY DESCRIPTION

A 5WP44628 - Drive, Compl 2300, 21.7 x 32.6

1 5WP44681 1 Yoke, 1-3/8 - 6 Spline QD

2 5WP38352 1 U-Joint Repair Kit 2400

3 5WP38394 1 Slide Lock Collar Repair Kit

4 5WP40778 2 Screw, Guard Retainer

5 5WP40766 2 Bearing Ring, Guard

6 5WP40777 2 Chain, Guard Anti-Rotation

7 5WP38498 1 Yoke, 1-3/8 - 6 Spline QD

8 5WP38478 1 U-Joint Repair Kit 2300

9 5WP40589 1 Slide Lock Collar Repair Kit

10 5WP44682 1 Yoke & Shaft, Male

11 5WP44693 1 Guard, Outer Half

12 5WP44665 1 Drive, Male Half Complete

13 5WP44683 1 Yoke & Shaft, Female

14 5WP44694 1 Guard, Inner Half

15 5WP44666 1 Drive, Female Half Complete

REF PART QTY DESCRIPTION

A 5WP44629 - Drive, Compl 2300, 26.0 x 41.5

1 5WP44681 1 Yoke, 1-3/8 - 6 Spline QD

2 5WP38352 1 U-Joint Repair Kit 2400

3 5WP38394 1 Slide Lock Collar Repair Kit

4 5WP40778 2 Screw, Guard Retainer

5 5WP40766 2 Bearing Ring, Guard

6 5WP40777 2 Chain, Guard Anti-Rotation

7 5WP38498 1 Yoke, 1-3/8 - 6 Spline QD

8 5WP38478 1 U-Joint Repair Kit 2300

9 5WP40589 1 Slide Lock Collar Repair Kit

10 5WP44684 1 Yoke & Shaft, Male

11 5WP44695 1 Guard, Outer Half

12 5WP44667 1 Drive, Male Half Complete

13 5WP44685 1 Yoke & Shaft, Female

14 5WP44696 1 Guard, Inner Half

15 5WP44668 1 Drive, Female Half Complete

FM1017 Wing Drive All Rear Wing Drives

REF PART QTY DESCRIPTION

A 5WP44630 - Drive, Compl 2300, 28.7 x 47.0

1 5WP44681 1 Yoke, 1-3/8 - 6 Spline QD

2 5WP38352 1 U-Joint Repair Kit 2400

3 5WP38394 1 Slide Lock Collar Repair Kit

4 5WP40778 2 Screw, Guard Retainer

5 5WP40766 2 Bearing Ring, Guard

6 5WP40777 2 Chain, Guard Anti-Rotation

7 5WP38498 1 Yoke, 1-3/8 - 6 Spline QD

8 5WP38478 1 U-Joint Repair Kit 2300

9 5WP40589 1 Slide Lock Collar Repair Kit

10 5WP44686 1 Yoke & Shaft, Male

11 5WP44697 1 Guard, Outer Half

12 5WP44669 1 Drive, Male Half Complete

13 5WP44687 1 Yoke & Shaft, Female

14 5WP44698 1 Guard, Inner Half

15 5WP44670 1 Drive, Female Half Complete

REF PART QTY DESCRIPTION

A 5WP44627 - Drive, Compl 2300, 26.8 x 43.3

1 5WP38498 1 Yoke, 1-3/8 - 6 Spline QD

2 5WP38478 1 U-Joint Repair Kit 2300

3 5WP40589 1 Slide Lock Collar Repair Kit

4 5WP40778 2 Screw, Guard Retainer

5 5WP40766 2 Bearing Ring, Guard

6 5WP40777 2 Chain, Guard Anti-Rotation

7 5WP38498 1 Yoke, 1-3/8 - 6 Spline QD

8 5WP38478 1 U-Joint Repair Kit 2300

9 5WP40589 1 Slide Lock Collar Repair Kit

10 5WP44679 1 Yoke & Shaft, Male

11 5WP44691 1 Guard, Outer Half

12 5WP44663 1 Drive, Male Half Complete

13 5WP44680 1 Yoke & Shaft, Female

14 5WP44692 1 Guard, Inner Half

15 5WP44664 1 Drive, Female Half Complete

52 Parts

5WPMAN0183 (Rev. 7/9/2008)

FM1012, FM1015 & FM1017 REAR & WING DECK DRIVES (WALTERSCHEID)

