OPERATOR’S MANUAL
FLEX WING
GROOMING MOWERS
FM2012
FM2015
FM2017
Manual 5BP961206B
Date 11/11/2010
SAFETY
Take note! This safety alert symbol found throughout this manual is used to call your
attention to instructions involving your personal safety and the safety of others. Failure to
follow these instructions can result in injury or death.
This symbol means:
ATTENTION!
BECOME ALERT!
YOUR SAFETY IS INVOLVED!
Signal Words
Note the use of the signal words DANGER, WARNING and CAUTION with the safety messages. The
appropriate signal words for each have been selected using the following guidelines:
DANGER: Indicates an imminently hazardous situation that, if not avoided, will result in death or
serious injury.
WARNING: Indicates a potentially hazardous situation that, if not avoided, could result in death or
serious injury, and includes hazards that are exposed when guards are removed. It may also be used
to alert against unsafe practices.
CAUTION: Indicates a potentially hazardous situation that, if not avoided, may result in minor or
moderate injury.
INDEX
1 - GENERAL INFORMATION
2 - SAFETY PRECAUTIONS
3 - OPERATION
4
41.01 - General
41.02 - Warranty Information
51.03 - Model and Serial Number ID
6
62.01 - Preparation
72.02 - Starting and Stopping
72.03 - Messages and Signs
11
113.01 - Operational Safety
133.02 - Setup and Assembly Instructions
143.03 - Light Kit Installation
163.04 - Cutting Height Adjustment
173.05 - Pre-Operational Check
183.06 - Attaching to the Tractor
203.07 - Constant Velocity Driveline
213.08 - Hydraulic Lift System
4 - MAINTENANCE
5 - REPAIR PROCEDURES
213.09 - Frame Adjustments
253.10 - Start Up
273.11 - Working Speed
283.12 - Operating Techniques
293.13 - Uneven Terrain
30
304.01 - Maintenance Safety
314.02 - Service
344.03 - Blade Maintenance
364.04 - Belt Tension
374.05 - Belt Replacement
384.06 - Drivelines and Center Gearbox Timing
394.07 - Transport
404.08 - Storage
42
425.01 - Gearbox
425.02 - Blade Spindle
435.03 - Suggested Spare Parts
6 - TROUBLESHOOTING
7 - PRE-DELIVERY CHECKLIST
INDEX 3 FRONTIER
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FLEX WING GROOMING MOWERS OPERATOR’S MANUAL
1 - GENERAL INFORMATION
Thank you and congratulations for having chosen our implement. Your new Flex Wing
grooming mower is a technologically advanced machine constructed of high quality,
sturdy components that will fulfill your working expectations. Read this manual carefully.
It will instruct you on how to operate and service your mower safely and correctly.
Failure to do so could result in personal injury and/or in equipment damage.
1.01 - General
The implement described in this manual is to be used with tractors with PTO at 540 rpm
and clockwise rotation.
CAUTION: Always ensure that the coupling of the implement with the tractor is
done at the same PTO speed and direction of rotation. Do not operate this
implement at a PTO speed or direction of rotation other than that shown on the
implement. Serious damage can occur to the machine and/or the operator.
CAUTION: Unless otherwise specified, all hardware is metric. Use only metric
tools on metric hardware. Other tools that do not fit properly can slip and cause
injury.
CAUTION: Right hand and left hand sides of the implement are determined by
facing in the direction the implement will travel when going forward (see fig. 2).
1.02 - Warranty Information
Warranty coverage is provided by John Deere according to the terms of the
Agricultural/Commercial & Consumer Equipment Warranty Statement. Carefully read
the warranty statement on the back of your original purchase order for details on
coverage and limitations of this warranty.
Your Authorized Company Dealer has genuine parts in stock. Only these approved
replacement parts should be used.
GENERAL INFORMATION 4 FRONTIER
FLEX WING GROOMING MOWERS OPERATOR’S MANUAL
1.03 - Model and Serial Number ID
Attached to the frame is an ID plate showing the model and the serial number. Record
your implement model and serial number in the space provided below. Your dealer
needs this information to give you prompt, efficient service when you order parts.
GENERAL INFORMATION 5 FRONTIER
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LEX WING GROOMING MOWERS OPERATOR’S MANUAL
2 - SAFETY PRECAUTIONS
Safety is the primary concern in the design and manufacture of our products.
Unfortunately our efforts to provide safe equipment can be wiped out by a single
careless act of an operator.
In addition to the design and configuration of equipment, hazard control and accident
prevention are dependent upon the awareness, concern, prudence and proper training
of personnel involved in the operation, transport, maintenance and storage of
equipment. It is the operator’s responsibility to read and understand all safety and
operating instructions in the manual and to follow these.
Allow only properly trained personnel to operate the mower. Working with unfamiliar
equipment can lead to careless injuries. Read this manual, and the manual for your
tractor, before assembly or operation, to acquaint yourself with the machines. It is the
mower owner’s responsibility, if this machine is used by any person other than yourself,
is loaned or rented, to make certain that the operator, prior to operating, reads and
understands the operator’s manuals and is instructed in safe and proper use.
2.01 - Preparation
1. Before operating equipment read and understand the operator’s manual and the
safety signs (see fig. 2).
2. Thoroughly inspect the implement before initial operation to assure that all
packaging materials, i.e. wires, bands, and tape have been removed.
3. Personal protection equipment including hard hat, safety glasses, safety shoes, and
gloves are recommended during assembly, installation, operation, adjustment,
maintaining and/or repairing the implement.
4. Operate the mower only with a tractor equipped with an approved
Roll-Over-Protective-System (ROPS). Always wear your seat belt. Serious injury or
even death could result from falling off the tractor.
5. Clear area to be cut of stones, branches or other debris that might be thrown,
causing injury or damage.
6. Operate only in daylight or good artificial light.
7. Ensure mower is properly mounted, adjusted and in good operating condition.
8. Ensure that all safety shielding and safety signs are properly installed and in good
condition.
SAFETY PRECAUTIONS 6 FRONTIER
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LEX WING GROOMING MOWERS OPERATOR’S MANUAL
2.02 - Starting and Stopping
1. Be sure that no one is near the machine prior to engaging or while the machine is
working.
2. Be sure the tractor is in “Neutral” before starting engine.
3. Mower operating power is supplied from tractor PTO. Refer to your tractor manual
for PTO engagement and disengagement instructions. Always operate PTO at 540
rpm. Know how to stop the tractor and mower quickly in case of an emergency.
4. When engaging PTO, the engine rpm should always be low. Once engaged and
ready to start cutting, raise PTO speed to 540 rpm and maintain throughout cutting
operation.
5. Check the tractor master shield over the PTO stub shaft. Make sure it is in good
condition and fastened securely to the tractor. Purchase a new shield if old shield is
damaged or missing.
6. After striking an obstacle, disengage the PTO, shut the tractor down and thoroughly
inspect for damage before restarting.
7. Never engage the PTO until the mower is in the down position and resting on the
ground. Never raise the mower until all blades have come to a complete stop.
8. To park the vehicle safely, stop vehicle on a level surface (not on a slope),
disengage PTO, engage the parking brake, stop the engine, remove the key, and
wait for engine and all moving parts to stop before leaving the operator’s seat.
9. Stay clear of rotating drivelines. Entanglement in rotating driveline can cause serious
injury or death. Wear close fitting clothing. Stop the engine and be sure PTO
driveline is stopped before getting near it.
2.03 - Messages and Signs
1. Read and adhere to all safety and operating decals on this machine (see fig. 2).
2. Before dismounting tractor: Allow moving parts to stop, stop engine, set brake and
remove the key of unattended equipment.
3. Keep away from rotating blades and driveline.
4. Keep guards and shields in place and in good condition.
5. Do not mow with bystanders in area.
6. Allow no riders on tractor or mower.
7. Allow moving parts to stop before repair.
8. Securely support mower before working underneath.
9. Lock up raised wings before transport (see fig. 12).
Additional warning and operating decals are available at no extra charge. Please specify
model and serial number when ordering.
