OPERATOR S MANUAL & PARTS LIST

OPERATOR S MANUAL & PARTS LIST Flail Mower MODEL FL-72 FIRST PRODUCTS INC. 164 Oakridge Church Road Tifton, Georgia 31794 U.S.A. Phone (229) 382-4768 1-800-363-8780 Fax (229) 382-0506 Web: www.1stproducts.com Email: Sales@1stproducts.com Ser. 101 thru Printed in U.S.A. PBREV0204

Table of Contents Table of Contents Operators Manual Parts List TABLE OF CONTENTS...1 SAFETY SYMBOLS...2 SAFETY DECALS...3 INTRODUCTION...6 USING THIS MANUAL...6 Terminology:...6 Definitions:...6 OWNER ASSISTANCE...6 Serial Number Plate...6 SECTION 1 SETUP AND OPERATION SAFETY..7 TRACTOR REQUIREMENTS...7 UNDERSTANDING HOW THE SWING HITCH OPERATES (PRIOR TO HITCHING TO TRACTOR)...7 TRACTOR HOOK-UP...7 DRIVELINE INSTALLATION...7 OPERATION SAFETY...8 SECTION 2 OPERATING INSTRUCTION...9 TRANSPORTING...9 MOWING INSTRUCTIONS...9 OPERATING INSTRUCTIONS...9 SECTION 3 ADJUSTMENTS...10 CUTTING HEIGHT...10 3-POINT HITCH...10 Scalping...10 BELT TENSION...11 Belt Tightening...11 SECTION 4 MAINTENANCE AND LUBRICATION...12 MAINTENANCE...12 Service Mowing Knives...12 V-Belt Installation...12 Storage...13 LUBRICATION...13 WARRANTY INFORMATION... 16 PARTS LIST - HITCH... 17 PARTS LIST POWER TRANSMISSION... 19 PARTS LIST SHIELDS & ROLLERS... 21 PARTS LIST CUTTING DRUM... 23 PARTS LIST DRIVELINES... 24 1 FL72 Flail Mower 1/28/05

Safety Symbols Safety Symbols This is the safety alert symbol. It means: ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! DANGER Indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury. This signal word is limited to the most extreme situations, typically for machine components that, for functional purposes, cannot be guarded. WARNING Indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury, and includes hazards that are exposed when guards are removed. It may also be used to alert against unsafe practices. CAUTION Indicates potentially hazardous situation, which, if not avoided, could result in minor or moderate injury. It may also be used to alert against unsafe practices. ATTENTION: Read and understand the instructions and warnings carefully before using this machine. 1/28/05 FL72 Flail Mower 2

Safety Decals Safety Decals Your implement comes equipped with all safety labels in place. They were designed to help you safely operate your implement. 1. Read and follow decal directions. 2. Keep all safety decals clean and legible. 3. Replace all damaged or missing decal. 4. Refer to this section for proper decal placement. To install new decals: a. Clean the area the decal is to be placed. b. Peel backing from decal. Press firmly on surface being careful not to cause air bubbles under label. 1.) READ OPERATORS MANUAL AND LEARN TO OPERATE THIS MACHINE SAFELY. 2.) KEEP PEOPLE CLEAR WHEN OPERATING OR LIFTING FOR TRANSPORT. 3.) BEFORE LEAVING THE OPERATOR'S POSITION TO ADJUST, LUBRICATE, CLEAN, OR UNCLOG THE MACHINE, STOP ENGINE AND SET BRAKE. 4.) WAIT FOR ALL MOVEMENT TO STOP BEFORE SERVICING THE MACHINE. 5.) INSTALL AND SECURE ALL GUARDS BEFORE OPERATING. 6.) KEEP HANDS, FEET AND CLOTHING AWAY FROM POWER DRIVEN PARTS. VC50-025 VC50-025 General Warning Decal Both sides of PTO Shield DANGER GUARD MISSING DO NOT OPERATE BENEATH GUARD DANGER GUARD MISSING DO NOT OPERATE DANGER GP55-004 DANGER LABEL (OUTER DRIVE TUBE) Beneath Guards on Driveline & Mower DANGER ROTATING DRIVELINE CONTACT CAN CAUSE DEATH KEEP AWAY DO NOT OPERATE WITHOUT ALL DRIVELINE GUARDS,TRACTOR AND EQUIPMENT SHIELDS IN PLACE DRIVELINES SECURELY ATTACHED AT BOTH ENDS DRIVELINES GUARDS THAT TURN FREELY ON DRIVELINE GP55-007 DANGER LABEL (SHIELD) Driveline Shield 3 FL72 Flail Mower 1/28/05

Safety Decals AE50-114 Danger Hazard Decal Beneath PTO Shield AE50-113 Swing Frame Hazard Decal Both Sides of Mower AE50-076 Thrown Object Hazard Decal Back of Mower FL50-021 Rotating Knives Hazard Decal Both Sides of Mower 1/28/05 FL72 Flail Mower 4

Safety Decals AE50-075 Pinch Point Caution Decal Both Sides of Swing Hitch 5 FL72 Flail Mower 1/28/05

Introduction Introduction Thank you for purchasing the flail mower. This mower is designed to withstand years of continuous use and was manufactured by skilled workers using quality materials. Proper assembly, maintenance, and safe operating practices will help you get years of satisfactory use from this machine. Using This Manual This operator manual is designed to help familiarize you with safety, assembly, operation, adjustments, troubleshooting, and maintenance. Read this manual and follow the recommendations to help ensure safe and efficient operation. Read the warranty located on page 16. Fill in the required information on the warranty registration card provided, and return it to the address on the front of this manual. The warranty registration must be returned to validate warranty. To order a new Operator and Parts Manual, contact your authorized dealer or write to the address listed below in the Owner Assistance paragraph. Include the model and serial numbers of your unit. The information contained within this manual was current at the time of printing. Some parts may change slightly to assure you of the best performance. Terminology: Right or Left as used in this manual is determined by facing the direction the mower will travel while in use unless otherwise stated. Definitions: NOTE: A special point of information related to its preceding topic. The author s intention is that you read and note this information before continuing. IMPORTANT: A special point of information that the author feels you must be aware of before continuing with the instructions that follow. Owner Assistance If customer service or repair parts are required, contact your dealer. A dealer has trained personnel, repair parts, and the equipment needed to service you mower. These parts have been specifically designed for your mower and should only be replaced by genuine parts. Serial Number Plate Refer to Figure 1 for the location of your serial number plate. SERIAL NUMBER Figure 1: Serial Number Location For prompt service, always use the serial number and model number when ordering parts from your dealer. If for any reason you do not understand any part of this manual or not satisfied with service you received, discuss the matter with your dealership service manager. For further assistance, write to:, Inc Attn: Product Support 164 Oakridge Church Road Tifton, Ga 31794 1/28/05 FL72 Flail Mower 6

Section 1 Setup and Operation Safety Section 1 Setup and Operation Safety Tractor Requirements This mower is designed with a patented category 1 3-Point hitch. The hitch allows the operator to maneuver around obstacles without damaging the turf. The FL-72 weighs approximately 1300lbs with the front roller attached. Understanding How the Swing Hitch Operates (Prior to Hitching to Tractor) Push the swing mast rearward to disengage the swing lock. Grasp the hitch pins and rotate the A frame to simulate operation in a sharp turn. Release the hitch pins and slowly pull the swing mast forward as it would be pulled by the top link during lifting. Notice how one mast chain tightens causing the A frame and unit to realign and the spring on the lock link is compressed to make the swing lock engage upon alignment. Now push the swing mast rearward against the lock link tab to disengage the swing lock and loosen the chains to allow sharp turns again. This demonstrates how the top link of the tractor lift-system switches the mower between the trail and lift modes. Tractor Hook-Up 1. Align lower link arms of tractor to hitch pins on swing hitch. Insert these pins into the lower ball swivels and attach linch pins. 2. Attach tractor top link to swing mast on mower and secure with proper clevis and lock pins. 3. Adjust the tractor top link in or out to place the swing mast against the A frame. When the horizontal bar is level with the ground, the hitch is set properly. Refer to Figures 2 and 3. Driveline Installation 1. Make sure you have correct driveline. 2. Slide driveline end with overrunning clutch over splined shaft of gearbox and secure the spring loaded lock pin. 3. Slide other end of driveline over the tractor s splined PTO shaft and secure spring loaded ball collar. 4. Vigorously move the driveline back and forth to ensure it is secure on the PTO shaft of the tractor and mower gearbox. 5. Attach the chain from the driveline shield the PTO Shield to ensure that the shield does not rotate. Supply just enough slack to allow the driveline to move slightly as the mower makes sharp turns. FORWARD REARWARD SWING MAST MAST CHAINS CAUTION Tractor PTO shields and all mower guards must be in place at all times during operation. HORIZONTAL BAR SHARP TURN SWING LOCK "A" FRAME TOP LINK HITCH PIN LOWER LINK ARMS Figure 2: Swing Hitch Operation Figure 3: Tractor Hook-Up 7 FL72 Flail Mower 1/28/05

Section 1 Setup and Operation Safety Operation Safety Your Safety Is Always First! Familiarize yourself with the safety symbols and decals on pages 2 thru 5. All operators should read and understand all the provided sections of this manual prior to adjusting, maintaining, hitching to or operating the flail mower. Remove and read the driveline safety and maintenance manual taped to the driveline shield. After reading the driveline manual, place it inside this manual for reference. For a safety instruction of all operators, keep this manual stored on the mower at all times. Never attempt to adjust, maintain, or remove debris from any moving part of this machine while it is attached to a tractor or other power source with the engine running. After operating, always disengage the PTO and switch the engine off prior to dismounting from the tractor or other power source and approaching the unit. Prior to starting, always inspect operating area for any hazards such as large rocks, steep slopes, low tree branches or wires. Flag objects difficult to see such as irrigation heads and water meters. Instruct all people in the work area to stay clear of the operating unit at least 10 feet on the sides and 30 feet on the rear. Consult your tractor Operator s manual regarding operation on slopes. Do not lift the unit while the tractor is moving (or parked) sideways on slopes above 5 0. The swing hitch may allow the unit to swing to the downhill side and cause the tractor to roll over. On slopes from 5 0 to 15 0, always aim the tractor uphill before lifting the unit. We do not recommend the unit being used on slopes above 15 0. Use extreme care and maintain moderate ground speed when transporting or operating on slopes, over rough surfaces, or close to trees, ditches, and fences. Only operate during daylight hours or with good artificial light. The FL-72 is not equipped for highway use. Be careful of traffic when operating near or crossing roads. Before hitching to the mower, familiarize yourself with all of the tractors control functions. Be prepared to stop the tractor s movement, PTO operation, and the engine quickly in an emergency. 1/28/05 FL72 Flail Mower 8

Section 2 Operating Instruction Section 2 Operating Instruction Transporting 1. Always disengage PTO before raising the mower to transport position. 2. Be sure to reduce tractor ground speed when turning, leaving enough clearance so the mower does not contact obstacles such as buildings, trees, or fences. 3. Select a safe ground travel speed when transporting from one area to another. When traveling on roadways, transport in such a way that faster moving vehicles may pass safely. 4. When traveling over rough or hilly terrain, shift tractor to a lower gear. 5. When driving or backing a tractor and mower up or down load ramps, always shorten the top link to lift the rear of the mower as high as possible. Mowing Instructions 1. Grass is best cut when it is dry. Mowing wet grass can cause plugging resulting in grass clumps behind the mower. 2. Grass should be mowed frequently as shorter clippings deteriorate faster. 3. When mowing extremely tall grass, it is best to raise cutting height and mow the area, then lower cutting height and mow a second time at the desired height. 4. When mowing in sandy soil areas, wear may occur to the mower knives from sand erosion. Frequently inspect knives and replace if damaged. 5. Clear the area to be mowed of objects and debris that might be picked up and thrown by the mower blades. 1. Check oil level in gearbox. Refer to Section 4 Maintenance and Lubrication. 2. Check that all plugs in gearbox have been replaced and tightened properly. 3. Be sure all mower bolts and nuts are tight. 4. Be certain all guards and shields are in place and secure. 5. Grease driveline shaft and all other grease fittings. 6. Clear the area to be mowed of rocks, branches, and other foreign objects. 7. Lower mower to ground. Set tractor throttle to approximately ¼ open. Engage PTO to start blades rotating. 8. Operate with 540 rpm PTO tractor! 9. When lowering for operation, lower slowly until rear roller slightly touches ground. Then swiftly lower the mower completely to unlock the hitch. This is especially true when lowering the unit in a sharp turn. Failure to do this may cause the swing hitch not to disengage, resulting in damage to the mower. Do not turn the tractor with the swing lock engaged and the mower on the ground! 10. At first, begin mowing at a slow forward speed and shift up until the desired speed is achieved maintaining 540 PTO rpm. 11 After mowing the first 50 feet, stop and check to see that the mower is adjusted properly. 12. Do not back the unit up with the mower touching the ground. Always raise the unit, back to desired location, and then lower the machine. 13. Do not engage PTO with mower in the fully raised position. 14. Do not engage PTO with tractor at full throttle. Operating Instructions Proper servicing and adjustments are the keys to a long life of any machine. With careful and systematic inspection of the mower, costly maintenance, time, and repair can be avoided. Before beginning to mow, the following inspection should be performed: 9 FL72 Flail Mower 1/28/05

Section 3 Adjustments Section 3 Adjustments Cutting Height The cutting height of the mower depends primarily on the position of the rear roller. Refer to Figure 4. 1. Adjust turnbuckles until the rear roller is completely raised. This ensures that the turnbuckles start at the same location (0 cutting height for new blades). 2. Gradually rotate turnbuckles until desired height is reached. One complete turn of the turnbuckle is about 1/5 ; therefore, 5 complete turns will yield one approximately 1 of cut with new blades. It is only recommended that each side of the machine be adjusted 1 above the other before the opposite must be raised to level; otherwise, the turnbuckles may bind. 3. Snug the jam nut on the turnbuckle to help hold the cutting height during operation. 4. Slowly mow a small strip to check for adjustments and verify proper cutting height and that mower is cutting level. 5. If cutting height is unsatisfactory or uneven, make proper adjustments to turnbuckles and repeat step 4. CAUTION Engage parking brake, shut off tractor, remove key, and disengage PTO before making any adjustments! 3-Point Hitch The patented 3-point hitch is design to enhance the maneuverability of the mower by giving it the capability of cutting a 4-foot radius without harming the turf. However, proper adjustments must be made in order to avoid potential problems. In addition to this, hitch adjustment can affect the cutting height. Since tractors vary, be mindful of readjusting the hitch when changing from one tractor to another. 1. After slowly cutting a small strip, check to see if the horizontal bar is level with the ground (see Figure 3). If the hitch is nosed down, adjust the top link of the tractor to correct its position. 2. Check to see if there is proper clearance between the driveline and the bottom of the hitch. Different tractors have varying geometries; therefore, some tractors require special attention concerning driveline clearance. Scalping In certain situations, it is desirable to cut the turf very close to the soil (scalping). This procedure calls for an adjustment to the hitch and front roller. 1. The hitch must be locked out, meaning that the mast chains must be taken up to lock the hitch in place and prevent it from turning. Refer to Figure 5. HAIR PIN COTTER TURNBUCKLE 2 LINK TAKE-UP CLEVIS PIN JAM NUT Figure 4: Cutting Height Figure 5: Lock Out Adjustment for Scalping 1/28/05 FL72 Flail Mower 10

Section 3 Adjustments 2. Raise rear roller as high as possible and lock into place using the provided jam nuts. 3. Slowly mow a short strip and check the following: horizontal bar is level with ground (see Figure 3); mower is cutting level. If necessary, adjust tractor top link to level the bar and adjust turnbuckles to level cut (see Figure 4). It is preferred that the horizontal bar be level if not slightly tilted upward toward the front. 5. Lower the front roller using the attached turnbuckles until it lightly touches the ground. Lock it into place using the provided jam nuts. 1. Loosen the four flange nuts located under the jackshaft shield. 2. Rotate the 5/8 nut to tighten the belts to the desired tension. 3. Retighten the four flange nuts and secure all shields and guards back in place before operation. CAUTION Do not turn mower while hitch is locked! Turning in the locked position with the mower on the ground can cause serious damage to the mower. Belt Tension The belt tension should be checked after the first 20 hours of use and then every 40 hours thereafter. To check tension, apply approximately 25 pounds of pressure half way between the pulleys. There should be about 3/8 of deflection. If there is excessive belt deflection, then the belts need tightening. Belt Tightening Refer to Figure 6 during these steps. 5 8 HEX NUT Figure 6: Belt Tightening 4 FLANGE NUTS WARNING Excessive tension on the belt may lead to premature failure of belt and drive components. Excessive tension on the belt may also lead to a safety hazard to the operator or bystanders. 11 FL72 Flail Mower 1/28/05

Section 4 Maintenance and Lubrication Section 4 Maintenance and Lubrication Maintenance Proper servicing and adjustment is the key to the long life of any implement. With careful and systematic inspection, costly maintenance, time, and repair can be avoided. CAUTION For safety reasons, each maintenance operation must be performed with tractor PTO disengaged, the mower lowered completely to the ground and the tractor engine shut off with ignition key removed. After using the mower for several hours, check all bolts to be sure they are tight and check the tension of the drive belt. Refer to Belt Tension on page 11. Lubricate items as listed under Lubrication starting on page 13. Replace any worn, damaged or illegible safety labels by obtaining new decals from your local Dealer. Information safety decals are located under Safety Decals starting on page 3. Service Mowing Knives IMPORTANT: Make sure that each knife is the same length as the others on the mower. This will keep the cut smooth and cutting drum dynamically balanced. Always use knives to replace worn ones. 4. Reassemble the knives on the oval and d-rings and hold them in the grooves while a partner slides the retaining rod back through the end plate. Make sure the knives are facing the right direction. The cutting drum rotates over the top and forward. 5. Use new hardware to bolt the retaining rods back in place. Use the parts list to order the proper parts. WARNING Top-Lock Nuts are used to fasten the retaining rods. Standard nuts stand a greater risk of backing off causing serious danger to the operator and bystanders. Figure 7: Knife Replacement V-Belt Installation Refer to Belt Tension under Section 3 Adjustments for proper belt tension. Refer to Figure 6 for visual assistance. 1. Unbolt retaining rods. 2. Pull each retaining rod out through the hole provided in the side of the endplate. Refer to Figure 7. 3. Examine retaining rods, d-rings, and oval rings for wear, and replace if necessary. Remember, retaining rods can be rotated to provide extra life; however, if the grooves worn into retaining rods reduce its diameter to less than 3/8, replace immediately. 1. Remove belt cover and lift driveline shield. 2. Loosen the four flange nuts under the driveline shield. 3. Rotate 5/8 nut on push rod to lower top pulley. 4. Remove old belts and install new. 5. Rotate 5/8 nut to raise top pulley to desired tension. 6. Tighten the four flange nuts under the driveline shield. 7. Secure Belt cover and driveline shield before operation. 1/28/05 FL72 Flail Mower 12

Section 4 Maintenance and Lubrication Storage At the end of the working season or when the mower will not be used for a long period, it is good practice to clean off any dirt or grease that may have accumulated on the mower and any of its moving parts. 1. Clean as necessary. 2. Check the knives for wear and replace if necessary (see Service Mower Knives). 3. Inspect the mower for loose, damaged or worn parts and adjust or replace as needed. 4. Lubricate as noted in the Lubrication portion of this section. 5. Store unit inside if possible for longer life. 6. Repaint parts where paint is worn or scratched to prevent rust. Lubrication All rotor drum, roller, and jackshaft bearings are permanently sealed to ensure long life and do not require any maintenance. Lubrication Legend Multipurpose Spray Lubricant Multipurpose Grease Lubricant Multipurpose Oil Lubricant 50 Intervals At Which Lubricant Is Required PLASTIC BEARING CLUTCH PLASTIC BEARING 40 INNER TUBE U-JOINT CLUTCH INNER TUBE 16 16 FL55-001: FL72 DRIVELINE U-JOINT Type of Lubrication: Multipurpose Grease 8 INNER TUBE 8 U-JOINT INNER TUBE U-JOINT 8 FL55-005: FL72 SHORT DRIVELINE Type of Lubrication: Multipurpose Grease 13 FL72 Flail Mower 1/28/05

Section 4 Maintenance and Lubrication GEARBOX AS REQUIRED IMPORTANT: Mower should be level when checking oil in gearbox! GEARBOX Check the oil level in the gearbox by removing the plug at the side of the box on the right hand side. If oil should flow from the plug hole there is enough oil. Add oil if necassary by removing the top plug. FL54-001: FL72 GEARBOX Do not overfill! Should your gearbox require service, take it to your dearler. Type of Lubrication: SAE 90W Gear Lube TURNBUCKLE AS REQUIRED TURNBUCKLE Threads on turnbuckles are prone to rust over an extended period of time. Routine cleaning and application of anti-seizing lubricant will prolong the life of this part. FL50-008: CAT. 0 TOPLINK Type of Lubrication: Anti-Seizing Agent VERTICAL PIVOT HORIZONTAL PIVOT VERTICAL PIVOT GREASE WEEKLY GREASE WEEKLY HORIZONTAL PIVOT 3-POINT HITCH Type of Lubrication: Multipurpose Grease 1/28/05 FL72 Flail Mower 14

Section 4 Maintenance and Lubrication BEHIND PULLEY CUTTING DRUM BEARINGS 25 Type of Lubrication: Multipurpose Grease RIGHT SIDE FL50-006: CUTTING DRUM BEARING 15 FL72 Flail Mower 1/28/05

Warranty Information WARRANTY INFORMATION ONE YEAR LIMITED WARRANTY FIRST PRODUCTS INC. WARRANTS THIS PRODUCT TO BE FREE OF DEFECTS IN MATERIALS AND WORKMANSHIP FOR A PERIOD OF TWELVE MONTHS FROM THE ORIGINAL DELIVERY DATE. THIS WARRANTY DOES NOT COVER PARTS CAUSED TO BE DEFICIENT DUE TO NORMAL WEAR, MISUSE, ACCIDENTS, OR LACK OF PROPER MAINTENANCE. ANY PARTS THOUGHT TO BE DEFECTIVE MUST BE RETURNED TO THE DEALER/DISTRIBUTOR FOR WARRANTY CONSIDERATION JOINTLY WITH FACTORY REPRESENTATIVES. A RETURN AUTHORIZATION NUMBER MUST BE OBTAINED AND CLEARLY MARKED ON ALL PACKAGES OF PARTS REQUIRING RETURN TO THE FACTORY. THE OBLIGATION OF FIRST PRODUCTS INC. UNDER THIS WARRANTY SHALL BE EXCLUSIVELY LIMITED TO REPLACEMENT OF PARTS DETERMINED TO BE DEFECTIVE BY FIRST PRODUCTS INC. WITH FREIGHT PREPAID. IN NO EVENT SHALL FIRST PRODUCTS INC. BE LIABLE FOR INDIRECT, INCIDENTAL, OR CONSEQUENTIAL DAMAGES IN CONNECTION WITH THE USE OF THIS PRODUCT. FIRST PRODUCTS INC. RESERVES THE RIGHT TO MAKE CHANGES OR ADD IMPROVEMENTS TO ITS PRODUCTS AT ANY TIME WITHOUT OBLIGATION TO MAKE SUCH CHANGES OR IMPROVEMENTS ON PRODUCTS SOLD PREVIOUSLY. 1/28/05 FL72 Flail Mower 16