LIGHTING KIT

REF PART QTY DESCRIPTION

A 5WP1004486 - Lighting kit

1 5WP90401149 1 Lighting 4 pin LH

2 5WP90401150 1 Lighting 4 pin RH

3 5WP1004481 1 Light bracket LH

4 5WP1004480 1 Light bracket RH

5 5WP1004479 1 Wire harness

6 * - 356 mm (14 in) Tie strap

7 * - 178 mm (7 in) Tie strap

8 * - #10 x 1/2 Tapping screw

9 * - 1/4 NC x 1 Hex head cap screw GR5

10 * - 1/4 NC Lock nut

11 5WP62153 - 3/8 NC x 1 Hex hd cap screw flanged GR5

12 5WP14350 - 3/8 NC Flange lock nut

13 * - 3/8 Std Flat washer

* Obtain Locally

Check profile and order from correct parts list.

5WPMAN0183 (Rev. 7/9/2008)

Parts 53

CV DRIVE ASSEMBLY

PAGE 54

PAG E 5 5

(WALTERSCHEID PROFILE)

REF PART QTY DESCRIPTION

5WP44625 Drive, Walterscheid complete CV

2480, 35.8 x 48.4

1 5WP44671 1 Yoke, 1-3/8 - 6 Spline QD

2 5WP44674 1 U-Joint repair kit 2480

3 5WP38394 1 Slide lock collar repair kit

4 5WP40778 2 Screw, Guard retainer

5 5WP40766 2 Bearing ring, Guard

6 5WP40777 1 Chain, Guard anti-rotation

7 5WP40779 1 Grease fitting, Drive line

8 5WP44699 1 Shield, CV Cone & bearing

9 5WP44672 1 CV Body

10 5WP44673 1 Yoke, Inner profile

54 Parts

REF PART QTY DESCRIPTION

11 5WP44688 1 Guard, Outer half

12 5WP44661 1 Drive, Inner half complete

13 5WP44677 1 Yoke, Outer profile

14 5WP44689 1 Guard, Inner half

15 5WP44662 1 Drive, Outer half complete

16 5WP38352 1 U-Joint repair kit 2400

17 5WP40764 2 Pin, Spring 10mm x 80mm

18 5WP44675 1 Drive tube, Inner profile

19 5WP44676 1 Drive tube, Outer profile

20 5WP40767 1 Bearing, Guard support

21 5WP38351 1 Yoke, 1-3/8 - 6 Spline QD

5WPMAN0183 (Rev. 7/9/2008)

CV DRIVE ASSEMBLY

PAG E 5 4

PAGE 55

(WEASLER PROFILE)

REF PART QTY DESCRIPTION

A 5WP1021100 1 Drive, Weasler complete CV 35R,

1 5WP19851 2 Slide lock repair kit

2 5WP1021301 1 Yoke QD CV 1-3/8 - 6

3 5WP52520 2 U-Joint repair kit 35CV

4 5WP52522 1 CV Body w/fitting

5 5WP1021321 1 Yoke and shaft - CV splined 20.9

6 5WP1024636 2 Drive shaft bearing kit

7 5WP18864 1 Decal, danger rotating driveline

8 5WP1021302 1 Outer shield CV

9 5WP1021303 1 Inner shield CV

10 5WP33347 1 Decal, danger guard missing

11 5WP1021304 1 Yoke and tube 35R x 27.5 x 1.31 - 20

12 5WP110 1 Universal joint repair kit 35N

13 5WP55143 1 Yoke QD 36 1-3/8 - 6

5WPMAN0183 (Rev. 7/9/2008)

35.0 x 47.6

Parts 55

FM1012, FM1015 & FM1017 JACKSHAFT DRIVE ASSEMBLY (WALTERSCHEID)

Check profile and order from correct parts list.

REF PART QTY DESCRIPTION

A 5WP44626 Drive, Yk & shft non-tel 2400 x 26.4

1 5WP38351 1 Yoke, 1-3/8 - 6 Spline QD

2 5WP38352 1 U-Joint repair kit 2400

3 5WP38394 1 Slide lock collar repair Kit

4 5WP38353 1 Yoke, Inboard

5 5WP40764 1 Pin, Spring 10mm x 80mm

FM1012, FM1015 & FM1017 JACKSHAFT DRIVE ASSEMBLY (COMER)

