John Deere FM1012, FM1015, FM1017 User Manual

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 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.

 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

DANGER

SHIELD MISSING

DO NOT OPERATE - PUT SHIELD ON

5WPMAN0183 (Rev. 7/9/2008)

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

5WPMAN0183 (Rev. 4/25/2008)

Figure 3. Cutting Height Adjustment

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.

 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)

+ 46 hidden pages