SAFETY PRECAUTIONS 7 FRONTIER
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LEX WING GROOMING MOWERS OPERATOR’S MANUAL
Fig. 2 - Safety decals, main frame; replace immediately if damaged.
1
4
5
3
2
6
2
1
2
7
right sideleft side
Yellow reflective deca
7
8
8
Red reflective decal
8
3
3
456
SAFETY PRECAUTIONS 8 FRONTIER
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LEX WING GROOMING MOWERS OPERATOR’S MANUAL
Safety decals, decks; replace immediately if damaged.
placed under belt shieldsplaced under belt shields
SAFETY PRECAUTIONS 9 FRONTIER
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Safety decals, drivelines; replace immediately if damaged.
placed on outer tube
placed on outer shield
SAFETY PRECAUTIONS 10 FRONTIER
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LEX WING GROOMING MOWERS OPERATOR’S MANUAL
3 - OPERATION
The Flex Wing grooming mower represents the most advanced proposal for reducing
labor cost without sacrificing quality of cut. The high cutting speed of 8-10 mph along
with the wide working widths of up to 17’, allows for a reduction in man-hours and lower
fuel cost for the maintenance of large grass areas such as sport fields, parks, golf
courses and sod farms.
The Flex Wing grooming mower consists of a frame-carrier, mechanically connecting a
trio of rear discharge grooming mowers. The Flex can be used on tractors with
horsepower ranging from 25 to 80. The tractor PTO is connected, through a wide angle
driveline, to a 4 way splitter gearbox. The side and rear output shafts transfer power to
the individual speed multiplier gearboxes on each mower.
The 12’ model consists of two 4’ wing units and one 5’ rear unit, the 15’ model consists
of two 5’ wing units and one 6’ rear unit and the 17’ model uses three 6’ decks.
Each individual mower works completely independent from the others. They are
connected to the frame by floating arms. All mowers have four wheels allowing free
floating over uneven terrain. Even over rolling ground, the cut is accurate and uniform.
After mowing, during transport and for storage or maintenance, all three mowers can be
raised up hydraulically to a vertical position. During transport or maintenance
operations, it is imperative to be sure the wing mowers are locked in place with the
automatic locking system. To transport over extended distances, the wings should be
locked in their 90 degree vertical position with the transport locks and the metal
transport braces added to the two wing units for added safety. The two transport wheels
allow the Flex Wing mower, in its closed and locked position, to be transported safely on
lawns or private roads. The tires are not suitable for extended road travel.
The decks can be raised for easy cleaning and quick blade changes. Top grease fittings
make the greasing of hubs and spindles simple and quick.
3.01 - Operational Safety
CAUTION: Our mowers are designed considering safety as the most important
aspect and are the safest available in today’s market. Unfortunately, human
carelessness can override the safety features built into our machines. Injury
prevention and work safety, aside from the features on our mowers, are very
much due to the responsible use of the equipment. It must always be operated
prudently following with great care, the safety instructions laid out in this manual.
1. The use of this equipment is subject to certain hazards which cannot be prevented
by mechanical means or product design. All operators of this equipment must read
OPERATION 11 FRONTIER
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LEX WING GROOMING MOWERS OPERATOR’S MANUAL
and understand this entire manual, paying particular attention to safety and
operating instructions, prior to using.
2. Do not operate the tractor and mower when you are tired, sick or when using
medication.
3. Keep all helpers and bystanders at least several hundred feet from a rotary mower.
Only properly trained people should operate this machine.
4. When this machine is operated in populated areas where thrown objects could injure
persons or property, standard equipment safety chain shielding (which is designed
to reduce the possibility of thrown objects) must be installed.
5. The majority of accidents involve entanglements on the driveline, injury of
bystanders by objects thrown by the rotating blades, and operators being knocked
off the tractor by low hanging limbs and then being run over by the mower. Accidents
are most likely to occur with machines that are loaned or rented to someone who
has not read the operator’s manual and is not familiar with a rotary mower.
6. Always stop the tractor, set brake, shut off the tractor engine, remove the ignition
key, lower implement to the ground and allow mower blades to come to a complete
stop before dismounting tractor. Never leave equipment unattended with the tractor
running.
7. Never place hands or feet under mower with tractor engine running or before you
are sure all motion has stopped. Stay clear of all moving parts.
8. Do not allow riders on the mower or tractor at any time. There is no safe place for
riders.
9. Do not operate unless all personnel, livestock and pets are several hundred feet
away to prevent injury by thrown objects.
10.Before backing up, disengage the mower and look behind carefully.
11.Install and secure all guards and shields before starting or operating.
12.Keep hands, feet, hair and clothing away from moving parts.
13.This rotary mower is designed for use only on tractors with 540 rpm power take off.
14.Never operate tractor and mower under trees with low hanging limbs. Operators can
be knocked off the tractor and then run over by the rotating blades.
15. The rotating parts of this machine have been designed and tested for rugged use.
However, they could fail upon impact with heavy, solid objects such as steel guard
rails and concrete abutments. Such impact could cause the broken objects to be
thrown outward at very high velocities. To reduce the possibility of property damage,
serious injury, or even death, never allow the cutting blades to contact such
obstacles.
16.Frequently check mower blades. They should be sharp, free of nicks and cracks and
securely fastened.
17. Stop mower immediately upon striking an obstruction. Turn engine off, remove key,
inspect and repair any damage before resuming operation.
18. Stay alert for holes, rocks and roots in the terrain and other hidden hazards. Keep
away from drop-offs.
19.Use extreme care and maintain minimum ground speed when transporting on
hillside, over rough ground and when operating close to ditches or fences. Be careful
when turning sharp corners.
OPERATION 12 FRONTIER
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LEX WING GROOMING MOWERS OPERATOR’S MANUAL
20. Reduce speed on slopes and sharp turns to minimize tipping or loss of control. Be
careful when changing directions on slopes. Do not start or stop suddenly on slopes.
Avoid operation on steep slopes.
21. When using a unit, a minimum 20% of tractor and equipment weight must be on
tractor front wheels. Without this weight, tractor could tip over, causing personal
injury or death. The weight may be attained with a front end loader, front wheel
weights, ballast in tires or front tractor weights. When attaining a minimum 20% of
tractor and equipment weight on the front wheels, you must not exceed the ROPS
weight certification. Weigh the tractor and equipment. Do not guess or estimate!
22. Inspect the entire machine periodically1. Look for loose fasteners, worn or broken
parts, and leaky or loose fittings.
23. Use only the driveline supplied with the mower. Do not use it if it is missing any
shield or safety protection.
24. Pass diagonally through sharp dips and avoid sharp drops to prevent “hanging up”
tractor and mower.
25.Avoid sudden starts and stops while traveling up or downhill.
26. Always cut down slopes; never across the face. Avoid operation on steep slopes.
Slow down on sharp turns and slopes to prevent tipping and/or loss of control.
3.02 - Setup and Assembly Instructions
Notice to dealer: Pre-delivery setup and service including lubrication is the
responsibility of the authorized dealer. It is up to him to assure that the machine is in
perfect condition and ready to be used. It is his responsibility to ensure that the
customer is aware of all safety aspects and operational procedures for the mower. He
must also fill out the Pre-Delivery Checklist2 prior to delivering the mower.
At times, due to loading restraints the mower is shipped either with the three decks
separate from the frame or fully assembled but with the transport tires and the
telescopic wing arms retracted. It is the dealer’s responsibility to extend transport
tires and telescopic wing arms to proper operating width and to ensure final
assembly of the mower.
CAUTION: Stand clear of bands when cutting as they could be under sufficient
tension to cause them to fly loose. Take care in removing bands and wire, they
often have extremely sharp edges and cut very easily.
To hook the three mowers to the central frame, do the following:
1. Position the decks complete with hitches (see #8, fig. 3) near the telescopic wing
arms (see #1, fig. 3) which are bolted into the lift arms.
2. Insert the attaching pin (see #7, fig. 3) into the tube welded to the hitch (see #9, fig.
3). Place the shim washers (see #5, fig. 3) on either end of the attaching pin.
1
2
OPERATION 13 FRONTIER
See Chapter 4 - Maintenance.
See Chapter 7 - Pre-Delivery Checklist.
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LEX WING GROOMING MOWERS OPERATOR’S MANUAL
3. Place the two formed plates (see #3, fig. 3) on either end of the attaching pin (see
#7, fig. 3) with the bend facing outward.
4. With the wing arms down level with the mower decks, position the telescopic wing
arms (see #1, fig. 3) between the two formed plates (see #3, fig. 3). Attach them to
the bolts (see #10, fig. 3) provided.
5. Tighten the nuts (see #4, fig. 3) and bolts (see #10, fig. 3). Ensure after tightening
that the formed plates (see #3, fig. 3) move freely up and down over the attaching
pin (see #7, fig. 3).
6. Using the grease fitting on the hitch (see #6, fig. 3), grease the attaching pin and
formed plate.
Fig. 3 - Mowing unit assembly.
3.03 - Light Kit Installation
The light kit comes standard and contains two lights, two brackets and wiring harness.
To install the light kit do the following:
1. Attach the light fixtures to the bracket using the supplied bolts M6x25 and nuts M6.
Note: Be sure to route the wires through the large hole in the center of the mounting
bracket before installing bolts.
2. Route the strand of wires with green wire down the right side of the unit (remember
that left or right is determined by facing in the direction the implement will travel
when going forward). Route the strand of wires with yellow wire down the left side of
the unit. Do not install the wire ties. This will be done later in the assembly process.
3. Plug the wire harness to the wire harness on the light fixture (see photo A).
OPERATION 14 FRONTIER
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LEX WING GROOMING MOWERS OPERATOR’S MANUAL
4. Slide the assembled plug underneath the mounting plate and between the bolts (see
photo B).
5. Carefully insert the wires into the supplied 3/8” wire loom (see photo C). Use
electrical tape to attach the wire loom to the wire harness. Use enough wire loom to
follow the contour of the frame until it meets at the hydraulic cross. Cut the excess
wire loom. The excess will be used on the other side of the frame to protect the
wires on the other side (see fig. 4).
6. Starting at the light fixture, use wire ties at the points shown to secure the wires to
the frame (see photo D).
7. Remove the shaft protection.
8. Where the wire harness from the left side meets with the wire harness from the right
side at the hydraulic cross, begin to run both wires and hydraulic hose into the ¾”
wire loom (see photo E).
9. When fitting light harness up to tractor, you may need to separate the wire harness
and the hydraulic hose, so that they may reach the desired socket/port.
10.The light kit is shipped with the extra wire. It may be necessary to cut and splice the
wire to reduce the excess. Use electrical tape to seal splice point (see photo C).
Photo A Photo B
Photo C
Photo D Photo E
OPERATION 15 FRONTIER
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LEX WING GROOMING MOWERS OPERATOR’S MANUAL
Fig. 4 - Light kit layout.
Hydraulic hose and both
left and right wire harness
Wire routed
underneath frame
Left light
fixture
Routing of wire at
hydraulic cross
Wire routed
underneath frame
Right light
fixture
3.04 - Cutting Height Adjustment
WARNING: Keep hands and feet away from moving blades.
Be sure the tractor engine is off, parking brake is locked, and key is removed
before making any adjustments.
Never rely on the hydraulic system to hold the weight of the raised mowers.
Never walk or work under the raised mowers without first making sure the
automatic locking system is securely holding the wing units with the hydraulic
cylinders closed, and the hook is engaged to support the rear deck.
OPERATION 16 FRONTIER
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LEX WING GROOMING MOWERS OPERATOR’S MANUAL
The cutting height is the distance from the blades to the ground. The cutting height is
adjusted by moving the height adjustment spacers on the wheel yokes above or
below the wheel arm. Placing spacers between the wheel arm and the wheel yoke
raises the cutting height by the size of the spacer. Removing the spacers lowers it by
the same height (see fig. 5). All the wheel yokes are supplied with three different size
height adjustment spacers, ¼”, ½” and 1”.
Be sure all 12 wheels of the mowers are adjusted equally. This is the only way to
ensure a completely uniform cut.
IMPORTANT: Very low cutting heights should be avoided. Damaging shock loads
occur when the blades strike the ground repeatedly. This can cause damage to
the mower.
Cutting lower than 2” under most circumstances should be avoided.
The cutting height is adjustable from 1” to 5”.
Anti-scalping rollers come standard on each deck for uneven ground contours. The
roller rides the nose of the mower deck over a mound to help keep the nose from
bulldozing or the blade from scalping the ground. The roller is extremely helpful when
mowing particularly low.
Fig. 5
The cutting height is
adjusted by moving
the height adjustment
spacers on the wheel
yokes above or below
the wheel arm.
3.05 - Pre-Operational Check
IMPORTANT: Check each of the following, carefully, prior to engaging the equipment:
1. The spindle bearings have been greased.
2. The belts for proper tension.
3. The oil in the gearboxes.
OPERATION 17 FRONTIER
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LEX WING GROOMING MOWERS OPERATOR’S MANUAL
4. The drivelines cross and bearings have been greased.
5. All wheels are fully greased.
6. All grease points on Flex frame have been greased3.
7. No wrappings or foreign objects are around the blades, belts or drivelines.
8. The blades are properly installed and the blade bolts properly torqued4.
9. All hardware is tight.
10.The tractor, to ensure correct direction of PTO and rpm speed.
11.All safety shields and guards are in place and tightly attached.
12.No people or animals are in the work area.
13.The Flex frame is level to ensure its full floating capability.
DANGER: Stay clear of rotating driveline. Entanglement in rotating driveline can
cause serious injury. Disengage PTO, engage parking brake or place
transmission in “Park”, shut off the tractor and remove the key before working
around hitch, attaching or detaching driveline, making adjustments, servicing or
cleaning the machine.
3.06 - Attaching to the Tractor
The Flex Wing grooming mower may be used on any 540 rpm tractor with a drawbar
hitch and horsepower ranging from 25 to 805.
CAUTION: Check the tractor PTO rpm to ensure it is set at 540 rpm and turns
clockwise.
Always ensure that the tractor tire pressure is correct according to the tractor
operator’s manual.
To attach the mower to the tractor do the following:
1. Remove transport brace if it is installed.
2. Back the tractor up to the mower in order to slip the tractor drawbar hitch into the
adjustable hitch bracket. The hitch bracket is adjustable in 3 different positions to
conform to the tractor drawbar height. It may also be turned over for an additional 3
positions (see fig. 6). This is an important feature that permits the leveling of the
Flex frame. Be sure the pin you use can securely attach the mower to the tractor
drawbar
with the pin. Failure to ensure a secure coupling of the implement to the tractor
can cause injury and damage to the implement or tractor.
6
. Turn off the tractor engine. Secure the frame hitch to the tractor drawbar
3
4
5
6
OPERATION 18 FRONTIER
See Section 4.02 - Service.
See Table 1, page 41.
See Table 2, page 41.
Optional equipment includes a floating hitch for undulating terrain (see fig. 7).
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LEX WING GROOMING MOWERS OPERATOR’S MANUAL
3. Lower jack stand until the weight of the mower is on the tractor drawbar. Turn the
jack stand 90 degrees and pin into a horizontal position. For further safety, the jack
stand may also be removed and mounted on the storage area on the tongue.
4. Hook the hydraulic hose to the tractor remote port. Engage the tractor hydraulics to
raise all three mowers. Never use hydraulics without the restrictors installed. Do
not stand or allow anyone to stand under any of the three mowers while
continuing the following instructions.
5. Lower the three mowers7.
6. Install the Constant Velocity driveline, only after ensuring it is the proper length8. The
CV end of the driveline is mounted on the tractor PTO.
7. Check the frame to ensure it is level9.
8. Engage the tractor PTO. It is very important to feather in the PTO.
Fig. 6
Tongue height
may be adjusted
in 6 different
positions to
ensure a level
frame on any
tractor drawbar.
DANGER: Never engage the PTO until all three mowers are in the down position
and resting on the ground. Never raise the mowers until all three deck blades
have come to a complete stop. Doing so will cause damage to the driveline yokes
and/or cross and bearings and can create a situation which endangers the
operator or bystanders.
7
8
9
See Raising the Mower Decks and the Automatic Lock Up System in Section 3.09.
See Section 3.07 - Constant Velocity Driveline.
See Section 3.09 - Frame Adjustments.
OPERATION 19 FRONTIER
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Fig. 7 - Optional floating hitch.
3.07 - Constant Velocity Driveline
It is extremely important that the Constant Velocity Driveline be at the correct length in
relation to the tractor on which it is to be used. The driveline length might be too long for
certain tractors whose tires allow for a very sharp turning radius. The proper length is
one which allows for a maximum of overlap without the possibility of bottoming out on
tight turns. The bottoming out of the driveline can seriously damage the tractor
PTO and/or the mower drive transmission. We recommend the following method for
determining the proper length. On the tightest turn possible (the tractor tires rubbing the
frame tongue) the driveline should be at least ½”-1” from bottoming out. Keep in mind
that the Constant Velocity Driveline is rated at a maximum of 80 degrees turning radius.
Towing a mower this size, most tractors cannot turn this sharply.
The following are instructions to prevent the possibility of bottoming out the driveline
and causing damage to the tractor or the mower:
1. Separate the two driveline halves. Connect the half with the CV joint to the tractor
PTO and the other half to the mower input shaft.
2. Hook the tractor to the mower and turn the tractor in the tightest possible turn. Hold
the half shafts side by side and mark the desired length on the outer female guard
tube leaving a ½” to 1” gap between the end of the guard tube and bell guard.
3. Cut off both guard tubes the same amount as marked. Shorten both drive tubes the
same amount as guard tubes.
4. De-burr and clean filings from the drive tubes and apply grease to the inside of the
outer telescoping tube.
OPERATION 20 FRONTIER
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5. Re-measure as described in step 2. Straighten out the tractor and measure the two
driveline halves to be sure that there is a minimum of 4”-6” shaft overlap to prevent
the driveline from separating during normal operation.
3.08 - Hydraulic Lift System
Standard single action lift cylinders are used on the Flex frame. They come with in-line
restrictors to prevent a sudden drop if the hydraulics fail.
DANGER: Never use hydraulics without the restrictors installed.
For correct operation, the lift cylinders for all three mowers must be completely
extended and relieved of pressure. This is done by assuring the tractor hydraulic remote
system is in the float position. See your tractor operator’s manual for correct procedure
on how to operate single action hydraulic cylinders and most importantly on how to hold
the tractor remote supply in “Float”. The “Float” setting is critical for the proper
function of the Flex mower. Both wing mowers and rear mower must have free up and
down movement for correct operation on uneven terrain.
3.09 - Frame Adjustments
Fig. 8
1. holes provided to increase
or decrease mower overlap
2. pivot pin
3. stamped plate
1
1
3
2
The complex frame carrier consists of three main parts; the drawbar, the center frame
which supports the two side wing mowers and the rear axle where the rear mower is
OPERATION 21 FRONTIER
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LEX WING GROOMING MOWERS OPERATOR’S MANUAL
attached and is carried by the transport tires. These three components are held together
by numerous large bolts M18x45. The main objective of the frame carrier of the Flex
mower is to allow the three mowing units to follow the ground contour and float freely
and independently from each other.
In order to achieve a perfectly uniform cut, it is important that all three mowers rest
completely on the ground at all times with all of their four wheels touching. This ensures
that each individual mower cuts level and maintains a uniform cut along the entire
cutting width of the machine. The free floating concept is indispensable when cutting
with gang mowers.
The three units are connected to the frame by a double pivot setup. The first pivot point
is at the overlapping pipes of the frame itself and the second in the telescopic arm
attaching the mowers to the frame. This articulating free floating system would not be
possible without the complete release of all hydraulic pressure as you will see with the
other important frame adjustments.
Telescopic Arms
The two wing mowers are connected to the frame with two adjustable telescopic arms
10
each. This unique feature, available only on our mower, allows the wing decks to
telescope in and out for additional overlap. Holes are provided for this purpose (see #1,
fig. 8). With the holes provided, you are able to adjust the cut overlap by up to 6” per
side. This is done by removing the retaining bolt and sliding the wing frame in or out to
the desired position (see fig. 8). You may choose to drill holes for additional adjustment
positions.
As the wing units, the central unit is also assembled to the frame with telescopic arms
that are adjustable in several positions (see fig. 10 & 11).
Important: Always check PTO length when adjusting the deck overlap.
Fig. 9
The arrow shows the pin centered
in the rectangular plates bolted to
the end of the telescopic arm.
Both the front and rear arm must be in
this position.
10
OPERATION 22 FRONTIER
See Section 4.06 - Drivelines and Center Gearbox Timing, prior to adjusting overlap width.
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LEX WING GROOMING MOWERS OPERATOR’S MANUAL
Leveling Flex Frame
The second pivot point is where the telescopic arms connect to the mowers. Each deck
has two pins, one in the front and one in the rear, nested between two stamped plates
with large slots. The plates are attached to each of the frame arms with three bolts. As
the mower floats over the ground, the slots allow it to follow the ground contour without
interference (see fig. 9).
Fig. 10 - Central mowing unit.
It is best to make leveling adjustments with the tractor and mower on flat ground. Lower
all three mowing decks ensuring the hydraulic pressure from the tractor is completely
released.
stamped plate
pivot pin
telescopic arm
hydraulic cylinder
locking hook
wheel arm
Fig. 11 - Central mowing unit.
OPERATION 23 FRONTIER
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LEX WING GROOMING MOWERS OPERATOR’S MANUAL
The frame is level when all three decks have each of their two pins in approximately the
same position in relation to the slots in the stamped plates which are attached to the
telescopic arms (see fig. 8).
Operating the machine with the hitch set too high or low will reduce float capability of
the decks and could result in scalping or an uneven cut.
If the front position is down and the rear position is up then the tractor hitch point is too
low. If the front position is up and the rear position is down then the tractor hitch point is
too high.
Before beginning work, ensure that all decks are level. Ensure the mower is adjusted by
using one of the six positions available (see fig. 6) on the front hitch of the Flex tongue
so that it will operate level on the ground surface11.
An additional adjustment on the carrier can be obtained with the transport tire system.
The wheel axle mounting bracket comes with 8 holes, 4 for the upper position and 4 for
the lower position. These 2 positions, along with the 6 different tongue positions give 12
different adjustment possibilities.
When the mounting brackets are in the upper position, the tongue rises. With the bolts
in the lower position, the tongue is lowered.
Raising the Mower Decks and the Automatic Lock Up System
To lock the mower decks into a secure position, do the following (see fig. 12):
Raise the three decks by means of the tractor hydraulics until the three locking hooks
(2) ride up over the locking pins (1). Allow the mowers to float back down so the crook
of the locking hooks sit securely over the pins and bracket.
Once the mower decks are raised, it is possible to lock the wings in a 90 degree vertical
position for transport safety. Manually rotate the wing decks, they will pivot on the front
and rear draw bars (12) up enough for the transport lock (11) to be positioned under the
wing arm (3).
Bolt the metal transport brace (13) into the holes in the front draw bars (12) for added
safety when the wing units are in the 90 degree vertical position (see fig. 12).
To lower the mowers, proceed as follows:
Raise the three decks with the tractor hydraulics. When they are fully raised, pull the
cord (10) tied to the unlocking lever (9) (this will pull the hooks away from the pins and
mounting bracket), and lower the decks with the tractor hydraulics. Release the cord
12
once the pins and mounting bracket are past the hooks
.
Before the three springs (7) have stretched to the point that they are unable to maintain
good downward pressure and keep the hooks (2) in place, it is important to move the
hook of the springs to a lower hole (8).
Over time the cords may have stretched. The cords can be tightened by loosening the
nuts on the rope clips, pulling the cords to increase the tension, and re-tightening the
nuts.
11
12
unhooking the three mowing decks.
OPERATION 24 FRONTIER
See Section 3.06 - Attaching to the Tractor, for further details.
