Page 2 - I n t r o d u c t i o n
2 I n t r o d u c t i o n Frontier (Rev. 12/5/2011) TO THE DEALER: Assembly and proper installation of this product is the responsibility of the Frontier dealer. Read manual instructionsand safety rules. Make sure all items on the Dealer’s Pre-Delivery and Delivery Check Lists in the Operator’s Manu...
Page 3 - I n t r o d u c t i o n 3; TABLE OF CONTENTS
I n t r o d u c t i o n 3 5WPMAN0862 (11/22/2010) TABLE OF CONTENTS INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3GENERAL INFORMATION ...
Page 4 - I n t r o d u c t i o n; GENERAL INFORMATION; NOTES
4 I n t r o d u c t i o n 5WPMAN0862 (11/22/2010) GENERAL INFORMATION ■ Some illustrations in this manual show the mower with safety shields removed to provide abetter view. The mower should never be operatedwith any safety shielding removed. The purpose of this manual is to assist you in operatinga...
Page 5 - S a fe t y 5; SAFETY RULES
S a fe t y 5 Frontier FM (Rev. 1/31/2007) TRAINING Safety instructions are important! Read all a t ta c h m e n t a n d p o w e r u n i t m a n u a l s ; f o l l o w a l lsafety rules and safety decal information. (Replace-ment manuals and safety decals are available fromyour dealer.) Failure to f...
Page 6 - S a f e t y
6 S a f e t y Frontier FM (Rev. 1/31/2007) (Safety Rules continued from previous page) Power unit must be equipped with ROPS or ROPS cab and seat belt. Keep seat belt securelyfastened. Falling off power unit can result in deathfr o m b e i n g ru n ov er o r cru s h ed . K eep f o l d ab l eROPS s...
Page 7 - S a fe t y 7
S a fe t y 7 Frontier FM (Rev. 1/31/2007) (Safety Rules continued from previous page) Always sit in power unit seat when operating controls or starting engine. Securely fasten seatbelt, place transmission in neutral, engage brake,a n d e n s u r e a l l o t h e r c o n t r o l s a r e d i s e n g ...
Page 8 - S a f e t y
8 S a f e t y Frontier FM (Rev. 1/31/2007) (Safety Rules continued from previous page) When lubricating telescoping PTO drives, keep fingers out of shield access slots to prevent injury. Wear gloves when installing belt. Be careful to prevent fingers from being caught between beltand pulley. U...
Page 9 - S a f e t y 9; ROTATING BLADES AND; SHIELD MISSING; DANGER; SAFETY & INSTRUCTIONAL DECALS; Replace Immediately If Damaged!
S a f e t y 9 5WPMAN0862 (11/22/2010) 5 - Serial Number Plate ROTATING BLADES AND THROWN OBJECTS Do not put hands or feet under or into mower when engine is running. Before mowing, clear area of objects that may be thrown by blade. Keep bystanders away. Keep guards in place and in good condition. BL...
Page 10 - 0 S a f e t y; ROTATING DRIVELINE
1 0 S a f e t y 5WPMAN0862 (11/22/2010) SAFETY & INSTRUCTIONAL DECALS ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Replace Immediately If Damaged! ROTATING DRIVELINE CONTACT CAN CAUSE DEATH KEEP AWAY! DO NOT OPERATE WITHOUT -- n ALL DRIVELINE GUARDS, TRACTOR ANDEQUIPMENT SHIELDS IN PLACE n ...
Page 11 - S a f e t y 11; RAISED MOWERS CAN
S a f e t y 11 5WPMAN0862 (11/22/2010) SAFETY & INSTRUCTIONAL DECALS ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Replace Immediately If Damaged! WARNING PIN INSERTED TO LOCKTRANSPORT LATCH PIN STORAGEPOSITION RAISED MOWER CAN DROP AND CRUSH n Before working underneath rear mower: n Raise r...
Page 12 - 2 S a f e t y; TO AVOID SERIOUS
1 2 S a f e t y 5WPMAN0862 (11/22/2010) SAFETY & INSTRUCTIONAL DECALS ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Replace Immediately If Damaged! HIGH-PRESSURE HYDRAULIC OIL LEAKS CAN PENETRATE SKIN RESULTING IN SERIOUS INJURY, GANGRENE OR DEATH. n Check for leaks with cardboard; never use...
Page 13 - O p e r a t i o n 1 3; OPERATION; CAUTION
O p e r a t i o n 1 3 5WPMAN0862 (11/11/2010) OPERATION The operator is responsible for the safe operation ofthe cutter. The operator must be properly trained.Operators should be familiar with the cutter, the tractor,and all safety practices before starting operation. Readthe safety rules and safety...
Page 14 - 4 O p e r a t i o n; NOTICE
1 4 O p e r a t i o n 5WPMAN0862 (11/22/2010) The PTO drive shaft is intended for use with tractorsthat have 14 inches between the end of the PTO shaftand the tractor's drawbar hitch pin hole. 3. Attach the safety chain to the tractor as shown in Figure 1. 4. Attach the mower drive shaft to tractor ...
Page 15 - O p e r a t i o n 1 5
O p e r a t i o n 1 5 5WPMAN0862 (11/11/2010) Figure 2. Level Trailer Frame CUTTING HEIGHT ADJUSTMENT Keep all persons away from operator control a r e a w hi l e p e r f or mi n g a d j u s t m e n ts , s e r v i c e , ormaintenance. Before working underneath, carefully read Oper- ator ’s Manua...
Page 16 - 6 O p e r a t i o n
1 6 O p e r a t i o n 5WPMAN0862 (11/22/2010) TRANSPORT When transporting the mower short distances, raisethe wings and the rear deck until all three transportlocks engage automatically. Install locking pins to secure the mower wings fortransport as shown in Figure 4 and Figure 5. Figure 4. Lock Pin...
Page 17 - O p e r a t i o n 1 7
O p e r a t i o n 1 7 5WPMAN0862 (11/11/2010) When engaging the PTO, engine rpm should always below. Once engaged and ready for mowing, increasePTO speed to 540 rpm and maintain speed throughoutthe cutting operation. Mower vibration tends to loosen bolts. All hardwareshould be checked regularly to m...
Page 18 - 8 O p e r a t i o n
1 8 O p e r a t i o n 5WPMAN0862 (11/22/2010) PRE-OPERATION CHECK LIST (OWNER's RESPONSIBILITY) ___ Review and follow all safety rules and safety decal instructions on pages 5 through 12. ___ Check that all safety decals are installed and in good condition. Replace if damaged. ___ Check that all shi...
Page 19 - O w n e r S e r v i c e 1 9; OWNER SERVICE
O w n e r S e r v i c e 1 9 5WPMAN0862 (11/22/2010) OWNER SERVICE The information in this section is written for operatorswho possess basic mechanical skills. If you need help,your dealer has trained service technicians available.For your protection, read and follow the safety informa-tion in this m...
Page 20 - 0 O w n e r S e r v i c e
2 0 O w n e r S e r v i c e 5WPMAN0862 (11/22/2010) LUBRICATION INFORMATION When lubricating telescoping PTO drives, keep fingers out of shield access slots to prevent injury. Do not let excess grease collect on or around parts,particularly when operating in sandy areas. Figure 7 and Figure 8 show...
Page 21 - O w n e r S e r v i c e 2 1
O w n e r S e r v i c e 2 1 5WPMAN0862 (11/22/2010) Figure 8. Lubrication Points - Deck REF DESCRIPTION FREQUENCY 1 Caster Wheel Pivots 8 Hours 2 Caster Wheel Hubs 8 Hours 3 Blade Spindles 24 Hours 4 Gearbox (Fill 1/2 full with Check For Leaks DailySAE 90W gear lube 5 Driveline U-Joints 8 Hours 6 Wi...
Page 22 - 2 O w n e r S e r v i c e
2 2 O w n e r S e r v i c e 5WPMAN0862 (11/22/2010) BELT SERVICE Belt Replacement One of the major causes of belt failure is improperinstallation. Before installing a new belt, check the fol-lowing: 1. Check pulley shafts and bearings for wear. 2. Check pulley grooves for cleanliness. 3. Make sure s...
Page 23 - O w n e r S e r v i c e 2 3
O w n e r S e r v i c e 2 3 5WPMAN0862 (11/22/2010) Figure 11. Belt Routing - FM1015 & FM1017 All Decks & FM1012 Rear Deck BLADE SERVICING Before servicing blades, raise and lock mower in transport position, turn off engine, set parkingbrake and remove key. Keep all persons away from ope...
Page 24 - 4 O w n e r S e r v i c e
2 4 O w n e r S e r v i c e 5WPMAN0862 (11/22/2010) CLEANING After Each Use ● Remove large debris such as clumps of dirt, grass,crop residue, etc. from machine. ● Remove belt shields and clean out all accumulatedgrass, dirt and other debris. ● Inspect machine and replace worn or damagedparts. ● Repl...
Page 25 - O w n e r S e r v i c e 2 5; TROUBLESHOOTING
O w n e r S e r v i c e 2 5 5WPMAN0862 (11/22/2010) TROUBLESHOOTING 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 inch of sam...
Page 26 - 6 O w n e r S e r v i c e
2 6 O w n e r S e r v i c e 5WPMAN0862 (11/22/2010) TROUBLESHOOTING BELT CONDITIONS * Check belt for damage by laying it flat on the floor. A belt that does not lie flat (has humps or twists, indicating brokenor stretched cords) must be replaced. PROBLEM POSSIBLE CAUSE SOLUTION Belt slippage Mower o...
Page 27 - D e a l e r S e r v i c e 2 7; DEALER SERVICE
D e a l e r S e r v i c e 2 7 MAN0826 (8/31/2010) DEALER SERVICE The information in this section is written for dealer ser-vice personnel. The repair described here requiresspecial skills and tools. If your shop is not properlyequipped or your mechanics are not properly trained inthis type of repair...
Page 28 - 8 D e a l e r S e r v i c e
2 8 D e a l e r S e r v i c e MAN0826 (8/31/2010) Spindle Disassembly 1. Place spindle assembly in press and press shaft down through housing. 2. Remove seals from housing. 3. Remove bearing cups from housing by placing a punch in the slots provided and driving them out.Alternate punch positions fro...
Page 29 - D e a l e r S e r v i c e 2 9
D e a l e r S e r v i c e 2 9 MAN0826 (8/31/2010) Spindle Installation NOTICE ■ Pulley installation sequence is very important for bearing life. Follow the sequence exactly. 1. Install spindle through bottom of mower and secure with four mounting bolts. 2. Install pulley and split taper bushing with...
Page 30 - 0 D e a l e r S e r v i c e
3 0 D e a l e r S e r v i c e MAN0826 (8/31/2010) Seal Installation NOTE: Proper seal installation is important. An improp-erly installed seal will leak. 1. Clean area in housing where seal outer diameter (OD) seats. Apply a thin coat of Permatex. 2. Inspect area of shaft where seal seats. Remove an...
Page 31 - D e a l e r S e r v i c e 3 1
D e a l e r S e r v i c e 3 1 MAN0826 (8/31/2010) 5. Remove vertical shaft seal (18). Replace with new seal (see Seal Replacement, page 29). Vertical seal should be recessed in housing. Horizontalseal should be pressed flush with outside of housing. NOTE: Distortion to seal cage or damage to seal li...
Page 32 - 2 D e a l e r S e r v i c e
3 2 D e a l e r S e r v i c e MAN0826 (8/31/2010) 12. While holding gear (1) in place, slide input shaft (3) through gear (1) and bearing (7). Align splines onshaft (3) and gear (1). 13. Slide spacer (12) over input shaft (3) and press bearing onto input shaft (3), using a round tube ofthe correct d...
Page 33 - D e a l e r S e r v i c e 3 3
D e a l e r S e r v i c e 3 3 MAN0826 (8/31/2010) 2. With snap rings removed, support drive in vise, hold yoke in hand and tap on yoke to drive cup upout of yoke. See Figure 21. Figure 21 3. Clamp cup in vise as shown in Figure 22 and tap on yoke to completely remove cup from yoke.Repeat Step 2 and ...
Page 34 - 4 A s s e m b l y; ASSEMBLY INSTRUCTIONS
3 4 A s s e m b l y 5WPMAN0862 (11/22/2010) ASSEMBLY INSTRUCTIONS DEALER SET-UP INSTRUCTIONS The mower is shipped mostly assembled but requiresdealer set-up. The Frontier dealer should deliver themower to the owner completely assembled, lubricated,and adjusted for normal conditions. Recommended torq...
Page 35 - A s s e m b l y 3 5
A s s e m b l y 3 5 5WPMAN0862 (11/22/2010) Attach the mower hydraulic hose to the tractor port.Hydraulic quick coupler is not supplied. NOTE: The mower hydraulic system should have beenfilled at the factory. Always assume it is empty. Fullypurge air and fill the hydraulic system by raising andlower...
Page 36 - 6 A s s e m b l y
3 6 A s s e m b l y 5WPMAN0862 (11/22/2010) Front Roller Kit Installation Figure 29 FM1012 Rear Deck and FM1015 and FM1017 Front Roller Kit Installation Figure 30 FM1012 Wing Deck Front Roller Kit Installation -- Roller Kit, Front Complete 2. 1/2 NC Flange Lock Nut 3. 1/2 NC x 9 HHCS GR5 4. Flat Was...
Page 37 - A s s e m b l y 3 7
A s s e m b l y 3 7 5WPMAN0862 (11/22/2010) Hydraulic Latch Release Installation Figure 31. Hydraulic Latch Release Installation 1. Remove four 1/3 NC x 2 hex head cap screws and 1/2” flat washers from top of shield on trailer. 2. Attach item 1 on top of shield using hardware previously removed. 3. ...
Page 38 - 8 D e a l e r C h e c k L i s t; DEALER CHECK LISTS
3 8 D e a l e r C h e c k L i s t 5WPMAN0862 (11/22/2010) DEALER CHECK LISTS PRE-DELIVERY CHECK LIST(DEALER’S RESPONSIBILITY) Inspect the equipment thoroughly after assembly toensure it is set up properly before delivering it to thecustomer. The following check lists are a reminder of points toinspe...
Page 39 - P a r ts 3 9; PARTS INDEX
P a r ts 3 9 5WPMAN0862 (11/22/2010) PARTS INDEX COMMON PARTS MAIN FRAME ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 - 41 TRAILER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 - 43 WING FRA...
Page 41 - P a r ts 4 1
P a r ts 4 1 5WPMAN0862 (11/22/2010) FM1012, FM1015 & FM1017 MAIN FRAME ASSEMBLY REF PART QTY DESCRIPTION 1 ----- 1 Trailer assembly (see page 42) 2 ----- 1 Right wing assembly (see 44) 3 ----- 1 Left wing assembly (see page 44) 4 ----- 1 Right deck assembly FM1012 (see page 46) -or- 4 ----- 1 R...
Page 43 - P a r ts 4 3
P a r ts 4 3 5WPMAN0862 (11/22/2010) FM1012, FM1015 & FM1017 TRAILER ASSEMBLY REF PART QTY DESCRIPTION 1 ----- 1 Trailer frame 2 5WP1009501 1 Hitch, Cat 1 -or- 2 5WP1009502 1 Hitch, Cat 2 -or- 2 5WP1003635 1 Hitch, rigid clevis (optional) 3 5WP1006689 2 Hitch adjustment link 4 5WP44639 2 .76 x 1...
Page 45 - P a r ts 4 5
P a r ts 4 5 5WPMAN0862 (11/22/2010) FM1012 CENTER DECK FM1015 & FM1017 CENTER & WING DECK ASSEMBLY REF PART QTY DESCRIPTION 1 5WP1031795 1 5’ Mower Deck (FM1012 Rear, FM1015 Wings) 1 5WP1031796 1 6’ Mower Deck (FM1015 Rear, FM1017 All) 2 5WP1001244 1 V-Belt W99 (FM1012 Rear, FM1015 Wings) 2...
Page 47 - P a r ts 4 7
P a r ts 4 7 5WPMAN0862 (11/22/2010) HEIGHT ADUSTMENT POST HUB & AXLE ASSEMBLY REF PART QTY DESCRIPTION 1 5WP58993 1 Caster Arm, RH (FM1012) - or - 1 5WP1031754 1 Caster Arm, RH (FM1015, FM1017) 2 5WP58994 1 Caster Arm, LH (FM1012) - or - 2 5WP1031755 1 Caster Arm, LH (FM1015, FM1017) 3 5WP58998...
Page 49 - P a r ts 4 9
P a r ts 4 9 5WPMAN0862 (11/22/2010) CASTER ARM & WHEEL ASSEMBLY FM1012 FM1015 & FM1017 REF PART QTY DESCRIPTION 1 5WP38267G 1 Wheel 15.00 x 6.00 x 6 Gray 5WP38476G Wheel Rim 6.00 x 6 w/cups Gray 2 5WP195 1 Grease fitting, 1/8 pipe thread 3 5WP2306 2 Bearing cup 4 5WP2304 2 Bearing cone 5 5W...
Page 51 - P a r ts 5 1
P a r ts 5 1 5WPMAN0862 (11/22/2010) BLADE & SPINDLE ASSEMBLY REF PART QTY DESCRIPTION 1 5WP37009 Nut, Jam 7/8 NF 2 * Screw HHCS 1/4 NC x 1 GR5 3 5WP52898 Washer, Lock .929 x 1.66 4 * Washer, Lock 1/4 5 5WP34440 Bushing, H 1 Strt bore w/key 6 5WP12622 Sheave, H 1 BK 5.0 PD (FM1012 Wing Deck, FM1...
Page 53 - P a r ts 5 3
P a r ts 5 3 5WPMAN0862 (11/22/2010) REAR ROLLER ASSEMBLY (OPTIONAL) REAR CHAIN SHIELDING ASSEMBLY REF PART QTY DESCRIPTION 5WD55348 Chain shield assembly, 5 ft. deck 5WD53566 Chain shield assembly, 6 ft. deck 1 5WP1007854 1 Pin, 40 to 42 chains, 5 ft. deck -or- 1 5WP1007856 1 Pin, 52 to 54 chains, ...
Page 55 - P a r ts 5 5
P a r ts 5 5 5WPMAN0862 (11/22/2010) FM1012, FM1015 & FM1017 REAR & WING DECK DRIVES FM1012 Wing Drive FM1015 Wing Drive REF PART QTY DESCRIPTION A 5WP1023226 Drive, Cmpl 40, 21.3 x 32.3 1 5WP1026999 1 Complete collar yoke C12 2 5WP36990 1 U-Joint Repair Kit 50 3 5WP38478 1 U-Joint Repair Ki...
Page 57 - P a r ts 5 7
P a r ts 5 7 5WPMAN0862 (11/22/2010) JACKSHAFT DRIVE ASSEMBLY REF PART QTY DESCRIPTION A 5WP1011759 Complete jackshaft drive assembly 1 5WP1028775 1 Complete collar yoke 2 5WP36990 1 U-Joint repair kit 3 5WP1011756 1 Yoke, outer 4 5WP1001330 1 Flexible pin 5 5WP1028776 1 Outer bearing ring REF PART ...
Page 59 - P a r ts 5 9
P a r ts 5 9 5WPMAN0862 (11/22/2010) LIGHT KIT (OPTIONAL) REF PART QTY DESCRIPTION 5WD1031385 TBW Light kit 1 5WP90401149 1 Light, 4 pin right 2 5WP90401150 1 Light, 4 pin left 3 5WP1031386 2 Light bracket 4 5WP1031388 2 Blank .16 x 4.00 x 4.00 5 5WP1004479 1 Wire harness 6 * 3/8 NC x 3-1/2 HHCS GR5...
Page 61 - A p p e n d i x 6 1; BOLT TORQUE CHART
A p p e n d i x 6 1 Bolt Torque & Size Charts (Rev. 3/28/2007) 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 ...
Page 62 - 2 A p p e n d i x; BOLT SIZE CHART
6 2 A p p e n d i x Bolt Torque & Size Charts (Rev. 3/28/2007) BOLT SIZE CHART NOTE: Chart shows bolt thread sizes and corresponding head (wrench) sizes for standard SAE and metric bolts. ABBREVIATIONS AG .............................................................. Agriculture ASABE .............
Page 63 - I n d e x 6 3; INDEX
I n d e x 6 3 MAN0826 (8/31/2010) INDEX Adjustments Cutting Height 15 Leveling Mower 14 Dealer Check List Delivery Check (Dealer’s Responsibility) 39 Pre-Delivery Check List (Dealer’s Responsibility) 39 Dealer Service Blade Spindle Assembly 28 Disassembly 28 Installation 29 Removal 27 Repair 27 Serv...
Page 64 - PART NUMBER
PART NUMBER 5WPMAN0862 ©2002 Woods Equipment Company. All rights reserved. WOODS and the Woods logo are trademarks of Woods Equipment Company. FrontierEquipment and the Frontier logo are trademarks of Deere & Company. All other trademarks, trade names, or service marks that appear in this man-ua...
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