John Deere GM1190 User Manual

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OPERATOR’S MANUAL

GM1190

Rear Discharge

Serial Number 1XFGM11XKB0000121 & Above

GROOMING MOWERS

5WPMAN0879 (Rev. 8/5/2011)

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.

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. 2/4/2009)

TABLE OF CONTENTS

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

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

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

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

SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

OWNER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

DEALER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

DEALER CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

PARTS LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

BOLT TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

BOLT SIZE CHART & ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 44

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

LEA EL INSTRUCTIVO!

Si no lee Ingles, pida ayuda a

alguien que si lo lea para que le

traduzca las medidas de seguridad.

5WPMAN0879 (3/18/2011)

Introduction 3

SPECIFICATIONS

WARNING

GM1190

3-Point Hitch Category 1 and 2

Cutting Width 90"

Cutting Height Range 1-1/2" - 7"

Operating Weight with Chain Shielding 1200 lbs

Blade Speed (feet per minute) 17,000

Blade Speed (RPM) 2,074

Blade Spindles 3

Number of Blades 6

Universal Drive Series ASAE Cat. 4

Caster Wheels 13 x 5 x 10 Solid Rib Tire

-or-

13 x 5 x 6 Pneumatic Tire

Tractor PTO Speed RPM 540

Recommended Maximum Tractor Horsepower 75HP

Mower Frame Thickness 5/16"

GENERAL INFORMATION

■ Some illustrations in this manual show the

mower with safety shields removed to provide a better view. The mower should never be operated with any safety shielding removed.

The purpose of this manual is to assist you in operating and maintaining your 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.

The illustrations and data used in this manual were current at the time of printing. However, due to possible inline production changes, your machine may vary slightly in detail. We reserve the right to redesign and change the machines as may be necessary without notification.

Throughout this manual, references are made to right and left directions. These are determined by standing behind the tractor facing the direction of forward travel.

4 Introduction

5WPMAN0879 (3/18/2011)

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.

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

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



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.

 Never allow children or untrained persons to operate equipment.

PREPARATION

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

 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.

 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.

 If equipped with driveline guard tether chains, make sure they are attached to the tractor and

GM1190 SRTemplate (3/22/2011)

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.

 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 system in “locked up” position at all times.

 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 25% 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 a loader. Weigh the tractor and equipment. Do not estimate.

OPERATION

 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).

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

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

It is possible for objects to ricochet

Safety 5

 Keep bystanders away from equipment.

SAFETY RULES

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

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

 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.

 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.

 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.

TRANSPORTATION

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

 Do not operate PTO during transport.

 A minimum 25% 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 a loader. Weigh the tractor and equipment. Do not estimate.

 Do not operate or transport on steep slopes.

 Do not operate or transport equipment while

under the influence of alcohol or drugs.

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

 Never allow riders on power unit or attachment.

MAINTENANCE

 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.

 Do not modify or alter or permit anyone else to modify or alter the equipment or any of its components in any way.

 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.

 Make certain all movement of equipment components has stopped before approaching for service.

 Never go underneath equipment (lowered to the ground or raised) unless it is properly blocked and secured. Never place any part of the body underneath equipment or between moveable parts even when the engine has been turned off. Hydraulic system leak down, hydraulic system failures, mechanical failures, or movement of control levers can cause equipment to drop or rotate unexpectedly and cause severe injury or death. Follow Operator's Manual instructions for working underneath and blocking requirements or have work done by a qualified dealer.

 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

6 Safety

GM1190 SRTemplate (3/22/2011)

installed securely to ensure equipment is in a safe



SAFETY RULES

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

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.

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

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

STORAGE

 Follow manual instructions for storage.

 Keep children and bystanders away from stor-

age area.

GM1190 SRTemplate (3/22/2011)

Safety 7

9 - 5WP57123 9" Red Rear Reflector

SHIELD MISSING

DO NOT OPERATE

PUT SHIELD ON

DANGER

18867--B

6 - 5WP15503

5 - 5WP18867

1 - Serial Number Plate

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

PRODUCT IDENTIFICATION NUMBER

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

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.

SAFETY & INSTRUCTIONAL DECALS

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Replace Immediately If Damaged!

8 Safety

5WPMAN0879 (3/18/2011)

GUARD MISSING.

DO NOT OPERATE.

DANGER

33347E

DANGER

GUARD MISSING.

DO NOT OPERATE.

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

2 - 5WP18865

10 - 5WP1004114

8 - 5WP33347

7 - 5WP18864

3 - 5WP18877

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

1003751-A

11 - 5WP1003751

DO NOT EXCEED PTO SPEED OF

540 RPM

PTO speeds higher than 540 RPM can cause

equipment failure and personal injury.

WARNING

18866-D

4 - 5WP18866

CONTACT CAN CAUSE DEATH

 All driveline guards, tractor and

 Drivelines securely attached at both ends

 Driveline guards that turn freely on

SAFETY & INSTRUCTIONAL DECALS

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

DANGER

ROTATING DRIVELINE

KEEP AWAY!

DO NOT OPERATE WITHOUT -

equipment shields in place

driveline

Replace Immediately If Damaged!

18864-C

If shaft connection is visible, shield is missing. Replace shield before operating equipment.

1004114

18877-C

WARNING

TO AVOID SERIOUS

INJURY OR DEATH:

 Read Operator's Manual (available

from dealer) and follow all safety precautions.

 Keep all shields in place and in good

condition.

 Operate mower from tractor seat only.

 Lower mower, stop engine and remove

key before dismounting tractor.

 Allow no children or untrained persons

to operate equipment.

 Do not transport towed or

semi-mounted units over 20 mph.

FAILURE TO OPERATE SAFELY

5WPMAN0879 (3/18/2011)

CAN RESULT IN

INJURY OR DEATH.

Safety 9

OPERATION

DANGER

WARNING

CAUTION

WARNING

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

This mower is designed for light brush shredding and grass mowing. It is especially useful in cane, berry, grape and vegetable crops for mowing and shredding prunings.

Recommended mowing speed for most conditions is from 2 to 5 mph.

 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).

It is possible for objects to ricochet

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

TRACTOR STABILITY

 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.

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

10 Operation

Figure 1. Tractor Stability

ATTACHING MOWER TO TRACTOR

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

The standard 1-3/8" 6B-spline driveline with a QD yoke is used to connect the mower to the tractor.

5WPMAN0879 (3/18/2011)

Refer to Figure 2

1. Tractor top link A. Mower top link attachment point B. Mower hitch pin

C. Category 2 sleeve D. Lower hitch arm attachment point

E. Mower hitch arm

CM906

Tether Chain

WARNING

1. For Category 1 hitch, position mower hitch arms (E) with offset toward center of mower. For Category 2 hitch, position mower hitch arms (E) with offset toward outside of mower.