In the place of the pull rope (see #10, fig. 12), a hydraulic cylinder is available for automatically
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LEX WING GROOMING MOWERS OPERATOR’S MANUAL
Fig. 12
3.10 - Start Up
WARNING: Never engage the PTO until all three mowers are in the down position
and resting on the ground. Never raise the mowers until all three deck blades
have come to a complete stop. Doing so will cause damage to the driveline yokes
and/or cross and bearings and can create a situation which endangers the
operator or bystanders.
Before engaging the Flex mower, ensure that all twelve mower tires are firmly on the
ground. The two front wheels of the rear mower are locked into a non-swiveling position
to prevent sliding of the mower while operating over a steep lateral hillside (see fig. 13).
OPERATION 25 FRONTIER
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LEX WING GROOMING MOWERS OPERATOR’S MANUAL
With the engine idling, slowly engage the PTO drive. Move the throttle lever until the
PTO speed indicated on the mower is obtained.
The mower is set for a PTO speed of 540 rpm. Shift the transmission to a slow speed
gear and start forward, increase the ground speed by shifting upward until the desired
speed is obtained. Do not mow in reverse unless absolutely necessary and only after
careful observation of the area behind the mower.
Fig. 13
The two front wheels of the rear
mower are locked into a non-swiveling
position to prevent sliding of the mower
while operating over a steep lateral
hillside.
CAUTION: Do not operate this mower at a PTO speed or direction of rotation other
than that shown on the mower. Serious damage can occur to the machine and/or
the operator.
CAUTION: Before mowing check area for stones, branches and other debris that
might be thrown.
Before starting to mow, never forget that the operator is responsible for the following:
1. Safe and correct driving of the tractor and mower.
2. To learn precise, safe operating procedures for both the tractor and the mower.
3. To ensure all maintenance and lubrication has been performed on the mower.
4. To have read and understood all safety aspects for the mower in the operator’s
manual.
5. To have read and understood all safety decals on the mower.
6. Checking the condition of the blades. Worn or damaged blades should be changed
before starting13.
7. Checking to ensure that the cutting edge is the leading edge of the blade.
8. Checking that there is no wire, weed, grass or other material wrapped around
blades.
13
OPERATION 26 FRONTIER
See Section 4.03 - Blade Maintenance, for details.
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LEX WING GROOMING MOWERS OPERATOR’S MANUAL
9. Checking to see if front weights to be added to the tractor in order to maintain
balance.
10.Checking the tractor tires for the proper pressure in accordance with the tractor
operator’s manual.
11.Checking that the PTO shield, belt shields and all other shielding are on the
machine and securely in place.
12.Making sure the proper attire is worn. Avoiding loose fitting clothing which can
become entangled. Wearing sturdy, tough-soled work shoes and protective
equipment for eyes, hands, ears and head. Never operate tractor or implements in
bare feet, sandals or sneakers.
13.Checking area for stones, branches and other debris that might be thrown.
14.Ensuring proper lighting is available, sunlight or good artificial lighting.
15.Checking to ensure the safety chain is properly installed.
16.Safety lighting is visible and is working properly.
3.11 - Working Speed
The mowing speed depends on ground conditions, tractor HP, mowing height and grass
thickness. Only a test run will enable you to gauge the optimal working speed for your
conditions.
Under most conditions a 4 to 7 mph ground speed is best. As a rule of thumb and if the
conditions permit, grass dispersion is increased by higher ground speeds.
In order to obtain the best cut possible, always keep the tractor to 540 rpm. When
increasing or decreasing mowing ground speed, always use gear selection, not engine
speed. This will maintain the constant maximum blade speed necessary for a clean cut.
Fig. 14
The mulching kit is an available
option, consisting in 3
multilevel cutting edge blades
and add-on containment
baffling which bolts to the
underside of the mower deck,
to mulch and pulverize grass
and leaves.
OPERATION 27 FRONTIER
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LEX WING GROOMING MOWERS OPERATOR’S MANUAL
The mulching kit is an option available for our mowers. This kit, containing 3 multilevel
cutting edge blades and add-on containment baffling which bolts to the underside of
each mower deck, mulches and pulverizes grass and leaves.
Another benefit of the mulching kit is safety. In fact, the kit greatly reduces the possibility
of thrown objects. This is particularly important when mowing around schools, public
parks and golf courses. If you are using a mulching kit, you need to reduce your
ground speed to under 2 mph (see fig. 14).
3.12 - Operating Techniques
All of the following factors are important in selecting the proper forward speed:
1. Height of grass.
2. Type of grass.
3. Density of grass.
4. Type of terrain.
5. Grass condition, wet or dry.
6. Type of blades.
This mower has been designed to cut grass with heights from 4” to 8”. It is
recommended to avoid cutting grass taller than 10”. For the best results, try cutting the
grass at least once per week during growing season. Tall, dense grass should be cut at
low speed, while thin medium grass can be cut at a faster ground speed. For cleaner
cuts and efficient mowing, the blades must be kept sharp14.
Always operate PTO at 540 rpm. This is necessary to maintain proper blade speed and
obtain 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. If this occurs reduce the tractor
ground speed but maintain a 540 rpm engine speed. The lower ground speed will permit
the grass to at least partially rebound. Under some conditions grass will not rebound
enough to be cut evenly, resulting in an uneven appearance. In general, lower cutting
height gives a more even cut with less tendency to leave tire tracks. If cut is still not
satisfactory, cut the area twice.
Mow extremely tall grass twice. On the first pass use a high cutting height. On the
second pass position the mower at the desired height and, when practical, mow at a
right angle in travel to the first pass.
Plan your pattern to travel straight forward whenever possible.
It is better to cut grass more often, than too short. Short grass deteriorates rapidly in hot
weather and invites weed growth during growing season.
If at any time the mower should jam resulting in belt slippage of 2 or more seconds,
raise the mower and continue for 2-3 minutes. This will allow the pulleys to cool and
prolong belt life.
Because of the size and high cutting speed of the Flex mower, it is extremely important
that the operator becomes familiar with its width while mowing around trees, buildings,
14
See Sharpening Blades in Section 4.03 - Blade Maintenance.
OPERATION 28 FRONTIER
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LEX WING GROOMING MOWERS OPERATOR’S MANUAL
etc. Since the Flex mower cuts better at higher speeds it is indispensable that the
operator knows the mower before entering into areas where trees, fences, curbs and
other obstacles can be hit.
DANGER: The mower blades can throw objects hundreds of feet which could
result in personal or property damage.
Pick up all rocks and other debris before mowing.
Enter new areas carefully. Cut grass higher at first, allowing mower to clear
hidden objects.
CAUTION: For emergency reasons learn how to stop the tractor and mower
quickly. On the finishing mowers always disengage the PTO, lock parking brake,
stop engine and allow the mower blades to come to a complete stop before
dismounting the tractor.
3.13 - Uneven Terrain
DANGER: Be careful of rollover when operating tractor and mower over uneven
ground.
The following precautions should always be observed when working on uneven terrain:
1. In extremely uneven terrain rear wheel weights, front tractor weights, and/or tire
ballast should be used to improve stability.
2. Observe the type of terrain and develop a safe working pattern.
3. Whenever traction or stability is doubtful, first test drive over the terrain with the PTO
disengaged.
4. Operate the implement up and down steep slopes, not across slopes, to prevent the
tractor from tipping. Avoid sudden stops and starts, and slow down before changing
directions on a slope.
5. Pass diagonally through sharp dips and avoid sharp drops to prevent hanging up the
tractor and implement.
6. Slow down on sharp turns and slopes to prevent tipping or loss of control.
7. Avoid tipping the mower while cutting.
8. Watch for holes, roots or other hidden objects. Do not use near the edge of a gully,
ditch or stream bank.
Anti-scalping rollers are mounted on each deck for uneven ground contours. The
roller rides the nose of the mower over a mound to help keep the nose from
bulldozing or the blades from scalping the ground.
OPERATION 29 FRONTIER
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LEX WING GROOMING MOWERS OPERATOR’S MANUAL
4 - MAINTENANCE
DANGER: Raise the three mower decks with the tractor hydraulics. Be sure all
three automatic locking hooks are securely in place. Place the wing units in their
90 degree vertical position with the transport locks (see #11, fig. 12).
Stop the engine, lock parking brake and remove key and bolt on the transport
brace (see #13, fig. 12). Never rely on the hydraulics alone to support the raised
decks. Always use gloves and safety glasses when performing any maintenance.
Keep fingers out of slots to prevent injury.
4.01 - Maintenance Safety
1. Good maintenance is your responsibility.
2. Keep service area clean and dry. Be sure electrical outlets and tools are properly
grounded. Use adequate light for the job at hand.
3. Make sure there is plenty of ventilation. Never operate the engine of the towing
vehicle in a closed building. The exhaust fumes may cause asphyxiation.
4. Make no repair or adjustments with the tractor engine running. Before working on
the machine, disengage the PTO, shut off the engine, set the brakes, and remove
the ignition key.
5. Be certain all moving parts on attachment have come to a complete stop before
attempting to perform maintenance.
6. Never work under equipment unless it is blocked securely.
7. Never trust the hydraulic pressure alone to maintain the mowers in the raised
position. When servicing the Flex with the mowers in the raised positions always lock
the wings with the three automatic locking hooks and bolt the transport brace (see
fig. 12).
8. Always use personal protection devices such as eye, hand and hearing protectors,
when performing any service or maintenance.
9. Frequently check mower blades. They should be sharp, free of nicks and cracks and
securely fastened.
10.Periodically tighten all bolts, nuts and screws and check that all cotter pins are
properly installed to ensure unit is in a safe condition.
11.Remove hydraulic pressure prior to doing any maintenance.
12. Never use your hands to locate a hydraulic leak on attachment s. Use a small piece
of cardboard or wood. Hydraulic fluid escaping under pressure can penetrate the
skin.
MAINTENANCE 30 FRONTIER
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LEX WING GROOMING MOWERS OPERATOR’S MANUAL
13.When disconnecting hydraulic lines, shut off hydraulic supply and relieve all
hydraulic pressure.
14.Do not attempt to mount a tire unless you have the proper equipment and
experience to do the job.
15. Inflating or servicing tires can be dangerous. Whenever possible, trained personnel
should be called to service and/or mount tires.
16. When completing a maintenance or service function, make sure all safety shields
and devices are installed before placing unit in service.
17.After servicing, be sure all tools, parts and service equipment are removed.
18.Be sure to lock the tractor brake and either lock the wings with the transport brace or
lower the mowers to the ground when completing work.
19. Never replace hex bolts with less than grade five bolts unless otherwise specified,
15
i.e., shear bolts
.
20.Where replacement parts are necessary for periodic maintenance and servicing,
genuine replacement parts must be used to restore your equipment to original
specifications. The company will not claim responsibility for use of unapproved parts
and/or accessories and other damages as a result of their use.
21. Unauthorized modifications to the machine may impair the function and/or safety of
the machine and reduce its life. If equipment has been altered in any way from
original design, the manufacturer does not accept any liability for injury or warranty.
4.02 - Service
The accompanying illustrations show lubrication points. The chart gives the frequency of
lubrication in hours, based on normal operating conditions. Severe or unusual
conditions may require more frequent lubrication.
Use a good quality SAE multipurpose type grease for all locations shown. Be sure to
clean fittings thoroughly before using grease gun.
Use 90 wt. or 140 wt. gear oil in gearboxes.
Hourly:
1. Check the condition of mower blades for nicks or dull edges. Sharpen if necessary.
2. Replace bent or damaged blades16.
3. Also check blades for damage after hitting an obstruction.
4. Clean foreign material from mower deck and belt area.
Every 8 hours:
1. Lubricate drivelines, lubricate caster wheels, wheel yokes and frame pivot
points; apply two or three shots of grease to the driveline cross and bearings and
the telescoping shafts; apply the same amount to the wheel arm grease fittings, the
wheel grease fittings (see fig. 16) and the frame grease fittings (see fig. 15, #1-10
for lubrication points). See the driveline manufacturer operator’s manual for further
information on the drivelines.
15
16
MAINTENANCE 31 FRONTIER
Refer to Table 1 - Torque Specifications, for head identification marking, page 41.
See Removing Blades in Section 4.03 - Blade Maintenance, for details.
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LEX WING GROOMING MOWERS OPERATOR’S MANUAL
2. Gearbox oil level; check gearboxes’ oil level, it should be between ½ and 2/3 full. If
needed add either
SAE 90 wt. or SAE 140 wt. gear oil.
Fig. 15
Grease points on
Flex frame.
Every 25 hours:
Check hardware tightness; mower vibration can loosen bolts17. Check tightness of the
hardware periodically, using Table 1 as a guide.
17
MAINTENANCE 32 FRONTIER
Table 1 gives the correct torque values for various bolts and nuts, page 41.
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LEX WING GROOMING MOWERS OPERATOR’S MANUAL
Every 50 hours:
1. Lubricate the nine spindles with two or three shots of multipurpose grease (see fig.
17). The top grease fittings are easily accessible from the top of the deck by simply
removing the plastic dust guards.
2. Check belt tension18.
3. Grease the main drive shaft carrier bearing (see #1, fig. 15).
Fig. 16 - Lubrication of wheel yokes and caster wheels.
Every 250 hours or at least once a year:
Hand pack with fresh grease the main carrier wheel bearings on the Flex frame (see #4
and #7, fig. 15).
Fig. 17
Lubrication of the spindle shafts easily
accessible from the top of the deck.
18
MAINTENANCE 33 FRONTIER
See Section 4.04 - Belt Tension, for details.
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LEX WING GROOMING MOWERS OPERATOR’S MANUAL
4.03 - Blade Maintenance
WARNING: To avoid possible injury always wear proper eye and hand protection
when servicing mower blade.
In order for the mower to work properly, and to always obtain a precision cut with lower
HP requirements thus keeping cost down, proper blade maintenance is important.
Blades must be kept sharp, at their original length and corners maintained. A blade
must be replaced if, due to wear or damage, its original shape has been distorted.
1
2
3
5
7
8
Fig. 18 - Spindle assembly.
1. grease fitting
2. hexagonal nut
3. pulley
4. rotor support
5. cover
6. shaft
6
9
7. blade
Ground
8. cup washer
9. blade bolt
10. cutting edge close to ground
11. lift wing
4
11
10
Installing or removing blades
If the mower blades need to be installed, do the following:
1. The blade turns in a counter clockwise direction when viewed from the bottom of
the deck. The cutting edge must be towards the direction of rotation. The lift wing of
the blades is closest to the deck and the cutting edge away from it (see fig. 18).
MAINTENANCE 34 FRONTIER
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LEX WING GROOMING MOWERS OPERATOR’S MANUAL
2. Install the cup washer (see fig. 18) over the blade bolt and secure the blade in place
as described above.
3. With a wrench, block the spindle and tighten the bolt to 103 lb. ft. (see fig. 19).
4. To remove the blades reverse the procedure.
WARNING: Do not substitute blades or any bolt for the blade retaining bolt.
Company blades and blade retaining bolts are specially made for this application.
Using non original parts can effect the quality of cut and may also cause damage
to the mower.
1
2
Fig. 19
3
1. spindle
2. blade
3. blade bolt
DANGER: Proper torque must be used when tightening the blade retaining bolt. If
these safety precautions are not followed, the blade could come off during
operation and be thrown hundreds of feet from the mower.
Sharpening blades
Blade sharpening is extremely important in order to get the best cutting results. Sharp
blades permit a high quality cut and also reduce HP thus lowering cost.
To sharpen blades, first remove them following the above instructions.
Place the blade in a vise and sharpen them by using a hand file or grinder. Do not
sharpen the blades to a sharp cutting edge. The cutting edge should be between
1
/64”
to 1/32” to prevent excessive pitting and dulling of the blades. Sharpen both ends of the
blade equally for balance and always maintain corners. Always keep all three blades
sharpened equally in order to maintain balance.
MAINTENANCE 35 FRONTIER
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LEX WING GROOMING MOWERS OPERATOR’S MANUAL
CAUTION: Unbalanced or warped blades can cause damage to the mower and/or
personal injury. Replace damaged blades before operating the mower. Sharpen
both ends of the mower blades equally or until the blade is balanced.
4.04 - Belt Tension
Fig. 20
The belt deflection should be
between 5/16"-3/8".
Belt tension control
Check the belt tension (see fig. 20) by applying a force of 12-15 lb. pushing against the
belt halfway between the pulleys. The belt deflection should be between 5/16”-3/8”.
1
3
Fig. 21
1. adjustment bolt
2. gearbox support plate
2
3. gearbox
MAINTENANCE 36 FRONTIER
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LEX WING GROOMING MOWERS OPERATOR’S MANUAL
Belt tension adjustment
To adjust the tension do the following (see fig. 21):
1. Remove belt shields. Clean foreign material from the mower deck and belt area.
2. Loosen the four nuts holding the gearbox support plate to the central plate.
3. Loosen the two blocking nuts on the adjustment bolt.
4. Turn the adjustment bolt clockwise until the proper belt tension is reached. This will
draw the gearbox support plate to the rear, thus tightening the belts.
5. Tighten the two blocking nuts on the adjustment bolt.
6. Retighten the four nuts holding the gearbox support to the central plate.
7. Reinstall the belt shields.
4.05 - Belt Replacement
If the belts have been stretched or damaged to the point where the proper tension
cannot be obtained they must be changed.
2
5
3
4
3
Fig. 22
1. drive pulley
2. central pulley
1
3. lateral pulleys
4. right belt
5. left belt
To replace belts do the following:
1. Remove belt shields. Clean foreign material from the mower deck and belt area.
2. Loosen the four nuts holding the gearbox support plate to the central plate.
3. Loosen the two blocking nuts on the adjustment bolt.
4. Turn the adjustment bolt counter clockwise, pushing the gearbox support plate
forward until all tension is released (see fig. 21).
5. Loosen rear nuts holding central plate (do not remove them).
6. Remove front nuts holding central plate.
7. Lift the front of the central plate and remove old belts.
8. Replace new belts (see fig. 22). Loop the first belt over the left spindle and around
the lower groove of the center spindle pulley and the lower groove of the gearbox
drive pulley. The second belt connects the upper grooves of the center spindle
pulley and the gearbox drive pulley with the right spindle pulley.
9. Lower central plate.
MAINTENANCE 37 FRONTIER
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LEX WING GROOMING MOWERS OPERATOR’S MANUAL
10.Replace front nuts. Tighten front and rear nuts holding down central plate.
11. Turn the adjustment bolt clockwise until the proper belt tension is reached. This will
draw the gearbox support plate to the rear, thus tightening the belts.
12.Tighten the two blocking nuts on the adjustment bolt.
13.Retighten the four nuts holding the gearbox support to the central plate and replace
the belt shields.
4.06 - Drivelines and Center Gearbox Timing
DANGER: Only use the original drivelines supplied with this mower and always
with the safety shielding in place. Carefully read and file away the driveline
operator’s manual supplied by the manufacturer. The following does not
substitute the information found in the driveline manual.
Your Flex mower drivelines for the decks are cut to fit in order to deliver a maximum
overlap when extended and without them bottoming out and damaging the mowers
when the Flex is folded into its transport position. It is important to try and maintain
approximately 2” from the two halves from bottoming out and a minimum of 6” overlap in
the working position (see fig. 23).
Fig. 23
min. 6"
MAX.
min. 2"
MIN.
IMPORTANT: If the wing mowers are moved in or out to change the overlap, or
the drivelines are replaced with new ones, it is important to cut them to the
proper length.
To determine the correct length do the following:
1. Separate the two driveline halves. Connect one half to the center splitter gearbox
and the other half to the mower gearbox.
MAINTENANCE 38 FRONTIER
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LEX WING GROOMING MOWERS OPERATOR’S MANUAL
2. Raise the mowers slowly with the hydraulics to the transport position. Hold the half
shafts side by side and mark the desired length on the outer female tube guard
leaving a 2” gap between the end of the guard tube and bell guard.
3. Cut off both guard tubes the same amount as marked in step 2.
4. Shorten both drive tubes to the same amount as guard tubes.
5. De-burr and clean filings from drive tubes and apply grease to outside of inner
telescoping tube.
6. Reassemble the driveline halves. Raise and lower mowers again slowly to be sure
drivelines do not bottom out in the shortest position.
7. Install both driveline safety chains.
If for any reason, such as when lubricating driveline sections, the wing unit
drivelines are detached from the main center gearbox, extreme care must be used
when reattaching to maintain the two side gearbox output shafts in a “timed”
position. A “timed” position is a position where both the left and right wing
universals are almost in line and allows the wings to fold up together in unison. If
they are aligned at 90 degrees from one another, only one can fold up and the
other yoke will be damaged by the hydraulics.
Tip: To accomplish this, make a mark on the center gearbox and on the driveline yoke
before removing the left and right drivelines. When reattaching the drivelines be sure
that these marks line up.
4.07 - Transport
CAUTION: Comply with state and local laws governing safety and movement of
farm machinery on public roads. When driving the tractor and equipment on the
road under 20 mph, at night or during the day, use flashing amber warning lights
and a Slow Moving Vehicle (SMV) identification emblem. Do not exceed 20 mph.
Reduce speed on rough roads and surfaces. Always install transport locks before
transporting the mower. Drive tractor and mower safely. Do not drink and drive.
Stop the tractor, leave the engine running and disengage the tractor PTO. Be sure the
blades have come to a complete stop before continuing. Set the parking brake.
Raise the three decks by means of the tractor’s hydraulics until the three locking hooks
ride up over the locking pins and rear mounting bracket. Allow the mowers to float back
down so the crook of the locking hooks sit securely over the pins and bracket. Only
transport very short distances this way. Do not trust the hydraulics alone except for
extremely short distances, such as between trees, over bridges, etc. and only when you
are sure no bystanders are near.
To transport over extended distances, the wing units should be secured in place with
the transport brace provided (see #13, fig. 12). This will keep the wing units in a vertical
position and cut down dramatically on the transport width.
MAINTENANCE 39 FRONTIER
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LEX WING GROOMING MOWERS OPERATOR’S MANUAL
The transport tires are not for highway use. Transportation for other than a very short
distance should be done with a trailer. When transporting the Flex mower, maintain a
safe speed and slow down when approaching turns.
4.08 - Storage
CAUTION: Following operation, or when unhooking, stop the tractor, set the
brakes, disengage the PTO, shut off the engine and remove the ignition key. Store
the unit in an area away from human activity. Do not permit children to play on or
around the stored unit. Make sure all parked machines are on a hard, level
surface and engage all safety devices.
After seasonal use it is important to perform the following for prolonged storage:
1. Raise the mowers and lock them in place with the hooks and if possible the transport
braces.
2. Wash the mower carefully.
3. Inspect the mower and replace worn or damaged parts.
4. Tighten all hardware. Grease all areas indicated under maintenance.
5. Loosen the belts if the mower is to be stored for an extended length of time.
6. Cover the mower from the elements in order to have it in perfect condition for the
start of the next season.
MAINTENANCE 40 FRONTIER
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LEX WING GROOMING MOWERS OPERATOR’S MANUAL
TABLE 1 - TORQUE SPECIFICATIONS
Metric (ISO)
treaded
bolts head
marking
Bolt
Thread
size
mm
When using lock washers with nuts, increase torque values by 5%.
mm
0.8M5
1M6
1.25M8
1M8
1.5M10
1.25M10
1M10
1.75M12
1.5M12
1.25M12
2M14
1.5M14
2M16
1.5M16
2.5M18
2M18
1.5M18
2.5M20
1.5M20
2.5M22
1.5M22
3M24
2M24
3M27
2M27
3.5M30
2M30
4M36
Class 8.8Class 5.8
Class 10.9
ft-lbN.mft-lbN.mft-lbN.m
794634
111571046
273618251216
283819261317
527135482331
557538512433
587839532635
9112362844054
9412864874156
9813366904459
144195981336284
1542091051426994
22330215220697131
236320161218104141
310421218295133181
327443229311145196
343465241327150203
437592306415189256
476646335454212288
595807418567254344
644873452613281381
7501017526714327444
8081095567769360488
110314967741050484656
117615948251119530719
1499203310471420668906
16592250118016007381000
260735351830248211311534
Inch (SAE)
treaded
bolts head
marking
Thread
Bolt
inch
size
inch
tpi
201/4”
281/4”
185/16”
245/16”
163/8”
243/8”
147/16”
207/16”
131/2”
201/2”
129/16”
189/16”
115/8”
185/8”
103/4”
163/4”
97/8”
147/8”
81”
121”
71-1/8”
121-1/8”
71-1/4”
121-1/4”
61-3/8”
121-3/8”
61-1/2”
121-1/2”
Grade 8Grade 5Grade 2
ft-lbN.mft-lbN.mft-lbN.m
121681157
1419101368
253317241115
273719261317
445931422027
496735472331
709549673243
7810655753648
106144751024866
120163851155575
1542081091477095
17123212116479106
21228715020397132
240325170230110149
376509266361172233
420569297403192261
606822430582167226
668906473642184249
9091232644873250339
9951348704955273371
128817467941077354480
144519588911208397539
1817246311201519500677
2012272812411682553750
2382323014691992655888
27123677167322687461011
31614286194926438691179
35574823219429749781326
TABLE 2 - FLEX WING GROOMING MOWER - TECHNICAL FEATURES
Flex Wing Mower for tractors up to 80 HP, PTO 540 rpm, air tires, CV-PTO.
Cutting
Working
HPModel
width
Transport
width
Transport
height
Weight
lb.
#
Blades
height
# Belts &
Type
# Wheels & Size
MAINTENANCE 41 FRONTIER
Driveline
1
ASAE 6
ASAE 6
ASAE 6th cat.12 - 11”x4” air6 SPBX1” - 5”92947103”100”17’35-80FM2017
3
/8 ”
th
cat.12 - 11”x4” air6 SPBX1” - 5”9269474”91”12’25-80FM2012
th
cat.12 - 11”x4” air6 SPBX1” - 5”9282692”97”15’30-80FM2015
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LEX WING GROOMING MOWERS OPERATOR’S MANUAL
5 - REPAIR PROCEDURES
CAUTION: All repair procedures must be done by authorized dealerships. It is not
recommended that untrained individuals perform any repair work. The following
operations are detailed for qualified personnel only.
5.01 - Gearbox
To remove the gearbox from decks do the following:
1. Remove the belt guards.
2. Loosen the nuts holding the gearbox support plate (see fig. 21).
3. Loosen the nut and turn the bolt in order to push the gearbox forward and release
tension on the belts (see fig. 21).
4. Remove the belts19.
5. Remove the nuts holding the central plate to the frame.
6. Remove the nut holding the pulley to the gearbox pinion shaft. Remove the pulley.
7. Unbolt the nuts holding the gearbox support plate to the central plate (see fig. 21).
Remove gearbox and gearbox support plate.
8. Unbolt the nuts holding the gearbox to the gearbox support plate. Remove the
gearbox.
If it is necessary to replace any part on the inside of the gearbox, it is important to
replace oil seals or gaskets to ensure a tight fit when reassembling.
To replace the gearbox, follow the above instructions in reverse order.
5.02 - Blade Spindle
To remove a blade spindle do the following:
1. Remove the belts20.
2. Remove the nut holding the pulley to the spindle shaft (see fig. 18).
3. Remove the blades
4. Unbolt the bolts holding the rotor support to the mower deck.
5. If necessary remove and replace the bearings from the rotor using presses or
extractors.
6. Reassemble in reverse order ensuring that the nut securing the top pulley (see
fig. 18) is tightened to 118 lb.ft.
19
20
21
See Section 4.05 - Belt Replacement.
See Section 4.05 - Belt Replacement.
See Section 4.03 - Blade Maintenance.
21
.
REPAIR PROCEDURES 42 FRONTIER
F
LEX WING GROOMING MOWERS OPERATOR’S MANUAL
5.03 - Suggested Spare Parts
It is suggested that the following spare parts be kept on hand for the mower at all times
to prevent a minor problem from delaying work.
QuantityDescription
9Blades
9Blade bolts and washers
3 setsBelts
2Wheels
41” Spacers
2½” Spacers
2¼” Spacers
8Cotter pins
REPAIR PROCEDURES 43 FRONTIER
F
LEX WING GROOMING MOWERS OPERATOR’S MANUAL
6 - TROUBLESHOOTING
WARNING: Be sure tractor engine is off, parking brake is locked, and key is
removed before making any adjustments.
SOLUTIONPOSSIBLE CAUSEPROBLEM
Uneven
cutting.
Blades turning
but not cutting.
Belt slippage.
Mower
vibrates.
Grass build up
at exit.
Belts are tight
when installing.
Streaking
conditions in
swath.
Cut grass
windrows.
Cup washer not between blade
and bolt.
Ground speed too fast.
Blades need sharpening.
Caster wheels uneven.
Direction of blades is wrong.
Splitter gearbox mounted in
wrong position.
Lack of tension.
Object clogging mower.
Debris in sheaves.
Object wrapped around blade.
Belt damaged.
Wet grass.
Grass too high.
Tractor rpm too slow.
Ground speed to slow.
Wrong belt size.
Belts installed incorrectly.
Too wet to mow.
Blades cannot cut grass
pressed down by wheels.
Dull blades.
Blades worn down, preventing
overlap.
Mowers not overlapping.
Not enough lift.
Ground speed too slow.
Tractor rpm too low.
Check washer location at all three
spindles.
Shift to lower gear.
Sharpen blades.
Adjust wheel position.
Blade should turn CCW when you
face deck bottom.
Rotate splitter gearbox to proper
position.
Tighten belt.
Remove object.
Clean sheaves.
Remove object.
Replace belt.
Tighten belt.Belt slipping.Belt squeal.
Allow grass to dry.
Raise mower, shift to lower gear,
make two passes over grass. Mow
grass high 1st pass, 2nd pass cut to
desired height.
Increase tractor rpm, check engine
and PTO speeds.
Increase ground speed.
Check belt size.
See Replacing Belts section.
Allow grass to dry.
Maintain engine speed and shift to
lower gear.
Sharpen blades.
Change blades.
Move side mowers in.
Use high lift blades.
Increase ground speed.
Increase tractor rpm, check engine
and PTO speeds.
TROUBLESHOOTING 44 FRONTIER
F
LEX WING GROOMING MOWERS OPERATOR’S MANUAL
7 - PRE-DELIVERY CHECKLIST
To the dealer: Inspect the machine thoroughly after assembly to assure it is
functioning properly before delivering it to the customer. The following checklist
is a reminder of points to cover. Check off each item as it is found satisfactory or
after proper adjustment is made.
Gearbox oil level.
Guards and shield properly fastened.
Lubrication of grease fittings.
All hardware properly tightened.
All decals properly located and readable (see fig. 2).
Blades properly installed, blade bolts and nuts tightened.
Overall condition (touch up scratches, clean and polish).
Test run, check for excessive vibration or overheating of bearings.
Operator’s Manual.
Review the Operator’s Manual with the customer. Explain the following:
Warranty.
Safe operation and service.
Correct machine installation and operation.
Daily and periodic lubrication, maintenance and inspections.
Troubleshooting.
Operational procedures and storage.
Parts and service.
Fill out the Pre-Delivery Checklist and the on-line Warranty Registration form.
Give customer the Operator’s Manual and encourage the customer to read the
manual carefully.
IMPORTANT: The dealer must complete the Warranty Registration, located on the
Frontier website. Warranty claims will be denied if the Warranty Registration has
not been completed.
Model Number: __________ Serial Number: __________
Delivery Date: __________ Dealer’s Signature: __________
PRE-DELIVERY CHECKLIST 45 FRONTIER
Use only original spare parts
All rights reserved. It is unlawful to copy, reprint or use any of the information or details in this manual
without the expressed written permission of the Company. Technical information provided in this
manual is approximate, the Company reserves the right to modify or improve the models shown for
technical or commercial purposes. Pictures in this manual do not necessarily show the machine as
delivered.
Manual 5BP961206B
Date 11/11/2010
Frontier OM 312, 315, 317-FLX (US)
Printed in the USA, December 12, 2010
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