Frontier Grooming Mowers FM1012R FM1015R FM1017R Operator's Manual(5WPMAN0143)

O P E R A T O R ' S

M A N U A L

GROOMING MOWERS FM1012R FM1015R FM1017R 15-Digit Serial Numbers prior to WDFM10XXR239170 Revision1Effective 2/2006 S

WPMAN0143 (Rev. 2/27/2006)

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

The dealer must complete the Warranty Registration, located on the Frontier website. Warranty claims will be denied if the Warranty Registration has not been completed.

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 IMPORTANT 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.

This Safety-Alert Symbol indicates a hazard and means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

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

CAUTION

Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury.

IMPORTANT

Indicates that failure to observe can cause damage to equipment.

NOTE

Indicates helpful information.

ii

WPMAN0143 (8/31/01)

TABLE OF CONTENTS INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--6 SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--10 BOLT TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 BOLT SIZE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 OWNER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 DEALER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30--31 ASSEMBLY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 INDEX TO PARTS LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 REPLACEMENT PARTS WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 PRODUCT WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . Inside Back Cover

SPECIFICATIONS FM1012R

FM1015R

FM1017R

15’

17’

Cutting Height Range . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0” -- 5.0”

1.0” -- 5.0”

1.0” -- 5.0”

Shipping Weight (Approximate) . . . . . . . . . . . . . . . . . 2,900 lbs.

3,200 lbs.

3,340 lbs.

Blade Speed (Feet per minute -- Approximate) . . . . . 16,950

16,950

16,950

Blades Spindles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

9

9

Number of Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

9

9

Cutting Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12’

Universal Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ------(Input: ASAE Cat 4; Wing: ASAE Cat 3)-----Transport Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.5 x 8.0--10

20.5 x 8.0--10

20.5 x 8.0--10

Caster Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 x 6.00--6

15 x 6.00--6

15 x 6.00--6

Tractor PTO Speed RPM . . . . . . . . . . . . . . . . . . . . . . . . 540

540

540

Minimum Tractor Horsepower . . . . . . . . . . . . . . . . . . . . . 30

35

40

(Rev. 9/28/01) WPMAN0143 (8/31/01)

1

GENERAL INFORMATION The purpose of this manual is to assist you in operating and maintaining your Flex Wing Mower.

Read it carefully. It furnishes information and instructions that will help you achieve years of dependable performance. These instructions have been compiled from extensive field experience and engineering data.

Some information may be general in nature due to unknown and varying operating conditions. However, through experience and these instructions, you should be able to develop procedures suitable to your particular situation.

change the machines as may be necessary without notification.

WARNING 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.

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

The illustrations and data used in this manual were current at the time of printing, but due to possible inline production changes, your machine may vary slightly in detail. We reserve the right to redesign and

NOTES

2

WPMAN0143 (8/31/01)

SAFETY RULES ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! J Never allow children or untrained persons to operate equipment.

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.

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

J Air in hydraulic systems can cause erratic operation and allows loads or equipment components to drop unexpectedly. Before putting into service or allowing anyone to approach the equipment, purge any air in the system by operating all hydraulic functions several times after connecting equipment, connecting hoses, or doing any hydraulic maintenance.

J Route hydraulic hoses carefully to prevent damage. Hoses must not be twisted, bent sharply, kinked, frayed, pinched, or come into contact with any moving parts.

Operate moveable components through full operational range to check clearances. Replace any damaged hose immediately.

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

J Always wear relatively tight and belted clothing to avoid entanglement in moving parts. Wear sturdy, rough-soled work shoes and protective equipment for eyes, hair, hands, hearing and head.

J When attaching a pull-type unit to the tractor drawbar, always use a highstrength drawbar pin. The drawbar pin must have a device that will lock it in position.

J Make sure implement is properly attached, adjusted and in good operating condition.

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

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.

TRAINING J Safety instructions are important!

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

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

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

J 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.

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

J Make sure that all operating and service personnel know that if hydraulic fluid penetrates skin, it must be surgically removed as soon as possible by a doctor familiar with this form of injury or gangrene, serious injury, or death will result. CONTACT A PHYSICIAN IMMEDIATELY IF FLUID ENTERS SKIN OR EYES. DO NOT DELAY. WPMAN0143 (8/31/01)

(Safety Rules continued on next page) 3

SAFETY RULES ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! (Safety Rules continued from previous page)

J Never attach the mower release rope to the operator, the operator’s clothing, or the tractor seat.

J Make sure driveline shield tether chains are attached to the tractor and equipment as instructed. Replace if damaged or broken and check that driveline guards rotate freely on driveline before operating equipment.

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

J Before starting tractor, check all equipment driveline guards for damage and make sure they rotate freely on all drivelines. Replace any damaged guards.

If guards do not rotate freely on drivelines, repair and replace bearings before operating.

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

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

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

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

J Inspect chain, rubber or curtain shielding before each use. Replace if damaged.

J Remove accumulated debris from this equipment, tractor and engine to avoid fire hazard.

J Full chain or rubber shielding must be used for all non-agricultural mowing. Full shielding is also recommended for all agricultural use to further reduce the risk of thrown objects.

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

J Never direct discharge toward people, animals or property.

J Make sure shields and guards are properly installed and in good condition.

Replace if damaged.

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

J Do not operate mower unless all side skids are properly installed and in good condition. Replace if damaged.

J Operate only in daylight or good artificial light.

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

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

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

J Never allow riders on power unit or attachment.

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

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

J Attach mower release rope to tractor structure so that full turns can be made without the rope pulling taut on the release mechanisms.

(Safety Rules continued on next page) 4

WPMAN0143 (8/31/01)

SAFETY RULES ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! (Safety Rules continued from previous page)

J Lower implement to ground or block securely, turn tractor engine off, remove key and disconnect driveline from tractor PTO before performing any service or maintenance.

J Before working underneath, carefully read operator manual instructions, disconnect driveline, raise mower, securely block up all corners with jackstands and check stability. Secure blocking prevents equipment dropping from hydraulic leak down, hydraulic system failures, or mechanical component failures.

J Always sit in tractor 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 tractor engine.

J Operate tractor PTO at RPM speed stated in “Specifications” section.

J Do not operate tractor PTO during transport.

J Do not operate mowers on terrain that raises mowers beyond 25 degrees. Exceeding this design limit will result in U-joint “knocking noise” and potential driveline failure, with the possibility of the driveline coming apart.

MAINTENANCE SAFETY J Before dismounting tractor or performing any service or maintenance, disengage power to implement, 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.

J Before performing any service or maintenance, disconnect driveline from tractor PTO. J Lower implement to ground or block securely, turn tractor engine off, remove key and disconnect driveline from tractor PTO before performing any service or maintenance.

J Before working underneath, carefully read operator manual instructions, disconnect driveline, raise mower, securely block up all corners with jackstands and check stability. Secure blocking prevents equipment dropping from hydraulic leak down, hydraulic system failures, or mechanical component failures.

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

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

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

J Always wear relatively tight and belted clothing to avoid entanglement in moving parts. Wear sturdy, rough-soled work shoes and protective equipment for eyes, hair, hands, hearing and head.

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

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

J Do not operate on steep slopes.

J Do not stop, start or change directions suddenly on slopes.

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

J Watch for hidden hazards on the terrain during operation.

J Stop tractor and implement immediately upon striking an obstruction. Turn off engine, remove key, inspect and repair any damage before resuming operation.

J Always connect safety chain from implement to towing vehicle when transporting.

J Before dismounting tractor or performing any service or maintenance, disengage power to implement, 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.

J Before performing any service or maintenance, disconnect driveline from tractor PTO. WPMAN0143 (8/31/01)

(Safety Rules continued on next page) 5

SAFETY RULES ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! installed. Replace if damaged. (See Safety Decals section for location.)

J Make sure shields and guards are properly installed and in good condition.

Replace if damaged.

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

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

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

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

(Safety Rules continued from previous page)

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

J Make sure implement is properly attached, adjusted and in good operating condition.

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

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

J Do not handle blades with bare hands.

Careless or improper handling may result in serious injury.

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

J Tighten all bolts, nuts and screws to torque chart specifications. Check that all cotter pins are installed securely to ensure equipment is in a safe condition before operating.

J Make sure all

safety

STORAGE J Block equipment securely for storage.

J Keep children and bystanders away from storage area.

decals are

NOTES

6

WPMAN0143 (8/31/01)

SAFETY & INSTRUCTIONAL DECALS ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Replace Immediately If Damaged!

FM1012R & FM1015R REAR DECK (FM1017R SIMILAR) LENEXA, KS, U.S.A.

5 - SERIAL NUMBER PLATE 2 7

1 - WP18867

DANGER SHIELD MISSING Do not operate.

Put shield on.

18867-A

1

18 -- WP1002941

CD5591

1

WARNING 2 - WP15503

DANGER

CRUSHING AND PINCHING HAZARD Be extremely careful handling various parts of the hitching mechanism. 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. 1002941

WPMAN0143 (8/31/01)

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. 15503-C

(Safety Decals continued on next page) 7

SAFETY & INSTRUCTIONAL DECALS ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Replace Immediately If Damaged!

(Safety Decals continued from previous page)

IMPORTANT OPERATING MOWERS AT RAISED ANGLES EXCEEDING 25° WILL CREATE U-JOINT KNOCKING NOISE AND DAMAGE DRIVELINE. FAILURES RESULTING FROM THIS OPERATION WILL NOT BE COVERED BY WARRANTY. 38446

16 -- WP38446 FM1015R & FM1017R WING (RIGHT WING SHOWN) (FM1012R SIMILAR)

3

4

2

CD5592

6

1

16 1

9 - WP18865

WARNING 3 - WP18864

DANGER

FALLING OFF CAN RESULT IN BEING RUN OVER. H Tractor must be equipped with ROPS (or ROPS CAB) and seat belt.

Keep foldable ROPS systems in “locked up” position at all times.

H Buckle Up! Keep seat belt securely fastened.

ROTATING DRIVELINE

CONTACT CAN CAUSE DEATH

KEEP AWAY! DO NOT OPERATE WITHOUT-All driveline guards, tractor and equipment shields in place Drivelines securely attached at both ends Driveline guards that turn freely on driveline 18864--C

H Allow no riders.

RAISED EQUIPMENT CAN DROP AND CRUSH. H Before working underneath, follow all instructions and safety rules in operator’s manual and securely block up all corners of equipment with jack stands.

H 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. 18865--C

8

WPMAN0143 (8/31/01)

SAFETY & INSTRUCTIONAL DECALS ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Replace Immediately If Damaged!

6 - WP38421

7 - WP44650

WARNING

PIN STORAGE POSITION

RAISED MOWER CAN DROP AND CRUSH H Before working underneath rear mower: H Raise rear mower to transport position.

H Insert pin to lock transport latch.

H Securely block up rear of mower. See manual.

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

44650

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

PIN INSERTED TO LOCK TRANSPORT LATCH

11 - WP44651

WARNING

PIN INSERTED TO LOCK TRANSPORT LATCH

RAISED MOWERS CAN DROP AND CRUSH

PIN STORAGE POSITION

H Keep away. Do not go underneath.

H When raised, insert pins to lock transport latches.

H Lower after transport.

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

44651

SIDE MOWER TRANSPORT LATCHES

WARNING RAISED MOWERS EXPOSE BLADES AND INCREASE THROWN OBJECT HAZARDS H Only raise for transport.

H Stop mowers before raising.

17 -- WP44656

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

44656

(Safety Decals continued on next page)

WPMAN0143 (8/31/01)

9

SAFETY & INSTRUCTIONAL DECALS ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Replace Immediately If Damaged!

(Safety Decals continued from previous page)

4

3

FM1012R, FM1015R & FM1017R TRAILER

13

13 -- WP20105 AMBER FRONT REFLECTOR

12 14 4

14 -- WP57123 RED REAR REFLECTOR 3 12 8 4

13

3

13

8

CD5593A

15 11 17

15 -- WP19924

WARNING

10

9

18 5

HIGH-PRESSURE HYDRAULIC OIL LEAKS CAN PENETRATE SKIN RESULTING IN SERIOUS INJURY, GANGRENE OR DEATH.

10 -- WP1002423

Read Operator's Manual before operating, servicing or repairing equipment. Follow all safety rules and instructions. (Manuals are available from your selling dealer.)

Never allow riders.

Keep bystanders away from equipment during operation.

Operate from tractor seat only.

Keep all shields in place and in good condition.

Lower equipment to ground, stop engine, remove key and set brake before dismounting tractor.

Never allow children or untrained persons to operate equipment.

FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN INJURY OR DEATH. 1002423-A

DANGER

8 - WP18866

WARNING

WARNING TO AVOID SERIOUS INJURY OR DEATH:

4 - WP33347

PTO speeds higher than 540 RPM can cause equipment failure and personal injury.

OPERATE PTO AT

540 RPM.

GUARD MISSING. DO NOT OPERATE.

DANGER 18866--C

12 -- WP18869

DANGER SHIELD MISSING

DO NOT OPERATE - PUT SHIELD ON

18869-B

19924-B

H Check for leaks with cardboard; never use hand.

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

H Consult physician immediately if skin penetration occurs.

GUARD MISSING. DO NOT OPERATE.

33347E

DANGER 10

WPMAN0143 (8/31/01)

BOLT TORQUE CHART 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 & J1701M JUL96.

A A Diameter (Inches) 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1

A

Diameter A & Thread Pitch (Millimeters) 6 x 1.0 8 x 1.25 10 x 1.5 12 x 1.75 14 x 2.0 16 x 2.0 18 x 2.5 20 x 2.5 22 x 2.5 24 x 3.0 30 x 3.0

SAE SERIES TORQUE CHART

Wrench Size 7/16” 1/2” 9/16” 5/8” 3/4” 13/16” 15/16” 1-1/8” 1-5/16” 1-1/2”

SAE Bolt Head Identification SAE Grade 2 (No Dashes)

MARKING ON HEAD SAE 5 Lbs.-Ft. N-m 10 13 19 26 35 47 55 75 85 115 121 164 170 230 297 403 474 642 722 979

SAE 2 Lbs.-Ft. 6 12 23 36 55 78 110 192 306 467

METRIC SERIES TORQUE CHART

Wrench Size 10 mm 13 mm 16 mm 18 mm 21 mm 24 mm 27 mm 30 mm 34 mm 36 mm 46 mm

SAE Grade 5 (3 Radial Dashes)

N-m 8 17 31 48 75 106 149 261 416 634

8.8 Metric Grade 8.8

COARSE THREAD MARKING ON HEAD Metric 8.8 Metric 10.9 N-m Lbs.-Ft. N-m Lbs.-Ft. 8 6 11 8 20 15 27 20 39 29 54 40 68 50 94 70 109 80 151 111 169 125 234 173 234 172 323 239 330 244 457 337 451 332 623 460 571 421 790 583 1175 867 1626 1199

Typical Washer Installations Bolt

Lockwasher

Flat Washer

Nut

WPMAN0143 (8/31/01)

11

Metric Bolt Head Identification

SAE Grade 8 (6 Radial Dashes) SAE 8 Lbs.-Ft. 14 27 49 78 120 171 240 420 669 1020

N-m 18 37 67 106 163 232 325 569 907 1383

10.9 Metric Grade 10.9

FINE THREAD MARKING ON HEAD Metric 8.8 Metric 10.9 N-m Lbs.-Ft. N-m Lbs.-Ft. 8 6 11 8 21 16 29 22 41 30 57 42 75 55 103 76 118 87 163 120 181 133 250 184 263 194 363 268 367 270 507 374 495 365 684 505 623 459 861 635 1258 928 1740 1283

Diameter A & Thread Pitch (Millimeters) 6 x 1.0 8 x 1.0 10 x 1.25 12 x 1.25 14 x 1.5 16 x 1.5 18 x 1.5 20 x 1.5 22 x 1.5 24 x 2.0 30 x 2.0

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

2

3

4

5

6

7

MM

25

50

75

100

125

150

175

Metric Bolt Thread Sizes

8MM

10MM

12MM

14MM

16MM

18MM

NOTES

12

WPMAN0143 (8/31/01)

OPERATION

valve levers to release any hydraulic pressure, set parking brake, stop engine, remove key, and unfasten seat belt.

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.

WARNING

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.

J Before performing any service or maintenance, disconnect driveline from tractor PTO. J Before working underneath, carefully read operator manual instructions, disconnect driveline, raise mower, securely block up all corners with jackstands and check stability. Secure blocking prevents equipment dropping from hydraulic leak down, hydraulic system failures, or mechanical component failures.

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

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

The operator is responsible for the safe operation of this mower. The operator must be properly trained.

Operators should be familiar with the mower and tractor and all safety practices before starting operation. Read the safety information on pages 3 through 10.

DANGER J Full chain or rubber shielding must be used for all non-agricultural mowing. Full shielding is also recommended for all agricultural use to further reduce the risk of thrown objects.

This mower is designed for lawn and grass mowing.

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

CAUTION

Recommended mowing speed for most conditions is from two to five mph. Always operate tractor PTO at 540 rpm.

J Stop tractor and implement immediately upon striking an obstruction. Turn off engine, remove key, inspect and repair any damage before resuming operation.

This section provides information for attaching the mower to the tractor and preparing it for field operation. Review this data prior to tractor hook-up and operation.

J Always wear relatively tight and belted clothing to avoid entanglement in moving parts. Wear sturdy, rough-soled work shoes and protective equipment for eyes, hair, hands, hearing and head.

Tractors should have the necessary equipment to prevent the 3-point hitch arms from contacting the mower. Otherwise, remove the 3-point hitch arms.

WARNING

WARNING

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

J Never allow children or untrained persons to operate equipment.

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

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

J Never allow riders on power unit or attachment.

J Before dismounting tractor or performing any service or maintenance, disengage power to implement, lower the 3-point hitch and all raised components to the ground, operate WPMAN0143 (8/31/01)

13

ATTACHING MOWER TO TRACTOR

Attach the mower transport lock release rope to the tractor structure so full turns, both left and right, can be made without the rope becoming taut and releasing the “self-locking” mechanisms.

Park the mower and tractor on a level, hard-surfaced area. Adjust tractor hitch bracket on trailer frame so the trailer is level when attached to the tractor. Pin the mower to the tractor.

WARNING

J Never attach the mower release rope to the operator, the operator’s clothing, or the tractor seat.

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

Attach the hydraulic hose from the mower to the tractor. Route the hose through the hose guide of the trailer frame and be sure the hose can slide freely in the guide. Do not allow hose slack to drag on the ground or become caught on tractor protrusions.

From the operator position, start the tractor and raise and lower the wings and the rear deck several times to purge the hydraulic cylinders and hoses of trapped air.

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

WARNING

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

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

Attach the safety chain to the tractor as shown in Figure 1. Attach the mower drive shaft to tractor PTO. Make sure the lock collar engages securely.

CV DRIVELINE TURNING LIMITS You must not exceed a turning angle of 80 degrees at the head of the Constant Velocity (CV) driveline or damage will occur.

9” MAX

To check for potential excessive turn angle, disconnect the driveline from the tractor, start engine and turn as far right or left as possible. Shut off the engine and try to connect the CV driveline to the tractor. If it cannot be connected, the turn angle is too severe.

Restart the tractor and straighten the angle slightly.

Shut off the engine and try to connect the CV driveline to tractor. Repeat the process until the driveline can be connected. The point at which the driveline can be connected is the maximum turn that can be made.

CD4316

LEVELING MOWER FOR OPERATION

Figure 1. Tow Chain Installation

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

WARNING

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

Complete the following procedure in sequence to level the flex mower for operation:

Attach the end of the mower transport’s lock release rope to a location on the tractor within easy reach of the operator. When routing the rope, do not route through the hydraulic hose guide and do not allow rope slack to drop between the driveline shields and the gearbox rotating shafts.

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

2. Inflate all tires to the recommended pressure; 70 psi for trailer tires and 30 psi for deck gauge tires.

14

WPMAN0143 (8/31/01)

3. Level the trailer frame by adjusting the hitch. (See Figure 2.) Remove the hitch clevis from the trailer frame and pin to the tractor drawbar. Use the parking jack to move the trailer frame to the level position. Align the nearest hitch adjustment hole in the hitch clevis with a hole in the trailer frame.

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

NOTE: For best results, run mower with rear of deck approximately 1/4” higher than front of deck.

FORWARD

B

CARRIER BEARING

Figure 3. Cutting Height Adjustment

CV DRIVE LINE

Cutting height is controlled by adjusting the front and rear caster wheels by removing deck and adjusting spacers as necessary.

DRIVELINE HEIGHT ADJUSTMENT HOLES

WARNING J Before working underneath, carefully read operator manual instructions, disconnect driveline, raise mower, securely block up all corners with jackstands and check stability. Secure blocking prevents equipment dropping from hydraulic leak down, hydraulic system failures, or mechanical component failures.

ADJUSTMENT HOLES HITCH CLEVIS

CD5594

Figure 2. Level Trailer Frame

To raise the rear of the mower, place additional caster adjustment spacers under the rear caster arms.

4. Attach the mower and the driveline to the tractor.

Level the driveline by placing a bolt through the carrier bearing and the driveline height adjustment holes.

To raise the front of the mower, place additional spacers under the front caster wheel arms.

Cutting Height Adjustment

Approx.

Cutting Height

IMPORTANT

Spacers Required Under Caster Arm Pivot Tube 1/2” Spacer

1” 1-1/2” 2” 2-1/2” 3” 3-1/2” 4” 4-1/2” 5”

J 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 driveline.

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

3/4” Spacer

1” Spacer

2 2 2

1 1 2 2 1 2 2

1 1 1 1 1

CUTTING HEIGHT CHART

Level each mower deck from side to side. Check by measuring from the mower frame to the ground at each deck rail. Verify that the same amount of spacers are under all caster arms. Loosen cap screws that attach the caster arm assembly to the deck. Set mower on the ground. Retighten cap screws. This equalizes the clearance in the bolt holes.

WPMAN0143 (8/31/01)

A CD3551B

TRANSPORT When transporting the mower short distances (from area to area), raise the wings and the rear deck until all three transport locks engage automatically.

15

CD5595

Figure 4. Front and Rear Pin Storage Positions To lower the wings and the rear deck, slightly raise the wings and rear deck to take pressure off the locking mechanisms. Remove the locking pins and store in holes provided. Pull the transport lock release rope to disengage the locks. Lower the wings and rear deck and release the rope.

sharply, kinked, frayed or pulled tight. Replace any damaged hoses immediately. ___ Make sure tractor ROPS or ROPS CAB and seat belt are in good condition. Keep seat belt securely fastened during operation.

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

STARTING AND STOPPING MOWER Power for operating the mower is supplied from the tractor PTO. Refer to your tractor manual for instructions on engaging and disengaging the PTO. Operate PTO at 540 rpm. Know how to stop tractor and mower quickly in case of an emergency.

PRE-OPERATION CHECK LIST (OWNER RESPONSIBILITY) ___ Review and follow all safety rules and safety decal instructions on pages 3 through 10. ___ Check that all safety decals are installed and in good condition. Replace if damaged. ___ Check to ensure blades are sharp, in good condition, and installed correctly. Replace if damaged. ___ Check that all shields and guards are properly installed and in good condition. Replace if damaged. ___ Check that all hardware and cotter pins are properly installed and secured. ___ 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. ___ 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 “Service, lubrication information”.

Make sure the PTO slip joint is lubricated and that the gearbox fluid levels are correct. ___ Check that all hydraulic hoses and fittings are in good condition and not leaking before starting tractor. Check that hoses are not twisted, bent

Should the mower become plugged, causing the belt to slip for over two seconds, raise mower just enough to clear slug and continue running at least two minutes, allowing pulleys to cool. Stopping the mower with belt in contact with a very hot pulley will bake and ruin belt. To reduce the risk of thrown objects, do not raise the mower higher than necessary.

WARNING J Do not operate tractor PTO during transport.

J Never direct discharge toward people, animals or property.

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

CAUTION J Stop tractor and implement immediately upon striking an obstruction. Turn off engine, remove key, inspect and repair any damage before resuming operation.

J Always sit in tractor 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 tractor engine.

16

WPMAN0143 (8/31/01)

OPERATING THE MOWER

Extremely tall material should be cut twice. Set mower at a higher cutting height for the first pass.

Then cut at desired height at a 90--degree angle to the first pass.

WARNING J Do not operate mowers on terrain that raises mowers beyond 25 degrees. Exceeding this design limit will result in U-joint “knocking noise” and potential driveline failure, with the possibility of the driveline coming apart.

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

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

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

Uneven Terrain

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

WARNING J Do not operate on steep slopes.

J Do not stop, start or change directions suddenly on slopes.

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

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

J Watch for hidden hazards on the terrain during operation.

MOWING TECHNIQUES Mowing Speed

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

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

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

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

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

Always operate tractor PTO at 540 rpm. This is necessary to maintain the proper blade speed needed to produce a clean cut.

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

Under certain seasonal 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 rebound partially.

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

DETACHING MOWER FROM TRACTOR AND PARKING

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

Follow local recommendations for suitable cutting height in your area.

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

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

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

Tips

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

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

WPMAN0143 (8/31/01)

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

17

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

WARNING J Before working underneath, carefully read operator manual instructions, disconnect driveline, raise mower, securely block up all corners with jackstands and check stability. Secure blocking prevents equipment dropping from hydraulic leak down, hydraulic system failures, or mechanical component failures.

CAUTION J Always wear relatively tight and belted clothing to avoid entanglement in moving parts. Wear sturdy, rough-soled work shoes and protective equipment for eyes, hair, hands, hearing and head.

BLOCKING METHODS The only approved blocking devices for this mower are jack stands with a load rating of 1,000 pounds or more. Twelve jack stands, located as shown in Figure 5, must be installed before working underneath this unit.

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

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

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

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

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

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

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

J Before dismounting tractor or performing any service or maintenance, disengage power to implement, 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.

J Before performing any service or maintenance, disconnect driveline from tractor PTO.

CD5596

Figure 5. Jackstand Placement 18

WPMAN0143 (8/31/01)

REF NO

5

4

DESCRIPTION

1 2 3 4 5 6 7 8

7

9 10

7

FREQUENCY

Front U-Joint Center U-Joint CV body Slip Joint Zerk Rear U-Joint Transport Wheel Hubs Shield Bearings Splitter Gearbox (Fill half full with SAE 90W gear lube) Rear Deck Pivot Arm Drive Carrier Bearing

8 hours 8 hours 8 hours 8 hours 8 hours 8 hours 8 hours Check Daily 8 hours 8 hours

5 7

1

5

9

7

4

8

CD5597

2

7

1

6

10 3

REF NO

1 2 3 4 5 6 7 8 9 10

DESCRIPTION

FREQUENCY

Caster Wheel Pivots Caster Wheel Hubs Blade Spindles Gearbox (Fill 1/2 full SAE90W Gear Lube) Rear U-Joint Front U-Joint Wing Pivots Slip Joint Zerks Shield Bearings Carrier Pivot

8 hours 8 hours 24 hours 1

Check Daily 8 hours 8 hours 8 hours 8 hours 8 hours 8 hours 8

1

2 10 3 5

9

4

9

2

7

CD5598

6 3 7

1 2

Figure 6. Lubrication Points WPMAN0143 (8/31/01)

1

3

19

DAILY SERVICE AND LUBRICATION

WARNING

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

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

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

Monthly lubricate idler arm pivot (J, Figure 7) by adding a drop or two of oil to felt washer on pivot post.

Figure 6 shows lubrication points. The charts give the frequency of lubrication in operating hours, based on normal operating conditions. Severe or unusual conditions may require more frequent lubrication.

SAFETY LATCH MAINTENANCE Check rear deck latch and wing latches to make sure they work freely without binding. Make sure that springs are in good repair; replace if worn or broken.

Make sure nuts are not so tight that springs go solid before clearing end of lug.

Use a lithium grease of #2 consistency with a MOLY (molybdenum disulfide) additive for all locations unless otherwise noted. Be sure to clean fittings thoroughly before attaching grease gun. When applied according to the lubrication chart, one good pump of most guns is sufficient. Use SAE 90W gear lube in gearboxes. Check wing and rear gearboxes using dipstick. Oil level is to be up to the ring but not over. See Figure 6.

BELT ROUTING & REPLACEMENT One of the major causes of belt failure is improper installation. Before a new belt is installed, check pulley shafts and bearings for wear. Check pulley grooves for cleanliness. Make sure spindles turn freely and without wobble. If grooves require cleaning, moisten a cloth with a non-flammable, non-toxic degreasing agent or commercial detergent and water.

Daily lubrication of PTO slip joints is necessary.

Failure to maintain proper lubrication can result in damage to U-joints, gearboxes and/or drive shafts.

Raise or lower mower until grease fittings in PTO shields are exposed. Insert grease gun through slots and apply grease to all sides of shafts. Always stand clear of mower and wing arm mechanism to avoid being pinched or crushed should the mower or wing suddenly lower.

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.

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

CAUTION

CAUTION

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

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

D

I

B

G

I F

B

H

G

D

1/8″

H

1/8″ J

F A

A CD5599

Figure 7. Belt Routing for Wing Decks -- FM1012R 20

WPMAN0143 (8/31/01)

Wing Decks - FM1012R

WARNING

(Figure 7)

J Make sure shields and guards are properly installed and in good condition.

Replace if damaged.

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

Position the belt around drive pulley “A”.

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

BLADE SERVICING

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

Inspect blades before each use to determine that they are mounted tightly and are in good condition.

Replace any blade that is bent, excessively nicked, worn, or has any other damage. Small nicks can be ground out when sharpening.

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

WARNING

5. Adjust belt guide “G” to provide 1/16” to 1/8” clearance from belt. Tighten the bolt to 85 lbs./ft.

J Before working underneath, carefully read operator manual instructions, disconnect driveline, raise mower, securely block up all corners with jackstands and check stability. Secure blocking prevents equipment dropping from hydraulic leak down, hydraulic system failures, or mechanical component failures.

Rear Deck -- FM1012R All Decks -- FM1015R & FM1017R (Figure 8)

D

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

C

Remove cap screws (3) and nuts (4).

G I E

F

A

B

1

1/8″

H

CD4989

Figure 8. Belt Routing for Rear Deck FM1012R, FM1015R, FM1017R

4

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

2

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

3 CD5060

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

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

1. Spindle assembly 2. Blade 3. 1/2 NC x 1-1/2” Hex head cap screw GR5 4. 1/2 NC Hex flange locknut Figure 9. Blade Removal

5. Adjust belt guide “G” to provide 1/16” to 1/8” clearance from belt. Tighten bolt to 85 lbs./ft.

WPMAN0143 (8/31/01)

21

Blade Sharpening (Figure 10)

CHAIN SHIELDING

Remove blades.

Always sharpen both ends at the same time to maintain balance. Follow original sharpening pattern.

Do not sharpen blade to a razor edge. Leave from 1/32” to 1/16” blunt edge. Do not sharpen back side.

DANGER J When this equipment is operated in populated areas or other areas where thrown objects could injure persons or property, full chain or rubber shielding (which is designed to reduce the possibility of thrown objects) must be installed. If this machine is not equipped with full chain or rubber shielding, operation must be stopped when anyone comes within several hundred feet.

IMPORTANT J When sharpening blades, be sure to balance them. Unbalanced blades will cause excessive vibration which can damage blade spindle bearings. Vibration may also cause structural cracks in mower components.

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

MAINTAIN CORNER FOLLOW ORIGINAL PATTERN

1/32″

CD3627

Figure 10. Blade Sharpening

NOTES

22

WPMAN0143 (8/31/01)

DEALER SERVICE

The information in this section is written for dealer service personnel. The repair described herein 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.

stands. Ensure that jack stands are stable at both top and bottom. Before working under any portion of the mower, test the stability of your blocking with the full weight of the mower units lowered onto the jack stands.

WARNING J Before working underneath, carefully read operator manual instructions, disconnect driveline, raise mower, securely block up all corners with jackstands and check stability. Secure blocking prevents equipment dropping from hydraulic leak down, hydraulic system failures, or mechanical component failures.

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

CD5596

CAUTION

Figure 11. Jack Stand Placement

J Always wear relatively tight and belted clothing to avoid entanglement in moving parts. Wear sturdy, rough-soled work shoes and protective equipment for eyes, hair, hands, hearing and head.

BLADE SPINDLE REPAIR 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.

BLOCKING METHOD

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

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

Permatex 3D Aviation Form-A-Gasket® or equivalent is recommended as a sealant.

The only approved blocking devices for this mower are jack stands with a load rating of 1,000 pounds or more. Twelve jack stands, located as shown in Figure 11, must be installed before working underneath this unit.

Spindle Removal Remove blade from spindle.

Remove belt from pulleys.

Remove jam nut and washers from top of spindle shaft.

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

Disassemble split taper bushing (located on top of pulley) by removing the two bolts and inserting them into the threaded holes of bushing flange. Tighten them alternately to remove split taper bushing.

Remove pulley.

When blocking, you must consider the overall stability of the unit. Just placing jack stands under the unit will not ensure your safety. The working surface must be level and solid to support the loaded weight of the jack WPMAN0143 (8/31/01)

Permatex 3D Aviation Form-A-Gasket is a registered trademark of the Permatex Corporation.

23

1

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

2 SEAL LIP

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

3 4

IMPORTANT

5

J Improper positioning of seals can cause seal damage.

Proper seal installation is important. An improperly installed seal will leak and could cause bearing failure.

6

Identify the open side of the seal containing the spring.

With Permatex, lightly coat the area of the housing where the seals seat.

5

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

4

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

2 SEAL LIP 1. Grease fitting 2. Seal 3. Sleeve 4. Bearing cone 5. Bearing cup 6. Spindle housing 7. Spindle shaft

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

7

Make sure that the seal lip did not roll under.

Distortion to the seal cage or damage to the seal lip will cause the seal to leak. Damaged seals must be replaced.

CD5061

Insert the shaft and bearing through the bottom of the housing.

Figure 12. Blade Spindle Assemblies

Fill the housing cavity with a medium grade grease.

Install the top bearing onto shaft to mate with the top cone.

Spindle Disassembly (Figure 12) Remove bolts attaching spindle to mower frame and remove spindle.

Remove grease fitting.

Place spindle assembly in press and press shaft down through housing.

Remove seals from housing.

Remove bearing cups from housing by placing a punch in the slots provided and driving out. Alternate punch positions from side to side. Take care to prevent damaging the housing.

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

Spindle Assembly (Figure 12)

Should you overtighten the bearings, hold the spindle housing and rap the spindle shaft with a lead hammer.

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

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

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

Carefully press the top seal in with the spring facing up. The top seal should be flush with the housing or to within 1/16” above the housing.

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

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

Install the grease fitting into the spindle shaft.

24

WPMAN0143 (8/31/01)

Spindle Installation

If leak occurred at the horizontal seal (20), remove and replace the old seal. Refer to seal installation.

Fill gearbox with SAE 80W or 90W gear lube until it runs out the level plug (18).

Install drive shield and driveline and place unit in service.

Install the spindle through the bottom of the mower and install four mounting bolts.

IMPORTANT

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

Seal Installation (Figure 13 & Figure 14)

Install the pulley and the split taper bushing with the integral key on the spindle shaft. Make certain that the bushing is in contact with the sleeve on the spindle shaft. Alternately tighten the split--taper bushing cap screws to 12 lbs./ft.

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

Clean area in housing where seal outer diameter seats and apply a thin coat of Permatex.

Install the toothed lockwasher and the nut on the spindle shaft. Tighten nut until snug. Bend up edge of lockwasher against a flat on the nut. Do not overtighten the nut and overload the bearings.

Inspect area of shaft where seal seats and remove any burrs or nicks with emery cloth.

Place seal (spring-loaded lip toward housing) squarely on cap. Select a piece of pipe or tubing with an OD that will set on outside edge of seal but will clear the housing. Tubing with an OD that is too small will bow seal cage and ruin seal.

WING GEARBOX MAINTENANCE (Figure 15)

Lubricate gear shaft and seal lips.

Read this entire section before starting any repair.

Many steps are dependent on each other.

Carefully press seal into housing, preventing distortion to the metal seal cage. Vertical seal should be recessed 0.275” in housing. Horizontal seal should be pressed flush with outside of housing.

Fill gearbox with SAE 80W or 90W gear lube until it runs out the side level plug (18).

Repair to this gearbox is limited to replacing the 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 other than replacing bearings, seals or gaskets is required.

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

Remove and replace any seal damaged in installation.

Inspect the gearbox for leakage and bad bearings.

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

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

Leakage Repair

CD1092

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

Figure 13. Incorrect Seal Installation

Leakage can occur at the vertical or horizontal gaskets and the shaft seals. Leakage at the horizontal gasket or seal can be repaired without removing the gearbox from the cutter.

2

Horizontal Shaft Leak Repair (Figure 15)

4 1. Seal 2. Pipe or tube CD1094 3. Seal seat Pipe or tube must press 4. Casting

Disconnect and remove the driveline from the gearbox.

Remove the drive shield.

Remove the vent plug (25) and siphon gear lube from housing through this opening.

If leak occurred at the horizontal O-ring, remove cap (6) and snap ring (17). Replace O-ring with new one, install cap (6) and install snap ring (17).

WPMAN0143 (8/31/01)

3

1

at outer edge of seal

Figure 14. Seal Installation 25

Removing Gearbox from Mower

Remove the bearings (10) and bearing spacer (5) from the vertical shaft (4).

(Figure 15)

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

Remove mower deck from wing frame.

Remove belt shields.

Remove driveline from gearbox input shaft. Remove drive shield.

Remove belt from gearbox sheave.

Inspect vertical and horizontal shafts for grooves, nicks, or bumps in the areas where the seals seat.

Resurface any damage with emery cloth.

Remove gear stand from mower.

Inspect housing and caps for cracks or other damage.

Remove gearbox sheave from gearbox by removing cotter pin and the castle nut.

Gearbox Assembly (Figure 15)

Remove gearbox from gearbox stand.

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 repairs other than replacing bearings, seals or gaskets are required.

Gearbox Disassembly (Figure 15) Remove gearbox from mower.

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

Remove 3/8” plug (18) from side of gearbox and pour out gear oil.

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

Remove internal snap ring (17) holding front cover (6) using two screwdrivers. Remove vent plug (25).

Support gearbox in hand press and push on the input shaft (3) to remove front cover (6), and bearing (8).

Insert the input bearing (9) into the housing using a round tube of correct diameter using a hand press.

Remove O-ring (21) from housing. Remove gear (1) and rectangular key (13) from horizontal input shaft (3).

Press gear (1) onto input shaft (3) making sure rectangular key (13) is aligned.

Remove input shaft (3) with bearing (8) from front cover (6). Remove bearing (8) from input shaft (3).

Press input shaft assembly (1, 3, 13) into input bearing (9).

Remove input bearing (9) by using a punch and hammer from outside the housing.

Secure O-ring (21) with grease in the housing.

Remove the input oil seal (20) by using a punch and hammer from outside the housing.

Press front cover assembly (6, 8) onto input shaft (3).

Install snap ring (17) into housing. Verify that snap ring (17) is seated correctly by measuring its internal diameter in two positions. Dimensions should be 4.70” or greater.

Press front bearing (8) in the front cover (6).

Support housing in vise in horizontal position.

Remove snap ring (16) on vertical housing using two screwdrivers.

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 (8).

Repeat until end float is less than 0.012”. Check rotational torque by hand. The torque should be less than 2.2 lbs./inch.

Stand gearbox vertically to remove shield washer (7).

Support housing in vise in horizontal position.

Remove dual lip seal (19) by driving screwdriver in the middle of the oil seal and extract by prying on the housing shoulder.

Install the following parts on the vertical shaft (4): bearing (10) and snap ring (14). Check end float, if it is greater than 0.012”, install shim (22a) between bearing (10) and snap ring (14). Check that the vertical shaft rotates freely. The torque should be less than 2.2 lbs.-inch.

Remove the internal retaining ring (15) using snap ring pliers.

Support housing in vise in vertical position.

Remove oil vent plug (25). Remove vertical shaft (4), bearings (10) and bearing spacer (5) assembly by using a punch and hammer to tap vertical shaft (4) through the oil vent plug hole.

Press the vertical shaft assembly (4, 10, 14), spacer (5), and bearing (10) into the housing (2). Install the snap ring (15) and make sure it fits securely.

Remove snap ring (14) from vertical shaft (4) using snap ring pliers.

Check that the gear backlash is between 0.006” to 0.016”. You should not have to adjust the backlash.

26

WPMAN0143 (8/31/01)

Apply grease to lower seal lips (19) and insert in vertical housing using tube of correct diameter, paying attention not to damage the seal lip. Press in housing so seal is recessed 0.275 to 0.314 inch.

Insert protective washer (7) by hand. Install snap ring (16) and position it together with dual lip seal (19) by pressing it into position.

Apply Permatex to horizontal shaft back bore and insert vent plug (25).

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.

Remove gearbox from water and dry off with compressed air. Add 0.65 quart (800 ml) SAE 80W or 90W EP oil and tighten all plugs.

Press input shaft oil seal (20) in, using tube of correct diameter. Be careful not to damage seal lip.

25

22C

9

26

2

18

1 21 8

13

3

22C

20

4

6

23

17 10 14 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

Bevel gear Gearbox housing Keyed gear shaft 12T Pinion shaft Spacer Gearbox cover Washer, 1.58 x 3.13 x .04 Ball bearing 6007 Ball bearing 6207 Ball bearing 6208 Castle nut Washer, 25mm x 44mm x 4mm Key Internal retaining ring 45mm Internal retaining ring 2.9mm x 80mm 16. Internal retaining ring 81mm

5 10 22B 17.

18.

19.

20.

21.

22A. 22B. 22C. 23.

25.

26.

15 Internal retaining ring 125mm 3/8 NPT Square head pipe plug 19 Metric seal 40 x 80 x 12 Metric seal 35 x 52 x 7 7 O-Ring seal .13 x 4.88 OD Shim, 40.3mm x 51.5mm 16 Shim, 69.0mm x 79.9mm Shim, 35.3mm x 48.0mm 3/16 x 2” Cotter pin 11 3/8 NPT Vent plug Cap

Figure 15. Wing Gearbox Exploded View WPMAN0143 (8/31/01)

22A

27

CD4837C

12

DRIVE PULLEY INSTALLATION

UNIVERSAL JOINT REPAIR

(Figure 16) Invert gear stand.

1. Yoke 2. Cup and bearings 3. Snap ring 4. Journal cross

When gear stand is installed on mower, dimension “A” (from the top of the mower deck to the center line of the drive pulley) must be 2-7/16” (plus or minus 1/32”). This is a critical dimension and must be carefully adjusted for proper belt life. Add or subtract shim washers under idler pulley to align with drive pulley.

3 3

2

4 2

3

2 3

Tighten gear stand hardware.

CD1645A

1

Fill gearbox half full of SAE 90W gear lube. Check level after waiting five minutes to permit lube to work through bearings and add lube, if necessary, until gearbox is half full.

Figure 18. U-Joint Exploded View

Replace driveline shield. Attach driveline to gearbox.

U-Joint Disassembly

1. Shim 2. Idler arm 3. Idler pulley 4. Drive pulley 5. Nut and cotter key 6. Gearbox stand

6

1

2

1. Remove snap rings from yokes in four locations as shown in Figure 19.

CD4991

DIM “A” 4

2

5

3

1

Figure 16. Pulley Alignment

CD1385A

WING DRIVE PHASING

Figure 19

(Figure 17)

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 20.

1

2

2

1

CD5070

CD1386

Figure 20

Figure 17. Wing Drive Phasing 28

WPMAN0143 (8/31/01)

3. Clamp cup in vise as shown in Figure 21 and tap

U-Joint Assembly

on yoke to completely remove cup from yoke.

Repeat steps two and three for opposite cup.

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.

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.

Tap yoke to aid in process.

2. Seat cups by placing a drift or socket (slightly

CD1387

smaller than the cup) on cup and rapping with hammer. See Figure 23. Install snap ring and repeat on opposite cup.

3. Repeat steps one and two to install remaining cups in remaining yoke.

Figure 21

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

4. Place universal cross in vise as shown in Figure 22 and tap on yoke to remove cup. Repeat step three for final removal. Drive remaining cup out with drift and hammer.

CD1388

CD1389

Figure 22 WPMAN0143 (8/31/01)

Figure 23 29

TROUBLE SHOOTING BELT CONDITIONS

Problem

Possible Cause

Solution

Mower overloading; material too tall or heavy

Reduce tractor ground speed but maintain full PTO rpm. Cut material twice, one high pass and then mow at desired height. Cut a partial swath.

Oil on belt from overlubrication

Be careful not to overlubricate. Clean lubricant from belt and pulleys with clean rag. Replace oil-soaked belt.

Belt hung up or rubbing

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

Belt misaligned

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

Pulley misalignment

Inspect to ensure belt is running in center of all idlers. Shim idler as necessary to align.

Pulley misalignment

Re-align.

Damaged belt

Replace belt.*

Foreign object in pulley grooves

Inspect all pulley grooves for rust, paint or weld spots and remove.

Worn pulley groove

Replace pulley.

Damaged belt

Rollover, high shock loads or installation damage

Replace belt.*

Belt breakage

High shock loads

Avoid abusive mowing. Avoid hitting the ground or large obstructions.

Belt came off drive

Check pulleys for foreign material in grooves. Avoid hitting solid objects or ground.

Belt slippage

Frayed edges on belt cover

Belt rollover

* 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.

30

WPMAN0143 (8/31/01)

TROUBLE SHOOTING MOWING CONDITIONS

Problem

Possible Cause

Solution

Grass cut higher in center of swath than at edge

Height of mower higher at front than at rear

Adjust mower height and attitude so that mower rear and front are within 1/2” of same height. See instructions.

Grass cut lower in center of swath than at edge

Height of mower lower at front than at rear

Adjust mower height and attitude so that mower rear and front are within 1/2” of same height. See instructions

Streaking conditions in swath

Conditions too wet for mowing

Allow grass to dry before mowing.

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

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

Dull blades

Sharpen or replace blades.

Material too high and too much material

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

Raise rear of mower high enough to permit material to discharge, but not so high that conditions listed above occur.

Grass wet

Allow grass to dry before mowing.

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

Cutting lower will help.

Rear of mower too low, trapping material under mower

Adjust mower height and attitude.

(See instructions.)

Material discharges from mower unevenly; bunches of material along swath

WPMAN0143 (8/31/01)

31

ASSEMBLY ___ Check that shields and guards are properly installed and in good condition. Replace if damaged. ___ Check all bolts to be sure they are properly torqued. ___ Check that all cotter pins and safety pins are properly installed. Replace if damaged. ___ Check that blades have been properly installed. ___ Check mower attitude and belt alignment. ___ Check and grease all lubrication points as identified in “Service, lubrication information.” ___ Check the level of gearbox fluids before delivery.

Service, if required, as specified in the “Service, lubrication information.”

CAUTION J Always wear relatively tight and belted clothing to avoid entanglement in moving parts. Wear sturdy, rough-soled work shoes and protective equipment for eyes, hair, hands, hearing and head.

WARNING

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

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

J Before performing any service or maintenance, disconnect driveline from tractor PTO. J Before working underneath, carefully read operator manual instructions, disconnect driveline, raise mower, securely block up all corners with jackstands and check stability. Secure blocking prevents equipment dropping from hydraulic leak down, hydraulic system failures, or mechanical component failures.

Delivery Check List (DEALER RESPONSIBILITY) ___ Show customer how to make adjustments and select proper PTO speed. ___ Show customer how to make sure driveline is properly installed and that collar slides freely and is seated in groove on tractor PTO shaft. ___ Show customer how to determine the turning limits of the CV PTO driveline. ___ Show customer the safe, proper procedures to be used when mounting, dismounting, and storing equipment. ___ Make customer aware of optional equipment available so that customer can make proper choices as required. ___ Instruct customer how to lubricate and explain importance of lubrication. ___ Point out the safety decals. Explain their meaning 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. ___ Explain to customer the potential crushing hazards 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 “Service, blocking methods” section of the operators manual. Explain that blocking up prevents equipment dropping from hydraulic leak down, hydraulic system failures or mechanical component failures. ___ Point out all guards and shields. Explain their importance and the safety hazards that exist when not kept in place and in good condition.

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

Recommended torque values for hardware are located on page 11.

Complete the following check lists when assembly is complete.

Pre-Delivery Check List (DEALER 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.

32

WPMAN0143 (8/31/01)

DEALER SET-UP INSTRUCTIONS Attaching Mower to Tractor Park the mower on a level, hard-surfaced area. Align tractor with hitch bracket on trailer frame. Set tractor parking brake and block mower transport wheels.

Adjust tractor hitch bracket on trailer frame so the trailer is level when attached to the tractor. Pin the mower to the tractor with a locking type hitch pin.

REMOVE HARDWARE

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

NOTE: Remove 3/8 bolt, washer, and nut from chain (as shown in Figure 24) from each side of rear deck.

This hardware is for factory transport only and can be discarded.

Figure 24. Remove Hardware Attach the implement hydraulic hose to the tractor port.

WARNING

NOTE: The implement hydraulic system should have been filled at the factory. Always assume it is empty.

Fully purge air and fill the hydraulic system by raising and lowering wings several times while hooked to a tractor hydraulic supply. Keep all personnel away while raising and lowering.

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

Attach towing safety chain to tractor drawbar as shown in Figure 25.

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

9” MAX

WARNING J Air in hydraulic systems can cause erratic operation and allows loads or equipment components to drop unexpectedly. Before putting into service or allowing anyone to approach the equipment, purge any air in the system by operating all hydraulic functions several times after connecting equipment, connecting hoses, or doing any hydraulic maintenance.

WPMAN0143 (8/31/01)

CD4316

Figure 25. Tow Chain Installation

33

NOTES

34

WPMAN0143 (8/31/01)

FM1012R, FM1015R & FM1017R INDEX TO PARTS LISTS COMMON PARTS MAIN FRAME ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36--37 TRAILER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38--39 WING FRAME ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 ROTATING CASTER WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 NON--ROTATING CASTER WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 HEIGHT ADJUSTMENT POST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 HUB & AXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 WING GEARBOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 BLADE AND SPINDLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 CV DRIVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 REAR & WING DRIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50--51 JACKSHAFT DRIVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 REAR CHAIN SHIELDING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 3-1/2 x 10” HYDRAULIC CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 3 x 8” SINGLE-ACTING HYDRAULIC CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . 54

FM1012R CENTER DECK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 WING DECK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 WING DECK ANTI--SCALP ROLLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 48

FM1015R CENTER & WING DECK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 FRONT ROLLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

FM1017R CENTER & WING DECK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 FRONT ROLLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

WPMAN0143 (8/31/01)

35

FM1012R, FM1015R & FM1017R MAIN FRAME ASSEMBLY

31 58

8

3

30 29

27 58

11

24

29 56 55 25 28 25

61

57

29 32

23

26 58 31 16

53

57

26

31 30 29 58

11

30 29

21 20 57

10

22 20

57

8 6

15

53 18

54

10

21 20

19 17

50

17

2

60

60

7 60

53

17 1

10 13 18

12

9

11

4

9 8

52

CD5600

50

8

54 11

11

10

53 51

12

14

11 7

33 -- COMPLETE DECAL SET

36

5

8

8

WPMAN0143 (8/31/01)

FM1012R, FM1015R & FM1017R MAIN FRAME ASSEMBLY Ref No 1 2 3 4

4 5

5 6

6 7

7

7 8 9 10 11

12 13 13 13 14 14 14

Ref Part No No No Used Description 15 WP58993 1 Caster Arm Asy, Right, FM1012R - or-15 WP58974 1 Caster Arm Asy, Right, FM1015R, FM1017R 16 WP58994 1 Caster Arm Asy, Left, FM1012R - or-16 WP58978 1 Caster Arm Asy, Left, FM1015R, FM1017R 17 WP38001 4 Pin, Wing Hinge 18 WP1791 6 Sleeve, HT .63 x 1.00 x .56 19 WP38296 1 Rope, .25 x 95.0 20 WP38295 3 Rope Clamp 21 WP38257 3 Hook, S .25 x 2.25 22 WP38294 1 Rope, .25 x 46.0 23 WP17628 1 Hose, HP 1/4 NPT x 108 24 WP26117 1 Hose, HP 1/4 NPT x 45 25 WP26116 2 Hose, HP 1/4 NPT x 33 26 WP26131 2 Cylinder, Hydraulic 3--1/2 x 10 (See page 53) 27 WP29547 1 Cylinder, Hydraulic 3 x 8 (See page 54) 28 WP38289 1 Cross, Hydraulic 4--Way 1/2 NPT 29 WP11893 7 Bushing, Pipe Reducing 1/2 x 1/4 30 WP38423 3 Elbow, 90 Deg 3/32 Rstr 1/4 x 1/4 31 WP8346 4 Pin, Headless 1.00 x 4.58 32 WP1631 2 Pin, Headless 1.00 x 3.63 33 WP40908 1 Complete decal set (not shown)

Part No No Used Description ---- ---- -1 Trailer assembly (See page 38) ---- ---- -1 Right wing assembly (See page 40) ---- ---- -1 Left wing assembly (See page 40) ---- ---- -1 Right deck assembly FM1012R (See page 42) - or----- ---- -1 Right deck assembly FM1015R, FM1017R (See page 41) ---- ---- -1 Left deck assembly FM1012R (See page 42) - or----- ---- -1 Left deck assembly FM1015R, FM1017R (See page 41) ---- ---- -1 Center deck assembly FM1012R (See page 41) - or----- ---- -1 Center deck assembly FM1015R, FM1017R (See page 41) WP44628 2 Drive, Cmpl 2300, 21.7 x 32.6 FM1012R (See page 50) - or-WP44629 2 Drive, Cmpl 2300, 26.0 x 41.5 FM1015R (See page 50) - or-WP44630 2 Drive, Cmpl 2300, 28.7 x 47.0 FM1017R (See page 50) ---- ---- -6 Rotating caster (See page 43) ---- ---- -2 Non--rotating caster (See page 44) -- ---- ---4 Height adjustment post (See page 45) WP58956 6 Caster Arm Asy w/Bearing WP31780 12 Bushing, Oilite 1.25 x 1.50 x 1.50 * 6 Grease Fitting, 1/4 -- 28 Tapered Thread WP58968 2 Caster Arm Asy, Non Rotating WP40947 1 Caster Arm Asy, FM1012R - or-WP40944 1 Caster Arm Asy, Right, FM1015R - or-WP40942 1 Caster Arm Asy, Right, FM1017R WP40947 1 Caster Arm Asy, FM1012R - or-WP40945 1 Caster Arm Asy, Left, FM1015R - or-WP40943 1 Caster Arm Asy, Left, FM1017R

(Rev. 1/11/02) WPMAN0143 (8/31/01)

Ref Part No No 50 * 51 * 52 * 53 WP11900 54 WP19025 55 WP12272 56 * 57 * 58 * 60 * 61 WP62789 * Obtain Locally

37

HARDWARE Description Screw, HHCS 5/8 NC x 2--1/2 GR5 Screw, HHCS 1/2 NC x 1--3/4 GR5 Screw, HHCS 1/2 NC x 3--1/4 GR5 Nut, Flanged Lock 1/2 NC Nut, Flanged lock 5/8 NC Washer, Flat 1.13 x 2.38 x .19 Washer, Flat 3/4 Standard Washer, Flat 1” Standard Pin, Cotter 1/4 x 1--3/4 Pin, Safety 3/16 Screw, HHCS 1/2 NC x 2 FT GR5

64

85

34

32

64

84

38

CD5601

76

82

64

64

30

31

27

26

80 21

79

6

60

81

32

64

17

67 72

13

56 75

66

16 77 15 78

19

72

9

64

64

62

71

80

73 55

33

59

57

72 58

14

21

18

74

66

5

22

29

28

83

62

66

1

7

8

20

63

53 62

70

7 11 58 72

23

25

61

24

73

3

4

4

72

13

69 2

72

54

57

10

3

12

67

68

69 52

63

51 50

10 68

FM1012R, FM1015R & FM1017R TRAILER ASSEMBLY

WPMAN0143 (8/31/01)

FM1012R, FM1015R & FM1017R TRAILER ASSEMBLY Ref No 1 2

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 -- --- --- -24 25 26 27 -- -28 29 30 31 32 33 34

Part No No Used Description -- ---- ---- 1 Trailer frame WP40803 1 Hitch, Adjustable Category 1 (FM1012R) - or-WP40928 1 Hitch, Adjustable Category 2 (FM1015R & FM1017R) WP40876 2 Link, Hitch Adjustment WP44639 2 Sleeve, .76 x 1.00 x 4.12 WP40804 1 Lock, Rear Deck WP40880 1 Lever, Rear Deck Lock Release WP40879 2 Lock, Wing Deck WP40938 1 Lever, Wing Deck Lock Release WP19201 1 H--Frame, CV Drive WP44641 2 Sleeve, HT .78 x 1.00 x .69 WP31464 2 Sleeve, .38 x .63 x .34 WP23790 1 Jack, Parking WP21957 3 Spring, Comp .58 x .08 x 2.4 40 WP484 2 Sleeve, HT .63 x 1.00 x .44 WP3502 1 Bearing, Ball -- -- ---- -- 1 Housing, Bearing (Not Serviced) WP1251 1 Bearing Holder w/Bearing (Includes Ref. 15, 16, 77, 78) WP44637 1 Shield, Front Drive WP44626 1 Drive, Yk & Shft Ntel 2400 x 26.4 (See page 52) WP19407 1 Chain, Safety 6400 Lb WP62440 2 Bumper Pad WP38264 1 Pin, Lynch Chain & Cotter Asy WP40933 1 Gear Box, 4--Way Splitter WP58815 2 Seal, Thru Shaft 4--Way Gr Box WP58816 2 Seal, Wing Shaft 4--Way Gr Box WP58817 6 Bearing, Cup & Cone 4--Way Box WP62626 4 Sleeve, .76 x 1.00 x 1.00 WP44636 1 Shield, Gear Box 4--Way WP38187 2 Hub, Wheel & Axle (See page 45) WP38298G 2 Wheel & Tire, 20.5 x 8.00 x 10 Gray WP38475G -- -- Wheel Rim, 5--Bolt 8.00 x 10 Gray WP44625 1 Drive, Cmpl CV 2480, 35.8 x 48.4 (See page 49) WP44627 1 Drive, Cmpl 2300, 26.8 x 43.3 (See page 50) WP58984 2 Pin, Rear Wing Hinge WP40805 1 Frame, Rear Wing WP44638 2 Chain, 16 Link 1/4 Proof WP3443 1 Hydraulic Hose Holder WP62484 1 Socket, SMV Emblem

WPMAN0143 (8/31/01)

Ref No

HARDWARE

Part No

Description

50

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

51

* Screw, HHCS 5/8 NC x 7 GR5

52

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

53

* Screw, HHCS 5/8 NC x 2 GR5

54

* Screw, HHCS 5/8 NC x 5 GR5

55

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

56

* Screw, HHCS 3/8 NC x 1 GR5

57

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

58

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

59

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

60

* Screw, HHCS 1/2 NC x 3 GR5

61

* Screw, HHCS 1/2 NC x 2 GR5

62

* Nut, Lock 5/8 NC

63

* Nut, Lock 3/4 NC

64

WP11900 Nut, Flanged Lock 1/2 NC

66

WP14350 Nut, Flanged Lock 3/8 NC

67

* Nut, Lock 3/8 NC

68

WP28873 Washer, Flat .75 x 1.50 x .25

69

WP44640 Washer, Cup 1.04 x 2.25 x .17

70

WP34467 Washer, Flat .63 x 2.00 x .38

71

WP10635 Washer, Cup .63 x 1.75 x 14 Ga

72

* Washer, Flat 3/8 Standard

73

* Washer, Flat 1/2 Standard

74

* Washer, Lock 1/2

75

* Washer, Lock 3/8

76

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

77

* Grease Fitting, 1/4--28 90° Tapered Thread

78

WP12128 Ring, Retaining .06 x 72 MM

79

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

80

* Grease Fitting,1/4--28 Tapered Thread

81

* Pin, Safety 3/16

82 83

WP62789 Screw, HHCS 1/2 NC x 2 FT GR5 * Screw, HHCS1/2 NC x 1-3/4 GR5

84

WP14139 Nut, Flanged Lock 5/16 NC

85

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

* Obtain locally

39

FM1012R, FM1015R & FM1017R WING FRAMES

6 8

11 10

11

9 2

6

7

9

5

3 5

Part No

8

7

8 4

Ref No

3

1

10 8

7 8

No Used

8

7

CD5602

Ref Part No No No Used Description 4 WP40895 2 Trunnion, Front Deck (FM1012R, FM1015R) - or-4 WP40887 2 Trunnion, Front Deck (FM1017R) 5 WP40896 2 Trunnion, Rear Deck (FM1012R, FM1015R) - or-5 WP40888 2 Trunnion, Rear Deck (FM1017R) 6 WP58980 2 Pin, Wing Deck Link 7 WP58982 4 Pin, Deck Link Trunnion 8 * 6 Pin, Safety 3/16 9 WP71444 2 Rubber Bumper 10 WP14139 2 Nut, Flanged Lock 5/16 NC 11 WP38264 2 Pin, Lynch Chain & Cotter Asy

Description

1

WP1000610 1 Frame, Right Wing (FM1012R)

1

- or-WP1006340 1 Frame, Right Wing (FM1015R)

1

- or-WP1000614 1 Frame, Right Wing (FM1017R)

2

WP1000611 1 Frame, Left Wing (FM1012R)

- or-2 WP1006341 1 Frame, Left Wing (FM1015R) 2

- or-WP1000615 1 Frame, Left Wing (FM1017R)

3

WP40907

3

- or-WP40881

4

2 Link, Wing Deck Lift (FM1012R) 2 Link, Wing Deck Lift (FM1015R, FM1017R)

* Obtain locally

40

(Rev. 2/27/2006) WPMAN0143 (8/31/01)

FM1012R CENTER DECK FM1015R & FM1017R CENTER & WING DECK ASSEMBLY 4

6 60

13

57 5

58 4

57

51 50

62

12

14 50 8

7

54

52

53

11

61 9

CD5603

60 58 10 2

Ref No

Part No

No Used

1 WP1000618 - or-1 WP1000617 2

WP18879 - or-WP31615

3

-- ----

4

WP44635 - or-WP44634

Description

1 Deck, Weld Assembly 6 Foot (FM1015R center, FM1017R all) 1 Deck, Weld Assembly 5 Foot (FM1012R center, FM1015R wings)

59

1

3 Ref No

Part No

No Used

11

WP58989

1 Idler Arm Assembly

12

WP53595

1 Idler, Flat 5.0 Dia.

13

WP67131

1 Spring, Ext .177 x 1.22 x 9.88

14

WP35193

2 Bearing, Ball

Ref No

Part No

1 V--Belt W112 (FM1015R center, FM1017R all) 1 V--Belt W99 (FM1012R center, FM1015R wings)

50

3 CW Spindle assembly (See page 47)

Description

HARDWARE Description

WP35141 Ring, Retaining Int .062 x 1.56

51 WP302178 Nut, Castle 5/8 NF

2 Shield, Belt (FM1015R center, FM1017R all)

52

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

53

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

54

* Washer, Flat 1/2 Standard

2 Shield, Belt (FM1012R center, 9180 wings)

57

WP11900 Nut, Flanged Lock 1/2 NC

58

WP19024 Screw, Flngd Hex Head 5/8 NC x 1--3/4

5

WP53534

1 Gearbox Stand

59

WP1517 Washer, Flat .63 x 1.38 x 7 Ga

6

WP53593

1 Gearbox, 1:1.92 (See page 46)

60

WP19025 Nut, Flanged Lock 5/8 NC

7

WP65197

1 Sheave, Offset 12.4 P.D.

61

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

8

WP29792

1 Key, HT 1/4 x 1/4 x 1--1/4

62

WP62153 Bolt, Flngd Whiz 3/8 NC x 1

9

WP53567

1 Guide, Belt 8 Ga Formed

10

WP64555

1 Idler, Flat 5.5 Dia.

WPMAN0143 (8/31/01)

* Obtain locally 41

FM1012R WING DECK ASSEMBLY 6

60

4 57 10 62

5

58

13 51

7

8

57 56

50

12

14

54

50 11

52

53

61 9

2 CD5604

1 Ref No

Part No

No Used

1 WP1000609 - or-1 WP1000608 2

WP40930

3

-- -- --

4

Description

1 Deck, Weld Asy 4 Foot Left 1 Deck, Weld Asy 4 Foot Right (Not shown) 1 V--Belt, W80 3 CW Spindle assembly (See page 47)

WP58953

1 Shield, Belt Left

- or-WP58954

1 Shield, Belt Right (Not shown)

5

WP58295

1 Gearbox Stand, Left

5

WP58294

1 Gearbox Stand, Right (Not shown)

6

WP53593

1 Gearbox, 1:1.92 (See page 46)

7

WP65197

1 Sheave, Offset 12.4 PD

8

WP29792

1 Key, HT 1/4 x 1/4 x 1--1/4

9

WP53567

1 Guide, Belt 8 Ga Formed

10

WP58952

11

WP57939

Ref No

Part No

12

WP57972

1 Idler, Flat 6.0 Dia

13

WP67131

1 Spring, Ext .177 x 1.22 x 9.88

14

WP35193

2 Bearing, Ball

Ref No

Part No

50

No Used

3

Description

HARDWARE Description

WP35141 Ring, Retaining Int .062 x 1.56

51 WP302178 Nut, Castle 5/8 NF 52

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

53

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

54 56

* Washer, Flat 1/2 Standard WP52877 Sleeve, .51 x .63 x .64

57

WP11900 Nut, Flanged Lock 1/2 NC

58

WP19024 Screw, Flngd Hex Head5/8 NC x 1--3/4

60

WP19025 Nut, Flanged Lock 5/8 NC

61

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

2 Shield, Belt

62

WP62153 Bolt, Flngd Whiz 3/8 NC x 1

1 Idler Arm Assembly

* Obtain locally 42

WPMAN0143 (8/31/01)

ROTATING CASTER WHEEL

16

Ref Part No No No Used Description 1 WP38267G 1 Wheel 15.00 x 6.00 x 6 Gray WP38476G -- -- Wheel Rim, 6.00 x 6 w/Cups Gray 2 * 1 Grease Fitting, 1/8 Pipe Thread 3 WP2306 2 Bearing, Cup 4 WP2304 2 Bearing, Cone 5 WP5624 2 Seal, 1.13 x 1.78 x .47 6 WP14318 2 Sleeve, HT .75 x 1.13 x 1.25 7 WP38111 1 Sleeve, HT .53 x .75 x 6.75 8 WP58958 1 Caster Yoke & Shaft Asy 9 WP35124 1 Pin, Klik 7/16 x 2 10 WP38107 1 Screw, HHCS 1/2 NC x 9 GR5 11 * 1 Nut, Hex 1/2 NC 12 WP11900 1 Nut, Flanged Lock 1/2 NC 13 WP58987 2 Sleeve, 1.50 x 1.90 x 1.00 14 WP58986 2 Sleeve, 1.50 x 1.90 x .75 15 WP58985 1 Sleeve, 1.50 x 1.90 x .50 16 WP6237 1 Washer, Flat 1.50 x 2.25 x 13 Ga

15 14 13

9

8

10 11

* Obtain locally

12

2 3

7

6

5

WPMAN0143 (8/31/01)

4

4

5

6

3 1

43

NON--ROTATING CASTER WHEEL

Ref Part No No No Used Description 1 WP38267G 1 Wheel, 15.00 x 6.00 x 6 Gray WP38476G -- -- Wheel Rim, 6.00 x 6 w/Cups Gray 2 * ---- Grease Fitting, 1/8 Pipe Thread 3 WP2306 2 Bearing, Cup 4 WP2304 2 Bearing, Cone 5 WP5624 2 Seal, 1.13 x 1.78 x .47 6 WP14318 2 Sleeve, HT .75 x 1.13 x 1.25 7 WP38111 1 Sleeve, HT .53 x .75 x 6.75 8 WP58961 1 Caster Yoke & Shaft Asy Non Rot 9 WP35124 1 Pin, Klik 7/16 x 2 10 WP38107 1 Screw, HHCS 1/2 NC x 9 GR5 11 * 1 Nut, Hex 1/2 NC 12 WP11900 1 Nut, Flanged Lock 1/2 NC 13 WP58987 2 Sleeve, 1.50 x 1.90 x 1.00 14 WP58986 2 Sleeve, 1.50 x 1.90 x .75 15 WP58985 1 Sleeve, 1.50 x 1.90 x .50 16 WP6237 1 Washer, Flat 1.50 x 2.25 x 13 Ga

16 15 14 13

8

9

10

11

* Obtain locally

12 6 5

2

4 3

CD5606

7

6

5

4

3 1

44

WPMAN0143 (8/31/01)

HEIGHT ADJUSTMENT POST

8 7 6

5

Ref No 1 2 3 4 5 6 7 8

Part No No Used Description WP58998 1 Sleeve, Drld .81 x 1.25 x 8.00 WP58999 1 Wear Pad * 1 Pin, Spirol .25 x 1.00 WP35124 1 Pin, Klik 7/16 x 2 WP52855 2 Sleeve, 1.28 x 1.66 x 1.00 WP52854 2 Sleeve, 1.28 x 1.66 x .75 WP52853 1 Sleeve, 1.28 x 1.66 x .50 * 1 Washer, Flat 1--1/4 Standard

* Obtain Locally

1 4 3

CD5607

2

HUB & AXLE ASSEMBLY Ref Part No No No Used Description 1 WP1001020 1 Wheel Hub & Axle Assembly 2 WP1001021

1 Axle Shaft

3

WP314

1 Seal, 1.50 x 2.44 x .31

4

WP2303

2 Bearing, Cone

5

WP38437

1 Wheel Hub, Housing w/Cups

6

WP2305

3

6

4

9

11

2 Bearing, Cup

7

* 2 Washer, Flat 3/4 Standard

8

WP5849

9

*

10

WP14133

11

WP531

12

6

2

1 Nut, Slotted Hex 3/4 NF

5

1 Pin, Cotter 3/16 x 1

12 7 8

1 Hub Cap, Assembly w/Fitting

1

1 Hub Cap * 1 Grease Fitting, 1/4 Tapered Thread

* Obtain Locally

WPMAN0143 (8/31/01)

4

10 CD4122

45

WING GEARBOX ASSEMBLY 25

22C

9

2

26

1 21

13

18

3

22C 8 17

6

4

20

23 10 14

22A

5 10 22B 15

Ref Part No No No Used Description -- WP53593 1 Gearbox 1:1.92 1 WP51949 1 Gear, Bevel 23 Tooth 2 ---- ---- --- Gearbox housing (not sold separately) 3 WP51945 1 Shaft, Input 4 WP51944 1 Gear, 12 Tooth Pinion & Shaft 5 WP20886 1 Spacer, 2.76 x 3.00 x 3.3 6 WP53594 1 Gearbox Cover w/Decal 7 WP20888 1 Washer, Flat 1.58 x 3.13 x .04 8 WP51850 1 Bearing, Ball 9 WP20890 1 Bearing, Ball 10 WP20891 2 Bearing, Ball 11 WP51946 1 Nut, Castle M24 x 2 12 WP20893 2 Washer, Flat 25mm x 44mm x 4m 13 WP20894 1 Key, 8mm x 10mm x 30mm 14 WP20895 1 Ring, Retaining Ext 45mm 15 WP39251 1 Ring, Retaining Int 2.9mm x 80mm 16 WP20897 1 Ring, Retaining Int 81mm 17 WP20898 1 Ring, Retaining Int 125mm 18 * 2 Plug, Pipe 3/8 NPT Square Head 19 WP20900 1 Seal, 40mm x 80mm x 12mm 20 WP20901 1 Seal, 35mm x 52mm x 7mm

19 7 16 12 11

CD4837C

Ref Part No No No Used Description 21 WP20902 1 O--Ring, .13 x 4.88 OD 22 WP20896 1 Shim Kit 22A -- ---- -- -- A/R Shim 40.3mm x 51.5mm 22B -- ---- -- -- A/R Shim 69.0mm x 79.9mm 22C -- ---- -- -- A/R Shim 35.3mm x 48.0mm 23 * 1 Pin, Cotter 3/16 x 2 25 WP39325 1 Plug, Vent 3/8 NPT 26 WP53592 1 Cap, 52mm Dia x 7mm * Obtain Locally

46

WPMAN0143 (8/31/01)

BLADE & SPINDLE ASSEMBLY

Ref No 1 2 3 4 5 6

Part No WP37009 * WP52898 * WP34440 WP12622

6

WP66694

7 8 9 10 11 12 14 19 21 22 23

WP52881 WP52949 WP52872 WP29899 WP52882 WP29898 WP52852 WP4358 * WP3379 WP11900

Description Nut, Jam 7/8 NF Screw, HHCS 1/4 NC x 1 GR5 Washer, Lock .929 x 1.66 Washer, Lock 1/4 Bushing, H 1 In Strt Bore w/Key Sheave, H 1 BK 5.0 PD (FM1012R Wing Deck & FM1015R Rear Deck & FM1017R Wing & Rear Deck) Sheave, H 1 BK 4.17 PD (FM1012R Rear Deck, FM1015R Wing Deck) Spindle, Assembly Complete Seal, 1.50 x 2.12 x .31 Sleeve, 1.14 x 1.50 x .55 Bearing, Cone Spindle, Housing w/Cups Bearing, Cup Shaft, Blade Spindle Screw, HHCS 1/2 NF x 1-1/4 GR5 Grease Fitting 1/4--28 Tapered Thread Screw, HHCS 1/2 NC x 1-1/2 GR5 Nut, Flanged Lock 1/2 NC

21

1 3

2

5

4 6 8

SEAL LIP

9 10

19

12 11 7

12 10

* Obtain Locally

CD5055

8 SEAL LIP

BLADE KITS WP7144BDKT

Blade Kit, High Lift FM1012R Complete

WP9180BDKT

Blade Kit, High Lift FM1015R Complete

WP9204BDKT

Blade Kit, High Lift FM1017R Complete

WP7144BDKT2

Blade Kit, Low Lift FM1012R Complete

WP9180BDKT2

Blade Kit, Low Lift FM1015R Complete

WP9204BDKT2

Blade Kit, Low Lift FM1017R Complete

WP58731KT2

Blade Kit, High Lift, 48” Decks

14 23

Blade Kit 22

WP1001511KT2 Blade Kit, Low Lift, 48” Decks WP1001513KT

Blade Kit, High Lift, 60” Decks

WP1001510KT

Blade Kit, Low Lift, 60” Decks

WP58731KT

Blade Kit, High Lift 72” Decks

WP1001511KT

Blade Kit, Low Lift 72” Decks

(Rev. 9/28/01) WPMAN0143 (8/31/01)

47

FM1012R CENTER DECK AND FM1015R & FM1017R FRONT ROLLER ASSEMBLY (Optional) Ref Part No No No Used Description -- -- WP53585KT 1 Roller Kit, Front Complete 1 WP63294 1 Roller, Front 2 WP53586 1 Bracket, Front Roller 3 WP20668 1 Pin, Retainer .25 x 3.1 4 WP20666 1 Pin, Front Roller 5 WP70069 5 Nut, Flngd Whiz 3/8 NC 6 * 1 Screw, HHCS 3/8 NC x 1 GR5 7 * 4 Bolt, Carriage 3/8 NC x 1 GR5

2

5

CD3552

6

7

1

5

* Obtain Locally

4

3

FM1012R WING DECK ANTI--SCALP ROLLER KIT

9.1 3.0

1.0 1.5 (4) .406 HOLES

6

7 CD5942--1

6

5 4

1 or 2 3 INSTALLATION INSTRUCTIONS 1. Drill (4) .406 holes located as shown.

2. Right deck shown, left deck similar.

8

Ref Part No No No Used Description -- WP1001000 1 Roller Kit, Front Complete 1 WP1001002 1 Brckt, Roller 48 R 2 WP1001001 1 Brckt, Roller 48 LH 3 WP63294 2 Roller, Front 4 WP20666 2 Pin, Front Roller 5 WP20668 2 Pin, Retainer .25 x 3.1 6 WP70069 10 Nut, Flngd Whiz 3/8 NC 7 * 2 Screw, HHCS 3/8 NC x 1 GR5 8 * 8 Bolt, Carraige 3/8 NC x 1 GR5 * Obtain Locally

48

(Rev. 9/28/01) WPMAN0143 (8/31/01)

CV DRIVE ASSEMBLY

12 11 9 4

1

8

2

10

2

7

3

17

13

19

45

18

17

16

6

21 3

4

5

20

CD5309

6 14

Ref No

Part No

-- --

No Used

15

Ref No

Part No

WP44625 -- Drive, Cmpl CV 2480, 35.8 x 48.4

11

WP44688 1 Guard, Outer Half

1

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

12

WP44661 1 Drive, Inner Half Complete

2

WP44674 1 U--Joint Repair Kit 2480

13

WP44677 1 Yoke, Outer Profile

3

WP38394 1 Slide Lock Collar Repair Kit

14

WP44689 1 Guard, Inner Half

4

WP40778 2 Screw, Guard Retainer

15

WP44662 1 Drive, Outer Half Complete

5

WP40766 2 Bearing Ring, Guard

16

WP38352 1 U--Joint Repair Kit 2400

6

WP40777 1 Chain, Guard Anti--Rotation

17

WP40764 2 Pin, Spring 10mm x 80mm

7

WP40779 1 Grease Zerk, Drive Line

18

WP44675 1 Drive Tube, Inner Profile

8

WP44699 1 Shield, CV Cone & Bearing

19

WP44676 1 Drive Tube, Outer Profile

9

WP44672 1 CV Body

20

WP40767 1 Bearing, Guard Support

10

WP44673 1 Yoke, Inner Profile

21

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

WPMAN0143 (8/31/01)

Description

49

No Used

Description

FM1012R, FM1015R, & FM1017R REAR & WING DECK DRIVES

12 11

1

2

10

13 3

5

4

6

7

8

9

4

5

6 14

15

50

CD5608

WPMAN0143 (8/31/01)

FM1012R, FM1015R, & FM1017R REAR & WING DECK DRIVES

Ref No

Part No

----

FM1012R Wing Drive No Used

FM1015R Wing Drive Ref No

Part No

WP44628 -- Drive, Cmpl 2300, 21.7 x 32.6

----

WP44629 -- Drive, Cmpl 2300, 26.0 x 41.5

1

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

1

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

2

WP38352 1 U--Joint Repair Kit 2400

2

WP38352 1 U--Joint Repair Kit 2400

3

WP38394 1 Slide Lock Collar Repair Kit

3

WP38394 1 Slide Lock Collar Repair Kit

4

WP40778 2 Screw, Guard Retainer

4

WP40778 2 Screw, Guard Retainer

5

WP40766 2 Bearing Ring, Guard

5

WP40766 2 Bearing Ring, Guard

6

WP40777 2 Chain, Guard Anti--Rotation

6

WP40777 2 Chain, Guard Anti--Rotation

7

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

7

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

8

WP38478 1 U--Joint Repair Kit 2300

8

WP38478 1 U--Joint Repair Kit 2300

Description

No Used

Description

9

WP40589 1 Slide Lock Collar Repair Kit

9

WP40589 1 Slide Lock Collar Repair Kit

10

WP44682 1 Yoke & Shaft, Male

10

WP44684 1 Yoke & Shaft, Male

11

WP44693 1 Guard, Outer Half

11

WP44695 1 Guard, Outer Half

12

WP44665 1 Drive, Male Half Complete

12

WP44667 1 Drive, Male Half Complete

13

WP44683 1 Yoke & Shaft, Female

13

WP44685 1 Yoke & Shaft, Female

14

WP44694 1 Guard, Inner Half

14

WP44696 1 Guard, Inner Half

15

WP44666 1 Drive, Female Half Complete

15

WP44668 1 Drive, Female Half Complete

Ref No

Part No

Ref No

Part No

FM1017R Wing Drive No Used

Description

Rear Wing Drive

No Used

Description

----

WP44630 -- Drive, Cmpl 2300, 28.7 x 47.0

----

WP44627 -- Drive, Cmpl 2300, 26.8 x 43.3

1

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

1

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

2

WP38352 1 U--Joint Repair Kit 2400

2

WP38478 1 U--Joint Repair Kit 2300

3

WP38394 1 Slide Lock Collar Repair Kit

3

WP40589 1 Slide Lock Collar Repair Kit

4

WP40778 2 Screw, Guard Retainer

4

WP40778 2 Screw, Guard Retainer

5

WP40766 2 Bearing Ring, Guard

5

WP40766 2 Bearing Ring, Guard

6

WP40777 2 Chain, Guard Anti--Rotation

6

WP40777 2 Chain, Guard Anti--Rotation

7

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

7

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

8

WP38478 1 U--Joint Repair Kit 2300

8

WP38478 1 U--Joint Repair Kit 2300

9

WP40589 1 Slide Lock Collar Repair Kit

9

WP40589 1 Slide Lock Collar Repair Kit

10

WP44686 1 Yoke & Shaft, Male

10

WP44679 1 Yoke & Shaft, Male

11

WP44697 1 Guard, Outer Half

11

WP44691 1 Guard, Outer Half

12

WP44669 1 Drive, Male Half Complete

12

WP44663 1 Drive, Male Half Complete

13

WP44687 1 Yoke & Shaft, Female

13

WP44680 1 Yoke & Shaft, Female

14

WP44698 1 Guard, Inner Half

14

WP44692 1 Guard, Inner Half

15

WP44670 1 Drive, Female Half Complete

15

WP44664 1 Drive, Female Half Complete

WPMAN0143 (8/31/01)

51

JACKSHAFT DRIVE ASSEMBLY 11 7 8 1

2

5

4

6

9

10 m5610

3 Ref No

Part No

-- --

No Used

Ref No

Part No

WP44626 -- Drive, Yk & Shft Ntel 2400 x 26.4

6

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

1

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

7

WP40778 1 Screw, Guard Retainer

2

WP38352 1 U--Joint Repair Kit 2400

8

WP40766 1 Bearing Ring, Guard

3

WP38394 1 Slide Lock Collar Repair Kit

9

WP40777 1 Chain, Guard Anti--Rotation

4

WP38353 1 Yoke, Inboard

10

WP40767 1 Bearing, Guard Support

5

WP40764 1 Pin, Spring 10mm x 80mm

11

WP44690 1 Guard, Inner Half

Description

No Used

Description

REAR CHAIN SHIELDING ASSEMBLY Ref Part No No No Used Description --- ---- ---- --- Chain shield assembly, 5 ft. deck --- ---- ---- --- Chain shield assembly, 6 ft. deck --- ---- ---- --- Chain shield assembly, 4 ft. deck 1 WP55346 1 Pin, Headless .38 x 54.6 -or1 WP53556 1 Pin, Headless .38 x 65.35 -or1 WP58996 1 Pin, Headless .38 x 41.25 2 WP4763 -- Chain, 3 Link 1/4 Proof (use 54 for 5 ft.; 66 for 6 ft.; 41 for 4 ft.)

CD4987

15 13

14 3 1

2

Ref No 3 3 3 13 14 15

Part No No Used Description WP55345 1 Shield, Chain Plate -orWP53554 1 Shield, Chain Plate -orWP58997 1 Shield, Chain Plate * -- Pin, Cotter 3/16 x 1 * -- Bolt, Carriage 3/8 NC x 1 GR5 WP14350 -- Nut, Flanged Lock 3/8 NC

* Obtain Locally

52

WPMAN0143 (8/31/01)

3-1/2 x 10” HYDRAULIC CYLINDER

DB653

Ref No 8D 8E 8F 8G 9 10 11 12 13 14 15

Ref Part No No No Used Description A WP26131 1 Cylinder, Hydraulic 3--1/2 x 10 1

N/A

1 Cylinder barrel

2

*

3

---- ---- -- --

1 Screw, SHCS 3/8 NC x 1-1/2 Not used

4

---- ---- -- --

Not used

5

N/A

6

*

1 Clevis, Cylinder Rod 1 Nut, Lock 3/8 NC

7

N/A

8

WP23540

1 Rod

8A

-- -- ---- --†

1 Wiper seal

8B

-- -- ---- --†

1 Back-up ring, head

8C

-- -- ---- --†

1 Rod seal, O-ring

1 Seal Kit, 3--1/2 Hyd Cylinder (includes items 8A thru 8G)

WPMAN0143 (8/31/01)

Part No No Used Description -- -- ---- --† 2 3-1/2 OD O-Ring -- -- ---- --† 1 Rod static seal, O-ring -- -- ---- --† 2 Piston back-up ring -- -- ---- --† 1 Piston seal N/A 1 Rod end housing N/A 1 Piston, 3--1/2 Hyd Cylinder N/A 1 Nut, Jam 1--14 UNS * 8 Nut, Jam 1/2 NF N/A 4 Tie Rod, 3--1/2 x 10 Cylinder N/A 1 Butt End, 3--1/2 Cylinder * 2 1/2 Pipe plug * Obtain Locally † Included in Seal Repair Kit N/A Not Available

53

3 x 8” SINGLE-ACTING HYDRAULIC CYLINDER

DC1105

Ref No 1 2

Part No No Used Description ---- ---- --- Not available WP19810

1 Seal Kit, 3 In Hyd Cylinder (includes items 2A thru 2G)

2A

-- ---- ---- † 1 Wiper seal

2B

-- ---- ----

2C

-- ---- ---- † 2 1-1/4 ID U-Cup

2D

-- ---- ---- † 2 Barrel O-ring

2E

-- ---- ----

2F

-- ---- ---- † 2 Piston back-up washer

2G

-- ---- ---- † 1 Piston seal O-ring

-- Not used on this cylinder

-- Not used on this cylinder

3

N/A

1 Rod end housing

4

N/A

1 Piston

5

*

1 Nut, Lock 3/4 NF

6

N/A

4 Cylinder tie rod

7 8

Ref No 9 10

-- ---- ----

11

WP11893

-- Not used on this cylinder 1 Bushing, Pipe Reducing 1/2 x 1/4

12

N/A

13

-- ---- ----

-- Not used on this cylinder

14

-- ---- ----

-- Not used on this cylinder

15

------ ---- * 8 Tie rod nut

16

N/A

17

1 Cylinder barrel

1 Clevis, Cylinder Rod * 1 Nut, Lock 3/8 NC

18

* 1 Screw, SHCS 3/8 NC x 1-1/2

19

N/A

20

WP38288

1 Cylinder rod -- Cylinder, Hydraulic 3 x 8

* Obtain Locally † Included in Seal Kit N/A Not available

* 2 1/2 Pipe plug N/A

Part No No Used Description ---- ---- --- Not used on this cylinder

1 Cylinder butt end 54

WPMAN0143 (8/31/01)

INDEX ADJUSTMENTS Cutting Height, 15 Leveling Mower for Operation, 14

OPERATION Attaching Mower to Tractor, 14 Cutting Height Adjustment, 15 CV Driveline Turning Limits, 14 Detaching Mower from Tractor, 17 Leveling Mower for Operation, 14 Mowing Techniques, 17 Mowing Speed, 17 Tips, 17 Uneven Terrain, 17 Operating the Mower, 17 Parking, 17 Pre-Operation Check List (Owner Responsibility), 16 Starting Mower, 16 Stopping Mower, 16 Transport, 15

ASSEMBLY Dealer Set-Up Instructions, 33–34 Attaching Mower, 33–34 Delivery Check List (Dealer Responsibility), 32 Pre-Delivery Check List (Dealer Responsibility), 32 DEALER SERVICE Blade Spindle Assembly, 24 Disassembly, 24 Installation, 25 Removal, 23 Repair, 23 Blocking Method, 23 Drive Pulley Installation, 28 Gearbox Assembly, 26 Disassembly, 26 Drive Pulley Installation, 28 Leakage Repair, Horizontal Shaft, 25 Removal, 26 Wing Gearbox Leakage Repair, 25 Seal Installation, 25 Maintenance, 25 Universal Joint Repair, 28 U-Joint Assembly, 29 U-Joint Disassembly, 28 Wing Drive Phasing, 28

OWNER SERVICE Belt Replacement, 20 Routing, 20 Blade Servicing, 21 Sharpening, 22 Chain Shielding, 22 Blocking Methods, 18 Daily Service, 20 Lubrication Information, 20 Safety Latch Maintenance, 20 PARTS Index to Parts Lists, 35 SAFETY Blocking Method, 18, 23 Check Lists Delivery (Dealer Responsibility), 32 Pre-Delivery (Dealer Responsibility), 32 Pre-Operation (Owner Responsibility), 16 Safety & Instructional Decals, 7, 8, 9, 10 Safety Latch Maintenance, 20 Safety Rules, 3–6 Safety Symbol (explanation), ii Uneven Terrain, 17

GENERAL Bolt Size Chart, 12 Bolt Torque Chart, 11 General Information, 2 Introduction, ii Specifications, 1 Table of Contents, 1 Warranties Product, Inside Back Cover Replacement Parts, 56

(Rev. 9/28/01) WPMAN0143 (8/31/01)

TROUBLE SHOOTING Belt Conditions, 30 Mowing Conditions, 31

55

PART NUMBER

WPMAN0143

E 2001 Woods Equipment Company. All rights reserved.