2. Attach the mower hitch pins (B) to lower tractor lift arms and secure.

3. Attach tractor top link (1) to mower top link bracket attachment point A. Connect driveline to tractor PTO shaft.

Figure 3. Attaching Mower to Tractor

4. Attach tether chain to tractor drawbar if drive

equipped with chain, (Figure 3).

5. Adjust the tractor lower 3-point arm anti-sway devices to prevent mower from swinging side to side during transport.

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

measuring 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.

5. Retighten cap screws. This equalizes the

clearance in the bolt holes.

6. Adjust front of mower level with or slightly lower than the rear to obtain best mowing results. See Figure 4.

5WPMAN0879 (3/18/2011)

Figure 2. Attachment Points

7. Control cutting height by adjusting front and rear

caster wheels.

8. To raise rear of mower, move caster adjustment spacers under rear caster arms. See Figure 6.

Operation 11

9. To raise front of mower, move spacers under front

Cut

Height

Axle

Position

1/2"

Spacer

3/4"

Spacer

1-1/2" A

2" A1

2-1/2" A1

3" A1 1

3-1/2" A2

4" A1 2

4-1/2" A2 2

5" A22

5-1/2" A122

6" A222

6-1/2" B122

7" B222

Spacers under caster arm pivot

tube

1. Tractor top link A. Mower top link attachment point B. Mower hitch pin

C. Category 2 sleeve D. Lower hitch arm attachment point E. Mower hitch arm

caster wheel arms.

Figure 4. Cutting Height Adjustment

Remember, measurement at location A (Figure 4) should not be less than location B and should not be over 1/2" greater than location B.

TRACTOR TOP LINK ADJUSTMENT

When the cutting height is set, adjust tractor top link until mower top link attachment point (A) is aligned vertically with mower hitch pin (B), Figure 7.

Adjust tractor top link so mower is level between caster wheel and ground (dimension C), Figure 8. This will allow the mower to follow ground contour.

The mower has three lower hitch plate attachment points (D), Figure 7. It may be necessary to change the mower hitch plate attachment point to obtain proper tire clearance and/or lift height.

Figure 6. Height Adjustment with Caster Arm Spacers

12 Operation

Figure 5. Cutting Height Chart

Figure 7. Top Link Adjustment

5WPMAN0879 (3/18/2011)

FRONT CASTER WHEEL INTERFERENCE

CAUTION

WARNING

CHECK

using proper procedure. Inspect and repair any damage before resuming operation.

NOTICE

■ Do not operate tractor and mower until this

interference check has been performed. If you change tractors, you must perform the check for that mounting.

Figure 8. Front Caster Wheel Interference Check

Perform this check with all of the spacers above caster wheel arm. This will place caster wheels in their highest position and provide lowest cutting height for mower.

1. Raise mower with tractor hydraulics to 16" at dimension C or maximum height of tractor lift, whichever is less.

2. Pivot both front caster wheels forward and check that there is clearance between caster wheels and tractor tires.

3. If there is interference adjust mower hitch arm (E) as shown in Figure 7.

Power for operating mower is supplied by tractor PTO. Operate PTO at 540 rpm. Know how to stop tractor and mower quickly in an emergency.

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

1. Maneuver equipment into a previously cut area and allow mower to clear accumulated material.

2. Continue running at least two minutes, allowing pulleys to cool. Stopping the mower in contact with a very hot pulley will bake and ruin belt.

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

Normally, ground speed will range from 2 to 5 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 and leave less 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.

NOTE: If interference continues, see tractor operator's manual and adjust tractor wheels to narrower spacing.

FRONT ROLLER (OPTIONAL)

The caster wheels and side skids effectively reduce scalping in most cases. However, you may encounter areas where the caster wheels and/or side skids drop into depressions and allow center of the mower to contact ground and scalp. An optional front roller may be installed to minimize scalping. See page 31.

OPERATING TECHNIQUE

 Stop power unit and implement immediately upon striking an obstruction. Dismount power unit,

5WPMAN0879 (3/18/2011)

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.

Analyze area to be cut to determine the best procedure. Consider height and type of grass and terrain type: hilly, level, or rough.

Operation 13

Plan your mowing pattern to travel straight forward

WARNING

whenever possible. Mow with uncut grass to the right. This will distribute the clippings over the cut area.

Uneven Terrain

 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.

Pass diagonally through sharp dips and avoid sharp drops to prevent hanging up tractor and mower.

Practice will improve your skills in maneuvering rough terrain.

MOWER REMOVAL & STORAGE

1. Disengage PTO, place tractor and mower on solid,

level surface. Raise mower with 3-point hitch.

2. Place blocks under mower side skids. Lower mower onto blocks.

3. Set parking brake, stop engine and remove key. Disconnect mower driveshaft from tractor PTO.

4. Collapse driveshaft as far as possible and store in driveshaft hanger bracket to prevent ground contact.

5. Disconnect mower from tractor 3-point hitch. Start tractor and carefully drive away from mower.

6. Before extended storage, see page 18 for cleaning instructions.

OWNER PRE-OPERATION CHECK LIST

(OWNER'S RESPONSIBILITY)

___ Review and follow all safety rules and safety

decal instructions on pages 5 to 9.

___ 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.

___ 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 to the tractor and the equipment as instructed.

___ 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” on page

15. Make sure the PTO slip joint is lubricated and that the gearbox fluid levels are correct.

___ Set tractor PTO at 540 rpm.

___ 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.

14 Operation

5WPMAN0879 (3/18/2011)

OWNER SERVICE

WARNING

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.

 Never allow children or untrained persons to operate equipment.

 Keep bystanders away from equipment.

 Before working underneath, carefully read Oper-

ator’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.

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

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

Figure 9. Blocking Method

LUBRICATION INFORMATION

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

Figure 10 shows the lubrication points. The accompanying chart gives the frequency of lubrication in operating hours, based on normal operating conditions.

BLOCKING METHOD

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

Raise mower completely, set tractor brakes, turn engine off, remove key, block tractor wheels front and rear, and disconnect mower driveline from tractor.

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

When blocking, you must consider overall stability of the unit. Just blocking under the unit will not ensure your safety. The working surface must be level and solid to support the loaded weight of the jackstands. Test jackstands stability before working under any portion of the mower.

Severe or unusual conditions may require more frequent lubrication. Some reference numbers have more than one location; be sure you lubricate all locations.

Use a lithium grease of #2 consistency with a MOLY (molybdenum disulfide) additive for all locations. 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 90W gear lube in the gearbox. Fill to plug on side of gearbox.

Check gearbox daily for evidence of leakage at both seals and the gasket between the housing and cover. If leakage is noted, repair immediately. There may be a small amount of lube emitted from the vent plug; this is not considered leakage.

Overfilling the gearbox will cause the excess gear lube to blow out vent plug and ruin the belt.

Driveshaft Lubrication

Lubricate the driveshaft slip joint every 8 operating hours. Failure to maintain proper lubrication could result in damage to U-joints, gearbox, and driveshaft.

1. Lower mower to ground.

2. Apply grease at five locations shown in Figure 10.

3. Raise and lower mower several times to distribute

grease.

5WPMAN0879 (3/18/2011)

Owner Service 15

Figure 10. Lubrication Points & Chart

REF DESCRIPTION FREQUENCY

1 Driveline U-Joints 8 Hours

2 Gearbox (Fill to center of horizontal shaft with SAE 90W gear lube) Check for

leaks daily

3 Caster Wheel (Four Wheels) 8 Hours

4 Caster Pivot (Four Yokes) 8 Hours

5 Slip Joint 8 Hours

6 Shield Bearing 8 Hours

7 Blade Spindles (Access through hole) 8 Hours

16 Owner Service

5WPMAN0879 (3/18/2011)

Figure 11. Belt Routing

WARNING

1. Blade Spindle

2. Blade

3. Blade Pin

4. Blade Lock

5. 1/2NC x 3/4 Nylok Bolt

NOTICE

■ Use care when installing or removing belt from

spring-loaded idler at step 6. Springs store energy when extended and, if released suddenly, can cause personal injury.

7. Adjust belt guide G to provide 1/8" to 3/16"

clearance from belt. Tighten bolt to 85 lbs-ft.

BLADE SERVICE

BELT SERVICE

Belt Replacement

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

1. Check pulley shafts and bearings for wear.

2. Check pulley grooves for cleanliness.

3. Make sure spindles turn freely and without wobble.

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

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

Belt Installation

 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.

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

Blade Removal

1. Remove Nylok bolt (5).

2. Remove blade lock (4) from groove in blade pin.

3. Remove blade (2) and pin (3) from spindle

assembly (1).

1. Disconnect idler spring from deck lug I.

2. Slide belt under drive pulley A and over idler arm.

Position belt around drive pulley A.

3. Route belt around pulley B, idler C and pulley D as shown.

4. Make sure belt is on drive pulley A, route around idler E, and connect idler spring to lug I on deck.

5. Loosen bolt holding belt guide G and swing it away from pulley F.

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

5WPMAN0879 (3/18/2011)

Figure 12. Blade Removal

Owner Service 17

Blade Installation

CAUTION

1. Blade Spindle

2. Blade

3. Blade Pin

4. Blade Lock

5. 1/2NC x 3/4 Nylok Bolt

DANGER

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

1. Always sharpen both blades at the same time to

maintain balance. Follow original sharpening pattern.

2. Do not sharpen blade to a razor edge. Leave at least a 1/16" blunt edge.

3. Do not sharpen back side of blade.

CHAIN SHIELDING

 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).

Check that chain shielding is in good condition and replace any damaged chain links.

It is possible for objects to ricochet

Figure 13. Blade Assembly

1. Install blade pin (3) thru blade (2) and blade

spindle (1).

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

3. Insert blade lock (4) into groove of blade pin (3).

4. Secure lock (4) with Nylok bolt (5).

Blade Sharpening

Figure 14. Blade Sharpening

NOTICE

■ When sharpening blades, grind the same

amount on each blade to maintain balance. Replace blades in pairs. Unbalanced blades will cause excessive vibration, which can damage gearbox bearings. Vibration may also cause structural cracks to cutter.

18 Owner Service

CLEANING

After Each Use

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

crop residue, etc. from machine.

● Inspect machine and replace worn or damaged

parts.

● Replace any safety decals that are missing or not

readable.

Periodically or Before Extended Storage

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

crop residue, etc. from machine.

● Remove the remainder using a low-pressure water

spray.

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

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

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

● Inspect machine and replace worn or damaged

parts.

● Sand down scratches and the edges of areas of

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

● Replace any safety decals that are missing or not

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

5WPMAN0879 (3/18/2011)

TROUBLE SHOOTING

MOWING CONDITIONS

PROBLEM POSSIBLE CAUSE SOLUTION

Grass cut higher in center of swath than at edge

Grass cut lower in center of swath than at edge

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

Height of mower higher at rear than at front

Height of mower lower at rear than at front

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

Dull blades Sharpen or replace blades.

Adjust mower height and attitude so that mower rear and front are within 1/2 inch of same height. See instructions on page 11.

Slow ground speed of tractor but keep engine running at full PTO rpm. Cutting lower will help. Adjust tractor tire spacing if possible.

Material discharges from mower unevenly; bunches of material along swath

Material too high and too much material

Grass wet Allow grass to dry before mowing.

Rear of mower too low, trapping material under mower

Reduce ground speed but maintain 540 rpm at tractor PTO, or make two passes over material. Raise mower for the first pass and lower for the second and cut at 90 degrees to first pass. Raise rear of mower high enough to permit material to discharge, but not so high that conditions listed above occur.

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

Adjust mower height and attitude.

5WPMAN0879 (3/18/2011)

Troubleshooting 19

TROUBLE SHOOTING

BELT CONDITIONS

PROBLEM POSSIBLE CAUSE SOLUTION

Belt slippage Mower overloading; Material too

tall or heavy

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

Belt hung up or rubbing Check belt position in pulleys and

Frayed edges on belt cover Belt misaligned or belt rubbing

guide

Pulley misaligned Inspect to ensure belt is running in

Reduce tractor ground speed but maintain full PTO rpm. Cut material twice, one high pass and then mow at desired height. Cut at 90 degrees to first pass.

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

idlers. Check belt for free travel in pulleys. Check under mower and around blade spindle shaft for wire, rags, or other foreign material. Clean all material from under mower.

Re-align belt. Be sure belt does not rub any other part while running.

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

Damaged belt Rollover, high shock loads or

installation damaged

Belt breakage High shock loads Avoid abusive mowing. Avoid hitting

Belt came off drive Check pulleys for foreign material in

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

or stretched cords) must be replaced.

Replace belt.*

the ground or large obstructions.

grooves. Avoid hitting solid objects or ground.

20 Troubleshooting

5WPMAN0879 (3/18/2011)

NOTES

5WPMAN0879 (3/18/2011)

Troubleshooting 21

DEALER SERVICE

WARNING

CAUTION

5. Spindle Housing

7. Spindle Shaft and Crossbar

8. Blade Lock

9. Blade Pin

10. 1/2NC x 3/4 Nylock HHCS

11. Blade

12. Sheave

13. Bushing

14. Key

15. 1" Lock Washer

16. 1NC Jam Nut

17. Grease Fitting

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

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

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

4. Disassemble split taper bushing (13) (located on

top of pulley) by removing the two bolts and key (14).

5. Insert bolts into the threaded holes of bushing flange.

6. Tighten bolts alternately to remove split taper bushing.

7. Remove pulley (12).

8. Remove bolts that attach spindle to mower frame

and remove spindle.

9. Remove grease fitting (17) from top of shaft.

BLOCKING METHOD

See "Blocking Method" instructions on page 15.