REF PART QTY DESCRIPTION

6 5WP44678 1 Shaft, Stub 1-3/8 - 6 x 26.38

7 5WP40778 1 Screw, Guard retainer

8 5WP40766 1 Bearing ring, Guard

9 5WP40777 1 Chain, Guard anti-rotation

10 5WP40767 1 Bearing, Guard support

11 5WP44690 1 Guard, Inner half

REF PART QTY DESCRIPTION

A 5WP1011759 Complete jackshaft drive asy

1 5WP1028775 1 Complete collar yoke

2 5WP36990 1 U-Joint repair kit

3 5WP1011756 1 Yoke, outer

4 5WP1001330 1 Flexible pin

5 5WP1028776 1 Outer bearing ring

56 Parts

REF PART QTY DESCRIPTION

6 5WP30922 6 Retainer, shield

7 5WP1011757 1 Centering ring

8 5WP1011755 1 Inner bearing ring

9 5WP1011754 1 Shield, complete (includes 5, 6, 7

& 8)

10 5WP1001340 1 Lock collar repair kit

11 NSS 1 Jackshaft

NSS Not Serviced Separately

5WPMAN0183 (Rev. 7/9/2008)

REAR CHAIN SHIELDING ASSEMBLY

REF PART QTY DESCRIPTION

- 5WP55348 Chain shield assembly, 5 ft. deck

- 5WP53566 Chain shield assembly, 6 ft. deck

- † Chain shield assembly, 4 ft. deck

1 5WP1007854 1 Pin, 40 to 42 chains (5 ft) -or-

1 5WP1007856 1 Pin, 52 to 54 chains (6 ft) -or-

1 5WP1007850 1 Pin, 31 to 33 chains (4 ft)

2 5WP4763 - Chain, 3 link, 1/4 Proof (use 54 for 5 ft;

66 for 6 ft, 41 for 4 ft)

3 5WP55345 1 Shield, Chain plate (5 ft) -or-

3 5WP53554 1 Shield, Chain plate (6 ft) -or-

3 5WP58997 1 Shield, Chain plate (4 ft)

14 * Bolt, Carriage 3/8 NC x 1

15 5WP14350 Nut, Flanged lock 3/8 NC

*nStandard Hardware, Obtain Locally

†nNo longer sold as a complete assembly: Order separately:

1 of 5WP58997, 1 of 5WP1007850, 3 of 5WP14350, 41 of 5WP4763, and obtain locally 3 Carriage bolts 3/8 NC x 1”

5WPMAN0183 (Rev. 7/9/2008)

Parts 57

HYDRAULIC CYLINDERS

Note: The center deck uses a 3 x 8 cylinder.

The wing decks use 3 x 10 cylinders. Verify cylinder size before ordering replacement parts.

3 x 8 3 x 10

REF PART PART QTY DESCRIPTION

1 5WP29547 5WP1019460 Complete cylinder

2 5WP19810 5WP19810 1 Seal repair kit (includes items 2A - 2G 2A † † 1 Wiper seal 2B † † 1 Rod seal 2C † † 1 Rod O-ring 2D † † 2 Cap seal 2E † † 2 Cap O-ring 2F † † 2 Piston seal

2G † † 1 Piston O-ring

3 N/S N/S 1 Cylinder housing - rod end

4N/S N/S1Piston

5N/S N/S1Jam nut

6 N/S N/S 4 Cylinder tie rod

7 * * 3 1/2 Pipe plug

8 N/S N/S 1 Cylinder housing - butt end

9 N/S N/S 2 Cylinder barrel

10 N/S N/S 8 Tie rod nut 11 N/S N/S 1 Cylinder clevis 12 N/S N/S 1 Cylinder rod 13 * * 1 Set screw 3/8 x 3/4 dog point

† Included in seal kit

* Standard hardware, obtain locally

N/S Not serviced

58 Parts

5WPMAN0183 (Rev. 7/9/2008)

HYDRAULIC HOSE ASSEMBLY

REF PART QTY DESCRIPTION

14 5WP1019460 2 Cylinder, Hydraulic 3 x 10 (See pg 58)

15 5WP29547 1 Cylinder, Hydraulic 3 x 8 (See pg 58)

16 5WP8346 4 Pin, Headless 1.00 x 4.58

17 5WP1631 2 Pin, Headless 1.00 x 3.63

18 * Pin, Cotter 1/4 x 1-3/4

19 5WP1006404 1 Hose, 108" x 9/16 JICF x 1/4 NPTM

20 5WP1006403 1 Hose, 48" x 9/16 JICF x 9/16 JICM

21 5WP1006402 3 Hose, 33" x 9/16 JICF x 9/16 JICM

22 5WP1006401 1 Cross, 9/16 JICM x 1/4 NPTF

23 5WP1006400 1 Bulkhead fitting, 9/16 JICM x 1/4 NPTM

24 5WP1006405 3 Elbow, 9/16 JICF x 1/2 NPTM 90° 3/32 RSTR

* Standard Hardware, Obtain Locally

5WPMAN0183 (Rev. 7/9/2008)

Parts 59

BOLT TORQUE CHART

SAE SERIES TORQUE CHART

SAE Bolt Head

Identification

SAE Grade 2

(No Dashes)

SAE Grade 5

(3 Radial Dashes)

SAE Grade 8

(6 Radial Dashes)

METRIC SERIES TORQUE CHART

Metric Bolt Head

Identification

8.8

Metric

Grade 10.9

10.9

Metric

Grade 8.8

Typical Washer Installations

Lock Washer

Flat Washer

8/9/00

Bolt

Always tighten hardware to these values unless a different torque value or tightening procedure is listed for a specific application.

Fasteners must always be replaced with the same grade as specified in the manual parts list. Always use the proper tool for tightening hardware: SAE for SAE hardware and Metric for metric hardware. Make sure fastener threads are clean and you start thread engagement properly. All torque values are given to specifications used on hardware defined by SAE J1701 MAR 99 & J1701M JUL 96.

MARKING ON HEAD

Diameter

(Inches)

1/4" 7/16" 6 8 10 13 14 18

5/16"1/2"121719262737

3/8"9/16"233135474967

7/16"5/8"3648557578106

1/2" 3/4" 55 75 85 115 120 163

9/16" 13/16" 78 106 121 164 171 232

5/8" 15/16" 110 149 170 230 240 325

3/4" 1-1/8" 192 261 297 403 420 569

7/8" 1-5/16" 306 416 474 642 669 907

1" 1-1/2" 467 634 722 979 1020 1383

Wrench

Size

SAE 2 SAE 5 SAE 8

lbs-ft N-m lbs-ft N-m lbs-ft N-m

Coarse Thread Fine Thread

Marking on Head Marking on Head

Diameter &

Thread Pitch

(Millimeters)

6 x 1.0 10 mm 8 6 11 8 8 6 11 8 6 x 1.0

8 x 1.25 13 mm 20 15 27 20 21 16 29 22 8 x 1.0

10 x 1.5 16 mm 39 29 54 40 41 30 57 42 10 x 1.25

12 x 1.75 18 mm 68 50 94 70 75 55 103 76 12 x 1.25

14 x 2.0 21 mm 109 80 151 111 118 87 163 120 14 x 1.5

16 x 2.0 24 mm 169 125 234 173 181 133 250 184 16 x 1.5

18 x 2.5 27 mm 234 172 323 239 263 194 363 268 18 x 1.5

20 x 2.5 30 mm 330 244 457 337 367 270 507 374 20 x 1.5

22 x 2.5 34 mm 451 332 623 460 495 365 684 505 22 x 1.5

24 x 3.0 36 mm 571 421 790 583 623 459 861 635 24 x 2.0

30 x 3.0 46 mm 1175 867 1626 1199 1258 928 1740 1283 30 x 2.0

60 Appendix

Wrench

Size

Metric 8.8 Metric 10.9 Metric 8.8 Metric 10.9

N-m lbs-ft N-m lbs-ft N-m lbs-ft N-m lbs-ft

Diameter &

Thread Pitch

(Millimeters)

Bolt Torque & Size Charts (Rev. 3/28/2007)

BOLT SIZE CHART

5/16 3/8 1/2 5/8 3/4 7/8

SAE Bolt Thread Sizes

MM 25 50 75 100 125 150 175

IN 1 7

Metric Bolt Thread Sizes

8MM 18MM14MM12MM10MM 16MM

NOTE: Chart shows bolt thread sizes and corresponding head (wrench) sizes for standard SAE and metric bolts.

ABBREVIATIONS

AG .............................................................. Agriculture

ASABE.................... American Society of Agricultural &

Biological Engineers (formerly ASAE)

ASAE ....... American Society of Agricultural Engineers

ATF ............................... Automatic Transmission Fluid

BSPP .............................British Standard Pipe Parallel

BSPTM ................British Standard Pipe Tapered Male

CV.....................................................Constant Velocity

CCW .............................................. Counter-Clockwise

CW............................................................... Clockwise

F ...................................................................... Female

FT ..............................................................Full Thread

GA .................................................................... Gauge

GR (5, etc.) ........................................... Grade (5, etc.)

HHCS ........................................Hex Head Cap Screw

HT........................................................... Heat-Treated

JIC .................Joint Industry Council 37° Degree Flare

LH .................................................................Left Hand

LT........................................................................... Left

m......................................................................... Meter

mm................................................................ Millimeter

M.......................................................................... Male

MPa......................................................... Mega Pascal

N.......................................................................Newton

NC ......................................................National Coarse

NF ...........................................................National Fine

NPSM.....................National Pipe Straight Mechanical

NPT .......................................... National Pipe Tapered

NPT SWF .........National Pipe Tapered Swivel Female

ORBM .......................................... O-Ring Boss - Male

P...........................................................................Pitch

PBY ...................................................... Power-Beyond

psi..........................................Pounds per Square Inch

PTO.....................................................Power Take Off

QD....................................................Quick Disconnect

RH ..............................................................Right Hand

ROPS ........................... Roll-Over Protective Structure

RPM ........................................Revolutions Per Minute

RT ....................................................................... Right

SAE ..........................Society of Automotive Engineers

UNC .....................................................Unified Coarse

UNF...........................................................Unified Fine

UNS......................................................Unified Special

Bolt Torque & Size Charts (Rev. 3/28/2007)

Appendix 61

INDEX

ASSEMBLY

Dealer Set-up Instructions 34

DEALER CHECK LISTS

Delivery (Dealer’s Responsibility) 36 Pre-Delivery (Dealer’s Responsibility) 36

DEALER SERVICE

Blade Spindle

Assembly 27 Disassembly 27 Installation 28 Removal 26

Servicing 26 Blocking Method 26 Drive Sheave Installation 32 Gearbox

Disassembly 30

Horizontal Leak Repair 29

Installation 32

Reassembly 30

Removal from Mower 30

Repair 29

Seal Installation 29

Seal Replacement 29

Vertical Shaft Repair 29 Universal Joint

Assembly 33

Disassembly 32

Repair 32

Cutting Height Adjustment 14 CV Driveline Turning Limits 14 Leveling Mower 14 Operating 16

On Uneven Terrain 17 Technique 16

Tips 16 Removing Mower from Tractor 17 Starting and Stopping Mower 16 Transporting 15

OWNER SERVICE

Belt

Installation 21

Replacement 21

Routing 22 Blade

Installation 23

Servicing 22

Sharpening 23 Blocking Method 19 Cleaning

After Each Use 23

Before Storage 23 Lubrication

Deck Lubrication Points 21

Lubrication Information 20

Trailer Lubrication Points 20 Troubleshooting

Belt Conditions 25

Mowing Conditions 24

GENERAL

Abbreviations 61 Bolt Size Chart 61 Bolt Torque Chart 60 General Information 4 Introduction, Inside Front Cover Specifications 4 Warranties

Product 64 Replacement Parts 65

OPERATION

Attaching Mower to Tractor 13 Check List

Owner Pre-Operation (Owner’s Responsibility)

62 Index

PARTS

Parts Index 37

SAFETY

Blocking Method 19, 26 Check Lists

Dealer Delivery (Dealer’s Responsibility) 36

Dealer Pre-Delivery (Dealer’s Responsibility)

Owner Pre-Operation (Owner’s Responsibility)

17 Safety Decals 9-12 Safety Rules 5-8 Safety Symbols explained, Inside Front Cover Uneven Terrain 17

5WPMAN0183 (Rev. 7/9/2008)

NOTES

5WPMAN0183 (Rev. 7/9/2008)

Index 63

WARRANTY

Please enter information below and save for future reference.

Date Purchased: ______________________ From (Dealer): _________________________

Model Number: ______________________ Serial Number: _________________________

Woods Equipment Company (“WOODS”) warrants this product to be free from defect in material and workmanship. Except as otherwise set forth below, the duration of this Warranty shall be for TWELVE (12) MONTHS COMMENCING ON THE DATE OF DELIVERY OF THE PRODUCT TO THE ORIGINAL PURCHASER.

The warranty periods for certain components are listed below:

Model No. Part Warranted Duration

Gearbox

GM1060, GM1072, GM1084, FM1012, FM1015, FM1017 and GM1190

GM3054, GM3060, GM3072

components

Blade spindles

Gearbox

components

Under no circumstances will this Warranty apply in the event that the product, in the good faith opinion of WOODS, has been subjected to improper operation, improper maintenance, misuse, or an accident. This Warranty does not apply in the event that the product has been materially modified or repaired by someone other than WOODS, a WOODS authorized dealer or distributor, and/or a WOODS authorized service center. This Warranty does not cover normal wear or tear, or normal maintenance items. This Warranty also does not cover repairs made with parts other than those obtainable through WOODS.

This Warranty is extended solely to the original purchaser of the product. Should the original purchaser sell or otherwise transfer this product to a third party, this Warranty does not transfer to the third party purchaser in any way. There are no third party beneficiaries of this Warranty.

WOODS makes no warranty, express or implied, with respect to engines, batteries, tires or other parts or accessories not manufactured by WOODS. Warranties for these items, if any, are provided separately by their respective manufacturers.

WOODS’ obligation under this Warranty is limited to, at WOODS’ option, the repair or replacement, free of charge, of the product if WOODS, in its sole discretion, deems it to be defective or in noncompliance with this Warranty. The product

must be returned to WOODS with proof of purchase within thirty (30) days after such defect or noncompliance is discovered or should have been discovered, routed through the dealer and distributor from whom the purchase was made, transportation charges prepaid. WOODS shall complete such repair or replacement within a reasonable time

after WOODS receives the product. THERE ARE NO OTHER REMEDIES UNDER THIS WARRANTY. THE REMEDY OF REPAIR OR REPLACEMENT IS THE SOLE AND EXCLUSIVE REMEDY UNDER THIS WA R R A N T Y.

THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE OF THIS WARRANTY. WOODS MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED, AND WOODS SPECIFICALLY DISCLAIMS ANY IMPLIED WARRANTY OF MERCHANTABILITY AND/OR ANY IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

WOODS shall not be liable for any incidental or consequential losses, damages or expenses, arising directly or indirectly from the product, whether such claim is based upon breach of contract, breach of warranty, negligence, strict liability in tort or any other legal theory. Without limiting the generality of the foregoing, Woods specifically

disclaims any damages relating to (i) lost profits, business, revenues or goodwill; (ii) loss of crops; (iii) loss because of delay in harvesting; (iv) any expense or loss incurred for labor, supplies, substitute machinery or rental; or (v) any other type of damage to property or economic loss.

This Warranty is subject to any existing conditions of supply which may directly affect WOODS’ ability to obtain materials or manufacture replacement parts.

No agent, representative, dealer, distributor, serviceperson, salesperson, or employee of any company, including without limitation, WOODS, its authorized dealers, distributors, and service centers, is authorized to alter, modify, or enlarge this Warranty.

For warranty services contact your selling dealer.

5 years from the date of delivery to the original purchaser

3 years from the date of delivery to the original purchaser

3 years from the date of delivery to the original purchaser (1 year if used in rental or commercial applications)

W-07011-V (Rev. 6/13/2008) (cf. F-3079)

WARRANTY

for Replacement Parts

Woods Equipment Company (“WOODS”) warrants this product to be free from defect in material and workmanship for a period of ninety (90) days from the date of delivery of the product to the original purchaser with the exception of V-belts, which will be free of defect in material and workmanship for a period of 12 months.

such defect or noncompliance is discovered or should have been discovered, routed through the dealer and distributor from whom the purchase was made, transportation charges prepaid. WOODS shall

complete such repair or replacement within a reasonable time after WOODS receives the product. THERE ARE NO OTHER REMEDIES UNDER THIS WARRANTY. THE REMEDY OF REPAIR OR REPLACEMENT IS THE SOLE AND EXCLUSIVE REMEDY UNDER THIS WARRANTY.

foregoing, Woods specifically disclaims any damages relating to (i) lost profits, business, revenues or goodwill; (ii) loss of crops; (iii) loss because of delay in harvesting; (iv) any expense or loss incurred for labor, supplies, substitute machinery or rental; or (v) any other type of damage to property or economic loss.

This Warranty is subject to any existing conditions of supply which may directly affect WOODS’ ability to obtain materials or manufacture replacement parts.

No agent, representative, dealer, distributor, service person, salesperson, or employee of any company, including without limitation, WOODS, its authorized dealers, distributors, and service centers, is authorized to alter, modify, or enlarge this Warranty.

For warranty services contact your selling dealer.

W-07012-V Rev. 3/24/2005 (cf. F-8494)

©2002 Woods Equipment Company. All rights reserved. WOODS and the Woods logo are trademarks of Woods Equipment Company. Frontier Equipment and the Frontier logo are trademarks of Deere & Company. All other trademarks, trade names, or service marks that appear in this manual are the property of their respective companies or mark holders. Specifications subject to change without notice.

PART NUMBER

5WPMAN0183

Frontier FM1012, FM1015, FM1017 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual