John Deere FM2112, FM2120, FM2117, FM2115 User Manual

OPERATOR’S MANUAL

FLEX WING

GROOMING MOWERS

FM2112 FM2115 FM2117 FM2120

Manual 5BP960382B

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

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

113.01 - Operational Safety

133.02 - Setup and Assembly Instructions

153.03 - Light Kit Installation

173.04 - Cutting Height Adjustment

183.05 - 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 31

314.01 - Maintenance Safety

324.02 - Service

344.03 - Blade Maintenance

364.04 - Belt Tension

384.05 - Belt Replacement

394.06 - Drivelines and Center Gearbox Timing

404.07 - Transport

414.08 - Storage 43

435.01 - Gearbox

435.02 - Blade Spindle

445.03 - 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.

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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.

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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.

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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.

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.

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LEX WING GROOMING MOWERS OPERATOR’S MANUAL

Fig. 2 - Safety decals, main frame; replace immediately if damaged.

4 5

right side

left side

Yellow reflective deca

Red reflective decal

456

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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

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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 20’, 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 Wing grooming mower can be used on tractors with horsepower ranging from 35 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, the 17’ model consists of three 6’ decks and the 20’ model consists of three 7’ 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.

OPERATION 11 FRONTIER

LEX WING GROOMING MOWERS OPERATOR’S 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 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.

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LEX WING GROOMING MOWERS OPERATOR’S MANUAL

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.

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 periodically

. 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.

1 2

See Chapter 4 - Maintenance. See Chapter 7 - Pre-Delivery Checklist.

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LEX WING GROOMING MOWERS OPERATOR’S MANUAL

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.

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.

OPERATION 14 FRONTIER

LEX WING GROOMING MOWERS OPERATOR’S MANUAL

3.03 - Light Kit Installation

The light kit comes standard and contains two lights, two brackets and wiring harness.

Photo A Photo B

Photo C

Photo D Photo E

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).

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

OPERATION 15 FRONTIER

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