BLADE SPINDLE SERVICE

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

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

Permatex recommended as a sealant.

Spindle Removal

1. Remove blade (11) from spindle (7).

2. Remove belt from pulleys.

3. Remove jam nut (16) and washer (15) from top of

3D Aviation Form-A-Gasket or equivalent is

spindle shaft, Figure 15.

Figure 15. Sheave and Blade Assembly

Spindle Disassembly

1. Place spindle assembly in press and press shaft

down through housing.

2. Remove seals from housing.

3. Remove bearing cups from housing by placing a

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

22 Dealer Service

5WPMAN0879 (3/18/2011)

Figure 16. Spindle Disassembly

3. Seal

5. Spindle Housing

7. Spindle Shaft and Crossbar

2. Sleeve

3. Seal

4. Bearing Cone

5. Spindle Housing

6. Bearing Cup

7. Spindle Shaft & Crossbar

17. Grease fitting

Spindle Assembly

Refer to Figure 17.

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

1. Lubricate new cups (6) with a light oil. Place them in spindle housing (5) so they will mate with bearing cones (4). Cups (6) and cones (4) are a press fit to minimize wear.

Seat cups (6) securely with a press or place a large drift in the flat lip and drive them into housing (5) until cup seats against machined shoulder of housing.

2. Place bottom bearing cone (4) into spindle with taper positioned to mate with cup (6).

NOTICE

■ Improper positioning of seals can cause seal

damage. An improperly installed seal will leak and could cause bearing failure.

3. Identify the open side of the seal (3) containing the

spring.

4. Apply a thin coat of Permatex to the area of housing where seals seat.

5. Install bottom seal (3) with spring up toward center of housing.

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

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

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

9. Insert shaft (7) through bottom of housing (5).

10. Fill housing cavity with a medium grade grease.

11. Install top bearing (4) on shaft (7) to mate with top

cone (6).

12. Apply a thin coat of Permatex to shaft area where sleeve will seat.

13. Install sleeve (2) on shaft and press sleeve and bearing into housing until all free play is removed and there is a very light drag on bearings (similar to adjusting front wheel bearings on an automobile). Check by spinning spindle. It should turn freely.

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

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

16. Carefully press top seal (3) in with spring up. Top seal should be flush with or to within 1/16" above the housing.

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

18. Install grease fitting (17) in spindle shaft.

Figure 17. Spindle and Shaft Assembly

5WPMAN0879 (3/18/2011)

Spindle Installation

NOTICE

■ Pulley installation sequence is very important

for bearing life. Follow the sequence exactly.

1. Install spindle through bottom of mower and secure

with four mounting bolts.

Dealer Service 23

2. Install pulley (12) and split taper bushing (13) with

1. Crown gear

2. Gearbox housing

3. Input shaft

4. Output shaft

5. Gear pinion

6. Bearing

7. Bearing

8. Protective flat washer

9. Cotter pin

10. Snap ring

11. Snap ring

12. Spacer

13. Shim

14. Castle nut

15. Castle nut M24 x 2

16. Shim

17. Flat washer

18. Oil seal (40 x 80 x 12 mm)

19. Oil seal (35 x 72 x 10 mm)

20. Cap

21. Snap ring

22. Top cover

23. Bolt M8 x 14 mm

24. Breather level plug

25. Cotter pin

26. Bearing

27. Ball bearing

integral key (14) on spindle shaft. Make sure bushing is in contact with sleeve on spindle shaft.

3. Alternately tighten split taper bushing cap screws to 20 lbs-ft.

4. Install lock washer and nut on spindle shaft. Tighten nut until snug, but do not over-tighten. Check shaft to make sure it spins freely..

GEARBOX REPAIR

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

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

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

Inspect gearbox for leakage and bad bearings.

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

Figure 18. Gearbox Assembly

24 Dealer Service

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

Seal Replacement

Recommended sealant for gearbox repair is Perma-

tex

Aviation 3D Form-A-Gasket or equivalent.

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

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

Seal Installation

NOTE: Proper seal installation is important. An improp-

erly installed seal will leak.

5WPMAN0879 (3/18/2011)

1. Clean area in housing where seal outer diameter

1. Seal

2. Pipe or tube

3. Seal seat

4. Casting

Pipe or tube must press at outer

edge of

Incorrect Installation

7. 5/8NC x 1-3/4 Flange HHCS

8. 5/8NC Flange Lock Nut

9. M8 x 1.25P x 16mm HHCS

11. 5/16 Flat Washer

12. 1/4 x 1/4 x 1-1/4 Key

13. 25 x 44 x 4mm Flat Washer

14. M24 x 2 Castle Nut

15. 3/16 x 2 Cotter Pin

1. Gearbox

2. Vent Plug

3. Gearbox Stand

4. Sheave

5. Shield

6. 1/2NC X 2 HHCS

(OD) seats. Apply a thin coat of Permatex.

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

3. Lubricate gear shaft and seal lips.

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

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

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

3. If the leak occurred at either end of horizontal shaft, remove oil cap (20) and/or oil seal (19). Replace with new one (see Seal Replacement, page 24).

Horizontal seal should be pressed flush with outside of housing.

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

Gearbox Removal from Mower

Refer to Figure 20.

Figure 19. Seal Installation

Vertical Shaft Seal Replacement

1. Disconnect and remove the driveline from the

gearbox.

2. Remove vent plug (24). Figure 18, and siphon gear lube from housing through this opening.

3. Remove gearbox stand from mower deck.

4. Remove gearbox and pulley from gearbox stand.

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

seal (see Seal Replacement, page 24).

Vertical seal should be recessed in housing.

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

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

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

Horizontal Shaft Seal Replacement

1. Disconnect and remove the driveline from the

gearbox.

2. Remove vent plug (24), Figure 18, and siphon gear lube from housing through this opening.

5WPMAN0879 (3/18/2011)

Figure 20. Gearbox Stand Assembly

1. Disconnect and remove the driveline from the

gearbox (1).

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

3. Remove gearbox stand (3) from mower deck rails by removing four cap screws (6).

Dealer Service 25

4. Remove four cap screws (9), flat washer (11), and remove shield (5) from gearbox.

5. Remove castle nut (14) and hardware from output shaft of gearbox.

6. Remove sheave (4) from gearbox.

7. Remove four bolts (9) that attach gearbox to

gearbox stand and remove gearbox.

Gearbox Disassembly

Refer to Figure 18.

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

gearbox upside down and pour out remaining gear oil from gearbox.

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

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

shaft (3).

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

5. Remove gear (1) from inside housing.

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

replaced).

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

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

9. Support housing in vise in a horizontal position.

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

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

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

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

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

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

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

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

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

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

Gearbox Reassembly

Refer to Figure 18.

NOTE: Repair to this gearbox is limited to replacing

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

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

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

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

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

26) until it rests against bearing (6).

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

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

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

7. Apply grease to lower seal lips (18) and press seal over output shaft (4), using a tube of the correct diameter. Be sure not to damage the seal lip. Press in housing so that seal is recessed.

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

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

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

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

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

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

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

15. Check input shaft end float by moving the input shaft (3) by hand. If end float is higher than 0.012”, insert shim between input shaft (3) and rear bearing (7). Repeat until end float is less than

0.012”. Check rotational torque by hand. The torque should be less than 2.2 lbs-inch.

26 Dealer Service

5WPMAN0879 (3/18/2011)

16. Check that the gear backlash is between 0.006”

1. Yoke

2. Cup and bearings

3. Snap ring

4. Journal cross

and 0.016”. You should not have to adjust the backlash.

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

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

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

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

UNIVERSAL JOINT REPAIR

Gearbox Installation

NOTE: Gearbox is heavy: do not attempt to move with-

out mechanical assistance.

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

2. Attach drive sheave to output shaft. Secure using castle nut and hardware previously removed. Torque castle nut to 170 lbs-ft.

3. Attach gearbox stand to mower using four flanged 1/2" cap screws.

Drive Sheave Installation

Refer to Figure 21.

1. When gear stand is installed on mower, the

distance from the top of the mower deck to the center line of the lower groove on the drive pulley must be 2-21/32" (±1/32"). This is a critical dimension and must be carefully adjusted for proper belt life.

2. Tighten gear stand hardware.

3. Fill gearbox half full with SAE 90W gear lube.

4. Check level after waiting five minutes to permit

lube to work through bearings. Add lube, if necessary, until gearbox is half full.

5. Replace driveline shield. Attach driveline to gearbox.

Figure 22. U-Joint Exploded View

U-Joint Disassembly

1. Remove external snap rings from yokes in four

locations as shown in Figure 23.

Figure 23

5WPMAN0879 (3/18/2011)

Figure 21. Drive Sheave Installation

Figure 24

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

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

Dealer Service 27

3. Clamp cup in vise as shown in Figure 25 and tap on yoke to completely remove cup from yoke. Repeat Step 2 and Step 3 for opposite cup.

Figure 25

final removal. Drive remaining cup out with a drift and hammer.

U-Joint Assembly

1. Place seals securely on bearing cups. Insert cup

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

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

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

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

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

Figure 26

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

and tap on yoke to remove cup. Repeat Step 3 for

28 Dealer Service

Figure 27

5WPMAN0879 (3/18/2011)

ASSEMBLY INSTRUCTIONS

WARNING

CAUTION

1. Wood Blocks

2. Chain Shielding

3. Rear Shipping Bracket

4. Front Shipping Bracket

5. PTO Hanger

6. Diagonal Brace

7. A-Frame Bar

8. U-Link

9. Sleeve

10. Caster Arms

11. Hitch Arm s

12. 1/2 NC x 1-1/2 HHCS

13. 1/2 NC x 4 HHCS

14. 1/2 NC x 6-1/2 HHCS

15. 1/2 NC Flange Lock Nut

16. 5/8 NC x 3-1/2 HHCS

17. 5/8 NC Flange Lock Nut

DEALER SET-UP INSTRUCTIONS

Assembly of this mower is the responsibility of the Frontier dealer. If should be delivered to the owner completely assembled, lubricated, and adjusted for normal cutting conditions.

Complete Dealer Check Lists on page 33 when you have completed the assembly.

The mower is shipped partially assembled. Assembly will be easier if components are aligned and loosely assembled before tightening hardware. Recommended torque values for hardware are located on page 43.

Select a suitable working area. Open parts boxes and lay out parts and hardware to make location easy. Refer to illustrations, accompanying text, parts lists and exploded view drawings.

Figure 28. Shipping Unit

Disassemble Shipping Unit (Figure 28)

1. Remove all parts that are wired and strapped to

mower.

2. Remove wood blocks (1) and chain shielding (2) attached to front of mower. Discard blocks.

3. Remove cap screws (12) and lock nuts (15) from rear shipping bracket (3). Discard bracket.

4. Remove cap screw (14) and lock nuts (15) from front shipping bracket (4). Discard bracket and

5WPMAN0879 (3/18/2011)

replace hardware through PTO hanger (5), diagonal braces (6), A-frame bars (7), U-link (8) and sleeve (9). Do not over tighten lock nut against the PTO hanger. PTO hanger should rotate freely.

Install Front Casters (Figure 28)

1. Remove cap screws (13) and lock nuts (15) from

outer caster arms (10).

2. Place arms inside of pockets in front corners of deck. Replace hardware.

Assembly 29

Torque Caster Arms

1. Tractor top link A. Mower top link attachment point B. Mower hitch pin C. Category 2 sleeve D. Lower hitch arm attachment point E. Mower hitch arm

A. Gearbox input shaft B. Locking collar

C. Anti-rotation chain

1. Gearbox

2. Shield

3. Driveline

4. Washer, flat standard 5/16

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

Install Driveshaft

1. Place mower on a hard level surface.

2. Loosen cap screws and lock nuts on all four caster

wheel arms. This allows clearance in the caster wheel assemblies to be equalized.

3. Torque all cap screws and nuts to 85 lbs-ft.

Install Hitch Arms

1. Remove cap screws, lock nuts and hitch arms (E)

from lower hitch arm attachment point (D).

2. Position arms according to Figure 29 and replace hardware.

1. Pull locking collar (B) back and, at the same time, push driveline onto gearbox shaft until locking device engages.

2. Rotate PTO hanger forward. Rest driveline on PTO hanger.

3. If so equipped, hook anti-rotation chain (C) on shield (2).

30 Assembly

Figure 29. Hitch Arm Installation

Figure 30. Driveshaft Installation

Fill Gearbox

NOTICE

■ Gearbox is not filled at the factory. Prior to

delivery, make sure each gearbox is filled half-full with 80W or 90W API GL-4 or GL-5 gear lube.

1. Make sure vent plug hole is clear. Fill gearbox half-

full with high quality gear oil that has a viscosity index of 80W or 90W and an API service rating of GL-4 or GL-5.

2. Fill gearbox until oil runs out the side plug on gearbox.

3. Pour in one pint of gear lube, wait five minutes and add additional gear lube until it just comes out of side hole.

4. Allow an additional five minutes for the lube to flow through bearings, then check to make sure oil level is at bottom of side hole. Replace side plug. Install vent plug.

5WPMAN0879 (3/18/2011)

Figure 31. Chain Shield Installation

1. Front chain shield plate

2. Rear corner chain shield plate

3. Left corner chain shield plate

4. Right rear chain shield plate

5. Left rear chain shield plate

6. 1/4 Chain - 3 link

7. 1/4 Chain - 4 link

8. Pin, 28 to 30 Chains

9. Pin, 7 to 9 Chains

10. Pin 40 to 42 Chains

11. 3/8 NC x 1 Carriage Bolt

12. 3/8 NC Flange Lock Nut

DANGER

1. Roller Bracket

2. Roller

3. Spacer

4. Bearing

5. 1/2 NC x 9 HHCS

6. 1/2 SAE Flat Washer

7. 1/2 NC Flange Lock Nut

8. 3/8 NC Carriage Bolt

9. 3/8 NC Flange Lock Nut

Install Chain Shielding

 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).

1. Install front and rear chain shields with hardware

shown.

Install Front Roller (Optional)

1. Remove center belt shield from mower.

2. Insert four carriage bolts (8) through top of deck

plate.

5WPMAN0879 (3/18/2011)

It is possible for objects to ricochet

3. Place roller bracket (1) over bolts; then install

flange lock nuts (9) on bolts and tighten.

4. Place front roller (2), two bearings (4), spacer (3) and two SAE flat washers (6) between roller bracket as shown in Figure 32.

5. Insert cap screw (5) through bracket and roller.

6. Secure with flanged lock nut (7). Do not

overtighten, roller must spin freely.

Figure 32. Front Roller Installation

Assembly 31

1. A-Frame Arm

2. Sleeve, .94 x 1.44 x 2.75 (Cat 2 Only)

3. Sleeve, .94 x 1.44 x 1.94 (Cat 1 Only)

4. Sleeve, .81 x 1.25 x 2.12

5. Sleeve, .88 x 1-1/8 x 19/32

6. 3/4 Flat Washer

7. 3/4 NC x 5-1/2 HHCS GR5

8. 3/4 NC Hex Nut

9. 1/2 Flat Washer

10. 1/2 NC x 6 HHCS

11. 1/2 NC x 2 HHCS

12. 3/8 Chain, 38-Link

Install Quick Hitch (Optional)

NOTE: This kit allows mower to fit Category 1 or

Category 2 standard quick hitches.

1. Lower hitch arms must be located in center attachment hole. See Figure 33 for adjustment.

2. For use with Category 1 quick hitch, lower hitch arms should be positioned with offset toward inside of mower. For use with Category 2 quick hitch, lower hitch arms should be positioned with offset toward outside of the mower.

3. Remove clevis pins from lower hitch arms. Pins will not be used for quick hitch.

4. Attach A-Frame arms (1) and sleeve (2) to lower hitch arms using cap screws (7), sleeve (5), washers (6) and hex nut (8).

Figure 33. Quick Hitch Kit Installation (Optional)

5. Attach upper end of A-Frame arms (1) and sleeve

(4) to U-bracket, using cap screw (7), washers (6) and hex nut (8).

6. Remove rear offset links. They will be replaced with chains (12).

7. Attach chains (12) to top of A-frame on both sides as shown, using cap screw (10), washers (9), and flange lock nut.

8. Attach opposite ends of chains (12) to rear mower frame using cap screws (11), washers (9), and flange lock nut. Vary length slightly as desired. Twist chain to make finite adjustments in length until unit lifts level.

9. Tighten all hardware.

32 Assembly

5WPMAN0879 (3/18/2011)

DEALER CHECK LISTS

PRE-DELIVERY CHECK LIST

(DEALER’S RESPONSIBILITY)

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

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

___ Check that all safety decals are installed and in

good condition. Replace if damaged.

___ Check that shields and guards are properly

installed and in good condition. Replace if damaged.

DELIVERY CHECK LIST

(DEALER’S RESPONSIBILITY)

___ Show customer how to make adjustments and

select proper PTO speed.

___ Instruct customer how to lubricate and explain

importance of lubrication.

___ Point out the safety decals. Explain their mean-

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

___ Present Operator's Manual and request that

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

___ Show customer how to make sure driveline is

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

___ Show customer the safe, proper procedures to

be used when mounting, dismounting, and storing equipment.

___ Check all bolts to be sure they are properly

torqued.

___ Check that all cotter pins and safety pins are

properly installed. Replace if damaged.

___ Check and grease all lubrication points as iden-

tified in “Lubrication Information” on page 15.”

___ Gearboxes are not filled at the factory. Prior to

delivery, fill as specified in the “Owner Service, lubrication information” on page 15 and check to see that there are no leaking seals.

___ Check that blades have been properly installed.

___ Explain to customer the potential crushing haz-

ards of going underneath raised equipment. Instruct that before going underneath to disconnect the driveline, securely block up all corners with jack-stands and to follow all instructions in the “Owner Service, Blocking Methods” section of the Operator’s Manual. Explain that blocking up prevents equipment dropping from hydraulic leak down, hydraulic system failures or mechanical component failures.

___ For mounted units, add wheel weights, ballast in

front tires, and/or front tractor weight to enhance front end stability. A minimum 20% of tractor and equipment gross weight must be on front tractor wheels. When adding weight to attain 20% of tractor and equipment weight on front tractor wheels, you must not exceed the ROPS weight certification. Weigh the tractor and equipment. Do not estimate!

___ Make customer aware of optional equipment

available so that customer can make proper choices as required.

___ Point out all guards and shields. Explain their

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

5WPMAN0879 (3/18/2011)

Dealer Check Lists 33

NOTES

34 Notes

5WPMAN0879 (3/18/2011)

Grooming Mower: GM1190

PARTS INDEX

MAIN FRAME ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 - 37

GEARBOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

DRIVESHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

BLADE & SPINDLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

CHAIN SHIELDING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

FRONT ROLLER ASSEMBLY (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . 42

QUICK HITCH KIT (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

5WPMAN0879 (3/18/2011)

Parts 35

GM1190 MAIN FRAME ASSEMBLY

36 Parts

5WPMAN0879 (3/18/2011)

GM1190 MAIN FRAME ASSEMBLY

REF PART QTY DESCRIPTION

1 ----- 1 Deck (not sold separately)

2 5WP1032786 2 Lower Hitch Arm

3 5WP56598 2 Sleeve .885 x 1.125 x 2.62

4 5WP19524 2 Sleeve .64 x 1.00 x 2.09 HT

5 5WP1032795 2 A-Frame Arm

6 5WP1032798 1 Sleeve .62 x .94 x 3.13

7 5WP1032797 1 U-Link

8 5WP1032796 2 Rear Offset Link

9 5WP1032811 1 PTO Hanger

10 5WP1032789 1 Idler Arm

11 5WP35141 2 Retaining Ring

12 5WP35193 2 Bearing

13 5WP27211 1 Sleeve .63 x .88 x 1.18

14 5WP19570 2 Flat Pulley (includes item 15)

15 5WP6095 2 .626 x 1.85 Ball Bearing

16 5WP28928 1 Ext. Spring .187 x 1.3 x 8.17

17 ----- 3 Spindle Assembly (see page 40)

18 5WP1032808 1 Belt Guide

19 5WP1032799 1 2V Powerband Belt 2W174.5

20 5WP1032779 1 Gearbox Stand

21 5WP1002499 1 Gearbox 1:1.92 (see page 38)

22 5WP1032751 1 Sheave, 11.50 PD, 2B

23 5WP1002048 1 Clutch Shield

24 ----- 1 Driveline (see page 39)

25 5WP1032809 1 Belt Shield, Inner

26 5WP1032810 2 Belt Shield, Outer

27 5WP1026530 1 Manual Tube

28 5WP1032780 4 Caster Arm (includes item 29)

29 5WP31780 8 Bronze Bushing 1-1/4 x 1-1/2 x 1/2

30 5WP1032782 4 Caster Yoke

31 5WP20718G 4 13 x 5 x 10 Solid Tire (includes item

32) -or-

31 5WP19744G 4 13 x 5 x 6 Pneumatic Tire (includes

item 32)

32 5WP2306 8 Bearing Cup

33 5WP2304 8 Bearing Cone

34 5WP5624 8 Seal 1.13 x 1.78 x .47

35 5WP52744 8 Bushing .752 x 1.125 x .625 HT

36 5WP20714 4 Sleeve .525 x .75 x 5.80 HT

37 5WP52853 8 Sleeve 1.25 x 1.90 x .50

38 5WP52854 8 Sleeve 1.25 x 1.90 x .75

39 5WP52855 8 Sleeve 1.25 x 1.90 x 1.00

40 5WP1032812 2 Skid Shoe

REF PART QTY DESCRIPTION

50 * 3/16 x 1-1/2 Cotter Pin

51 * 3/16 x 2 Cotter Pin

51 * 3/16 Safety Pin

53 * 1/4 x 1/4 x 1-1/4 Key

54 * 1/4-28 Grease Fitting

55 5WP39254 M8 x 1.25P x 16mm HHCS

56 * 5/16 NC x 1 HHCS GR5

58 * 5/16 SAE Flat Washer

59 * 5/16 NC Flange Lock Nut

60 * 3/8 NC Flange Lock Nut

61 5WP27542 7/16 Klik Pin

62 * 1/2 NC x 1-1/2 HHCS GR5

63 * 1/2 NC x 2 HHCS GR5

64 * 1/2 NC x 4 HHCS GR5

65 * 1/2 NC x 6-1/2 HHCS GR5

66 5WP29604 1/2 NC x 8 HHCS GR5

67 * 1/2 NC x 1-1/2 Carriage Bolt

68 5WP1093 1/2 NC Hex Nut

69 * 1/2 NC Flange Lock Nut

70 5WP19024 5/8 NC x 1-3/4 Flange HHCS GR5

71 * 5/8 NC x 2 HHCS GR5

72 5WP23141 5/8 NC x 3-1/2 HHCS GR5

73 5WP20419 5/8 NC x 3 Carriage Bolt GR5

74 5WP1517 .625 x 1.38 x 7GA Flat Washer

75 * 5/8 NC Flange Lock Nut

76 5WP302178 5/8 NF Castle Nut

77 5WP1032818 7/8 x 3.9 Clevis Pin

78 5WP51946 M24 x 2 Castle Nut

79 * 1-1/4 Stand Flat Washer

80 5WP20893 25 x 44 x 4 mm Flat Washer

81 5WP1032834 1 Complete Decal Set

HHCS Hex Head Cap Screw

* Standard Hardware, Obtain Locally

(Rev. 8/5/2011)

5WPMAN0879 (3/18/2011)

Parts 37

GM1190 GEARBOX ASSEMBLY

REF PART QTY DESCRIPTION

A 5WP1002499 1 Gearbox Assembly, Complete

1 5WP57458 1 Gear, Crown 25T M5.3

2 NSS 1 Gearbox Housing

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

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

5 5WP57491 1 Pinion Gear 13T M5.3

6 5WP57476 1 Bearing Cup & Cone

7 5WP57462 1 Bearing Cup & Cone

8 5WP20888 1 Washer, 1.58 x 3.13 x .04

Protective Flat

9 * 1 Pin, Cotter B4 x 50

10 5WP57466 2 Snap Ring

11 5WP20895 1 Snap Ring, 45 mm

12 5WP57373 1 Spacer, 35.3 x 48 x 2.5

13 5WP57328 2 Kit, Shim 60.3 x 71.6

14 5WP57468 1 Nut, Castle

15 5WP51946 1 Nut, Castle M24 x 2

16 5WP57328 1 Kit, Shim 30.3 x 44

17 5WP57473 1 Washer, 21 x 37 x 3 mm Flat

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

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

REF PART QTY DESCRIPTION

21 5WP20897 1 Snap Ring SB 81 Int

22 5WP57375 1 Cover, Top

23 * 6 Bolt, 8 mm x 14 mm

24 5WP57076 1 Plug, 1/2 Breather Level

25 * 1 Pin, Cotter 5 x 50

26 5WP57478 1 Bearing Cup & Cone

27 5WP20890 1 Ball Bearing

* Standard Hardware, Obtain

Locally

38 Parts

5WPMAN0879 (3/18/2011)

GM1190 DRIVE SHAFT ASSEMBLY

REF PART QTY DESCRIPTION

A 5WP1029937 1 Drive Assembly Complete

1 5WP40574 2 Yoke, 1-3/8-6SP (complete with lock collar)

2 5WP110 2 Cross and bearing kit

3 5WP40764 2 Spring Pin, 10 mm x 80 mm

4 5WP40575 1 Inboard Youk (male drive tube)

5 5WP40587 1 Inner Profile (cut to length)

6 5WP40588 1 Outer Profile (cut to length)

7 5WP40576 1 Inboard Yoke (female drive tube)

8 5WP40776 1 Bearing Ring Kit (set of 2)

9 5WP40778 1 Screw, Guard Retainer (Pkg of 10)

10 5WP40779 2 Grease Zerk, Drive Line (Pkg of 10)

11 5WP40767 1 Bearing, Guard Support

12 5WP40589 2 Slide Lock Collar Repair Kit (without yoke)

13 5WP1029938 1 Shield, Outer Half Non-Rotating (also includes items 8 & 9)

14 5WP1029939 1 Shield, Inner Half Non-Rotating (also includes items 8, 9 & 11)

(Rev. 8/5/2011)

5WPMAN0879 (3/18/2011)

Parts 39

GM1190 BLADE & SPINDLE ASSEMBLY

REF PART QTY DESCRIPTION

1 5WP1032800 1 Blade Spindle, Complete

2 5WP18359 1 Sleeve 1-3/8 x 1-3/4 x 5/8

3 5WP2715 2 Seal 1.75 x 2.56 x .5

4 5WP2717 2 Bearing Cone

5 5WP1032806 1 Spindle Housing w/ Cups

6 5WP2716 2 Bearing Cup

7 NSS 1 Spindle Shaft & Crossbar (Included In

Item 1)

8 5WP1032815 2 Blade Lock

9 5WP1032814 2 Blade Pin

10 5WP13288 2 1/2 NC x 3/4 Nylock HHCS

11 5WP29186KT 1 CW Standard Blade Kit, 13" (Includes

All 6 Blades)

12 5WP1032794 1 Sheave, 5.75 PD, 2B

13 5WP13557 1 Bushing, P1 1-3/8 Straight Bore

14 5WP24549 1 5/16 x 5/16 x 1-3/4 Key

15 * - 1 Standard Lock Washer

16 5WP1386 - 1 NC Jam Nut

17 * - 1/4-28 Tapered Grease Fitting

HHCS Hex Head Cap Screw

NSS Not Serviced Separately

* Standard Hardware, Obtain Locally

40 Parts

(Rev. 8/5/2011)

5WPMAN0879 (3/18/2011)

GM1190 CHAIN SHIELDING ASSEMBLY

REF PART QTY DESCRIPTION

1 5WP1032821 2 Front Chain Shield Plate

2 5WP1032832 1 Right Corner Chain Shield Plate

3 5WP1032833 1 Left Corner Chain Shield Plate

4 5WP1032822 1 Right Rear Chain Shield Plate

5 5WP1032823 1 Left Rear Chain Shield Plate

6 5WP4763 90 1/4 Chain - 3 Link

7 5WP4765 100 1/4 Chain - 4 Link

8 5WP1003646 2 Pin, 28 to 30 Chains

9 5WP1007852 2 Pin, 7 to 9 Chains

10 5WP1007854 2 Pin, 40 to 42 Chains

11 * - 3/8 NC x 1 Carriage Bolt, GR5

12 * - 3/8 NC Flange Lock Nut

* Standard Hardware, Obtain Locally

(Rev. 8/5/2011)

5WPMAN0879 (3/18/2011)

Parts 41

GM1190 FRONT ROLLER ASSEMBLY (OPTIONAL)

REF PART QTY DESCRIPTION

A 5WD1032828 1 Front Roller Kit - Complete

1 5WP1032829 1 Roller Bracket

2 5WP1006418 1 Roller, 4 x 7.38

3 5WP1006420 1 Spacer, .75 x 7.27

4 5WP35193 2 Bearing

5 5WP38107 - 1/2 NC x 9 HHCS, GR5

6 * - 1/2 SAE Flat Washer

7 * - 1/2 NC Flange Lock Nut

8 * - 3/8 NC x 1-1/4 Carriage Bolt, GR5

9 * - 3/8 NC Flange Lock Nut

* Standard Hardware, Obtain Locally

REF PART QTY DESCRIPTION

A 5WD1032830 - Quick Hitch Kit

1 5WP1032826 2 Offset Link

2 5WP1002012 2 Sleeve, .94 x 1.44 x 2.75

(Cat 2 only)

3 5WP1016517 2 Sleeve, .94 x 1.44 x 1.94 (Cat 1 only)

4 5WP1002018 1 Sleeve, .81 x 1.25 x 2.12

5 5WP29281 2 Sleeve, 7/8 x 1-1/8 x 19/32 HT

6 * - 3/4 Flat Washer

7 * - 3/4 NC x 5-1/2 HHCS, GR5

8 * - 3/4 NC Plated Hex Nut

9 * - 1/2 Flat Washer

REF PART QTY DESCRIPTION

10 * - 1/2 NC x 6 HHCS GR5

11 * - 1/2 NC x 2 HHCS GR5

12 5WP1005401 2 Chain, 3/8 proof coil 38-link

HHCS Hex Head Cap Screw

* Standard Hardware, Obtain Locally

QUICK HITCH KIT (OPTIONAL)

42 Parts

5WPMAN0879 (3/18/2011)

(Rev. 8/5/2011)

BOLT TORQUE CHART

SAE SERIES TORQUE CHART

SAE Bolt Head

Identification

SAE Grade 2

(No Dashes)

SAE Grade 5

(3 Radial Dashes)

SAE Grade 8

(6 Radial Dashes)

METRIC SERIES TORQUE CHART

Metric Bolt Head

Identification

8.8

Metric

Grade 10.9

10.9

Metric

Grade 8.8

Typical Washer Installations

Lock Washer

Flat Washer

8/9/00

Bolt

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

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

Diameter

(Inches)

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

5/16"1/2"121719262737

3/8"9/16"233135474967

7/16"5/8"3648557578106

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

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

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

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

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

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

Diameter &

Thread Pitch

(Millimeters)

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

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

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

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

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

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

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

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

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

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

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

Wrench

Size

Wrench

Size

Metric 8.8 Metric 10.9 Metric 8.8 Metric 10.9

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

SAE 2 SAE 5 SAE 8

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

Coarse Thread Fine Thread

Marking on Head Marking on Head

MARKING ON HEAD

Diameter &

Thread Pitch

(Millimeters)

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

Appendix 43

BOLT SIZE CHART

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

SAE Bolt Thread Sizes

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

IN 1 7

MM 25 50 75 100 125 150 175

Metric Bolt Thread Sizes

8MM 18MM14MM12MM10MM 16MM

ABBREVIATIONS

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

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

Biological Engineers (formerly ASAE)

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

44 Appendix

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

INDEX

A Assembly

Chain Shielding Dealer Set-Up Instructions Initial Oil Fill Optional Equipment

Front Roller

D Dealer Check Lists

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

Dealer Service

Blade Spindle

Assembly Disassembly Installation Removal

Service Blocking Method Gearbox

Disassembly

Drive Sheave Installation

Horizontal Shaft Seal Replacement

Installation

Reassembly

Removal

Repair

Seal Installation

Seal Replacement

Vertical Shaft Seal Replacement Universal Joint

Assembly

Disassembly

Repair

G General

Abbreviations Bolt Size Chart Bolt Torque Chart General Information Introduction Specifications Table of Contents

O Operation

Adjustment

Cutting Height

Tractor Top Link

Attaching Mower to Tractor Front Roller (Optional) Levelling Mower Mower Removal & Storage Mowing Speed Recommended Operating

On Uneven Terrain Technique Tips

Pre-Operation Check List (Owners Responsibility)

14 Recommended Uses Storage Tractor Stability

Owner Service

Belt

Blade

Blocking Method Chain Shielding Cleaning Lubrication

P Parts

Index to Parts Lists

S Safety

Blocking Method Check Lists

Safety & Instructional Decals Safety Rules

T Trouble Shooting

Belt Conditions Mowing Conditions

Installation Replacement Routing Service

Assembly Service Sharpening

Driveshaft Information Lubrication Points & Chart

Delivery (Dealer’s Responsibility) Pre-Delivery (Dealer’s Responsibility) Pre-Operation (Owner’s Responsibility)

5, 6, 7

8, 9

5WPMAN0879 (3/18/2011)

Index 45

PART NUMBER

5WPMAN0879

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

John Deere GM1190 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual