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. 7/20/2007) 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 - Si no lee Ingles, pida ayuda a; TABLE OF CONTENTS
I n t r o d u c t i o n 3 5WPMAN0183 (Rev. 7/9/2008) Si no lee Ingles, pida ayuda a alguien que si lo lea para que le traduzca las medidas de seguridad. LEA EL INSTRUCTIVO! ! TABLE OF CONTENTS INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ...
Page 4 - SPECIFICATIONS; GENERAL INFORMATION; WARNING
4 I n t r o d u c t i o n 5WPMAN0183 (Rev. 7/9/2008) SPECIFICATIONS MODEL FM1012 FM1015 FM1017 Cutting Width 12' (3.66 m) 15' (4.57 m) 17' (5.18 m) Cutting Height Range 1.0" - 5.0" 1.0" - 5.0" 1.0" - 5.0" (25 - 127 mm) (25 - 127 mm) (25 - 127 mm) Shipping Weight (Approximatel...
Page 5 - S a fe t y; TRAINING; 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 fol...
Page 6 - S a f e t y; TRANSPORTATION
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 e r o r c ru s h e d . K e e p f o l d a b l eRO...
Page 7 - MAINTENANCE
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 a ...
Page 8 - STORAGE
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 preve nt fingers from be ing caught betwee n beltand pulley. Use ...
Page 9 - - Serial Number Plate; SHIELD MISSING; CRUSHING AND; ROTATING BLADES AND; SAFETY & INSTRUCTIONAL DECALS; Replace Immediately If Damaged!
S a fe t y 9 5WPMAN0183 (Rev. 7/9/2008) FM1012 & FM1015REAR DECK (FM1017 SIMILAR) PRODUCT IDENTIFICATION NUMBER L E N E X A , K S , U . S . A . L E N E X A , K S , U . S . A . 5 - Serial Number Plate SHIELD MISSING DO NOT OPERATE PUT SHIELD ON DANGER 18867--B 1 - 5WP18867 GUARD MISSING. DO NOT O...
Page 10 - IMPORTANT; ROTATING DRIVELINE; CONTACT CAN CAUSE DEATH
1 0 S a f e t y 5WPMAN0183 (Rev. 7/9/2008) SAFETY & INSTRUCTIONAL DECALS ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Replace Immediately If Damaged! IMPORTANT OPERATING MOWERS AT RAISED ANGLES EXCEEDING 25 • WILL CREATE U-JOINT KNOCKING NOISE AND DAMAGEDRIVELINE. FAILURES RESULTING FROM TH...
Page 11 - RAISED MOWER CAN DROP AND CRUSH; RAISED MOWERS CAN; RAISED MOWERS EXPOSE; DO NOT EXCEED PTO SPEED OF
S a f e t y 11 5WPMAN0183 (Rev. 7/9/2008) 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 Rais...
Page 12 - Front Reflector; Use a clean, damp cloth to clean safety decals.
1 2 S a f e t y 5WPMAN0183 (Rev. 7/9/2008) 15 13 13 14 11 17 10 9 18 5 8 3 4 12 3 4 12 13 3 4 CD5593A FM1012, FM1015 &FM1017 TRAILER 13 - 5WP20105 Amber Front Reflector 14 - 5WP57123 Red Rear Reflector HIGH-PRESSURE HYDRAULIC OIL LEAKS CAN PENETRATE SKIN RESULTING IN SERIOUS INJURY, GANGRENE OR ...
Page 13 - O p e r a t i o n; OPERATION; ATTACHING MOWER TO TRACTOR; CAUTION
O p e r a t i o n 1 3 5WPMAN0183 (Rev. 4/25/2008) 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 sa...
Page 14 - O p e ra t i o n; CV DRIVELINE TURNING LIMITS; LEVELING MOWER; CUTTING HEIGHT ADJUSTMENT
1 4 O p e ra t i o n 5WPMAN0183 (Rev. 4/25/2008) 4. Attach the mower drive shaft to tractor PTO. Makesure the lock collar engages securely. 5. Attach the end of the mower transport's lockrelease rope to a location on the tractor within easyreach of the operator. NOTE: When routing the rope, do not r...
Page 15 - TRANSPORTING
O p e r a t i o n 1 5 5WPMAN0183 (Rev. 4/25/2008) 5. Retighten cap screws. This equalizes the clear-ance in the bolt holes. 6. Best mowing results will be obtained with front ofmower level with, or slightly lower than, the rear. 7. Cutting height is controlled with front and rearcaster wheel adjustm...
Page 16 - STARTING AND STOPPING MOWER; OPERATING
1 6 O p e ra t i o n 5WPMAN0183 (Rev. 4/25/2008) STARTING AND STOPPING MOWER Do not operate PTO during transport. Never direct discharge toward people, animals, or property. Keep hands, feet, hair, and clothing away from equipment while engine is running. Stay clear of allmoving parts. Stop power un...
Page 17 - Uneven Terrain; REMOVING MOWER FROM TRACTOR
O p e r a t i o n 1 7 5WPMAN0183 (Rev. 4/25/2008) Analyze area to be cut to determine the best proce-dure. Consider height and type of grass and terraintype: hilly, level, or rough. Plan your mowing pattern to travel straight forwardwhenever possible. Mow with uncut grass to the right.This will dist...
Page 18 - NOTES
1 8 O p e ra t i o n 5WPMAN0183 (Rev. 4/25/2008) NOTES
Page 19 - O w n e r S e r v i c e; OWNER SERVICE; BLOCKING METHOD
O w n e r S e r v i c e 1 9 5WPMAN0183 (Rev. 4/25/2008) 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 th...
Page 20 - LUBRICATION INFORMATION
2 0 O w n e r S e r v i c e 5WPMAN0183 (Rev. 4/25/2008) LUBRICATION INFORMATION When lubricating telescoping PTO drives, keep fingers out of shield access slots to prevent injury. Remove belt shields and clean out all accumulatedgrass, dirt and other debris. Heat created by grassbuild-up can cause b...
Page 21 - BELT
O w n e r S e r v i c e 2 1 5WPMAN0183 (Rev. 4/25/2008) Figure 8 . Lubrication Points - Deck BELT 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 groove...
Page 22 - BLADE
2 2 O w n e r S e r v i c e 5WPMAN0183 (Rev. 4/25/2008) Figure 9 . Belt Routing Right Wing Figure 10 . Belt Routing Left Wing 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 itaway from pulley B. Route t...
Page 23 - Blade Installation; Blade Sharpening; CLEANING
O w n e r S e r v i c e 2 3 5WPMAN0183 (Rev. 4/25/2008) Make sure shields and guards are properly installed and in good condition. Replace if dam-aged. Blade Installation Your dealer can supply genuine replacement blades. Substitute blades may not meet originalequipment specifications and may be dan...
Page 24 - TROUBLESHOOTING; MOWING CONDITIONS
2 4 O w n e r S e r v i c e 5WPMAN0183 (Rev. 4/25/2008) 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 (1...
Page 25 - BELT CONDITIONS
O w n e r S e r v i c e 2 5 5WPMAN0183 (Rev. 4/25/2008) 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 broken or stretched cords) must be replaced. PROBLEM POSSIBLE CAUSE SOLUTION Belt slippage Mo...
Page 26 - D e a l e r S e r v i c e; DEALER SERVICE; BLADE SPINDLE; Spindle Removal
2 6 D e a l e r S e r v i c e 5WPMAN0183 (Rev. 4/25/2008) 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 o...
Page 27 - Spindle Disassembly; Spindle Assembly
D e a l e r S e r v i c e 2 7 5WPMAN0183 (Rev. 4/25/2008) 1. Nut, Jam 7/8 NF 2. Screw, HHCS 1/4 NC x 1 GR5 3. Washer, Lock .929 x 1.66 4. Washer, Lock 1/4 5. Bushing, H 1 Strt bore w/key 6. Sheave, H 1 BK 19. Screw, HHCS 1/2 NF x 1-1/4 GR5 21. Grease fitting Figure 15 . Sheave and Blade Assembly Spi...
Page 28 - Spindle Installation
2 8 D e a l e r S e r v i c e 5WPMAN0183 (Rev. 4/25/2008) NOTICE Improper positioning of seals can cause seal damage. An improperly installed seal will leak andcould cause bearing failure. 5. Apply a thin coat of Permatex to the area of hous-ing where seals seat. 6. Install bottom seal with spring u...
Page 29 - GEARBOX REPAIR
D e a l e r S e r v i c e 2 9 5WPMAN0183 (Rev. 4/25/2008) GEARBOX REPAIR Read this entire section before starting any repair.Many steps are dependent on each other. Fill gearbox with SAE 80W or 90W gear lube until itruns out the side level plug. Repair to this gearbox is limited to replacing bearing...
Page 30 - Gearbox Removal from Mower; Gearbox Disassembly; Gearbox Reassembly
3 0 D e a l e r S e r v i c e 5WPMAN0183 (Rev. 4/25/2008) Gearbox Removal from Mower (Figure 19) 1. Disconnect and remove the rear driveline from thegearbox. 2. Remove vent plug and siphon gear lube from hous-ing through this opening. 3. Remove gearbox stand (20) from mower deck byremoving four flan...
Page 32 - Gearbox Installation; DRIVE SHEAVE INSTALLATION; UNIVERSAL JOINT REPAIR
3 2 D e a l e r S e r v i c e 5WPMAN0183 (Rev. 4/25/2008) Gearbox Installation NOTE: Gearbox is heavy: do not attempt to move with- out mechanical assistance. 1. Set gearbox on gearbox stand and fasten withbolts and nuts. Torque bolts to 175 lbs.-ft. (237 N-m). 2. Attach drive sheave to output shaft...
Page 34 - A s s e m b l y; ASSEMBLY INSTRUCTIONS; DEALER SET-UP INSTRUCTIONS
3 4 A s s e m b l y 5WPMAN0183 (Rev. 4/25/2008) 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 ...
Page 35 - Attach Hydraulic Hoses; Lighting Kit Installation
A s s e m b l y 3 5 5WPMAN0183 (Rev. 4/25/2008) 4. Adjust tractor hitch bracket on trailer frame so thetrailer is level when attached to the tractor. 5. Pin the mower to the tractor with a locking typehitch pin. 6. Attach drive shaft to tractor PTO. Make sure lockcollar engages securely. 7. Attach e...
Page 36 - D e a l e r C h e c k L i s ts; DEALER CHECK LISTS; PRE-DELIVERY CHECK LIST; DELIVERY CHECK LIST
3 6 D e a l e r C h e c k L i s ts 5WPMAN0183 (Rev. 4/25/2008) 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 t...
Page 37 - COMMON PARTS
P a r ts 3 7 5WPMAN0183 (Rev. 7/9/2008) PARTS INDEX COMMON PARTS MAIN FRAME ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 - 39 TRAILER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 - 41 WING...
Page 38 - P a r ts
3 8 P a r ts 5WPMAN0183 (Rev. 7/9/2008) FM1012, FM1015 & FM1017 MAIN FRAME ASSEMBLY Ref e r to p a ge 59 fo r Hyd raul ic Hos e P a rt s li st . 33 - COMP LE TE DE CA L S E T
Page 45 - CASTER WHEELS
P a r ts 4 5 5WPMAN0183 (Rev. 7/9/2008) CASTER WHEELS NON-ROTATING ROTATING REF PART QTY DESCRIPTION 1 5WP38267G 1 Wheel & hub 15.00 x 6.00 x 6 Gray 5WP38476G Wheel rim & hub, 6.00 x 6 w/Cups gray 2 * 1 Grease fitting, 1/8 Pipe thread 3 5WP2306 2 Bearing, Cup 4 5WP2304 2 Bearing, Cone 5 5WP5...
Page 46 - HEIGHT ADJUSTMENT POST
4 6 P a r ts 5WPMAN0183 (Rev. 7/9/2008) HEIGHT ADJUSTMENT POST REF PART QTY DESCRIPTION 1 5WP58998 1 Sleeve, Drld .81 x 1.25 x 8.00 2 5WP58999 1 Wear pad 3 * 1 Pin, Spirol .25 x 1.00 4 5WP35124 1 Pin, Klik 7/16 x 2 5 5WP52855 2 Sleeve, 1.28 x 1.66 x 1.00 6 5WP52854 2 Sleeve, 1.28 x 1.66 x .75 7 5WP5...
Page 47 - WING GEARBOX ASSEMBLY
P a r ts 4 7 5WPMAN0183 (Rev. 7/9/2008) WING GEARBOX ASSEMBLY REF PART QTY DESCRIPTION A 5WP1002499 1 Gearbox asy, complete 1 5WP57458 1 Gear crown Z25 M5.3 2 NS 1 Gearbox housing 3 5WP1005320 1 Shaft, Input 1-3/8 -6 4 5WP1005321 1 Shaft, Output 1-1/4 5 5WP57491 1 Pinion gear Z13 M5.3 6 5WP57476 1 B...
Page 48 - BLADE & SPINDLE ASSEMBLY
4 8 P a r ts 5WPMAN0183 (Rev. 7/9/2008) 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 &...
Page 49 - FM1012 WING DECK ANTI-SCALP ROLLER KIT
P a r ts 4 9 5WPMAN0183 (Rev. 7/9/2008) FM1012 CENTER DECK AND FM1015 & FM1017 FRONT ROLLER ASSEMBLY (OPTIONAL) FM1012 WING DECK ANTI-SCALP ROLLER KIT REF PART QTY DESCRIPTION 5WP1006417 1 Front roller kit, complete 2 * 1 1/2 NC Flanged lock nut 3 5WP38107 1 1/2 NC x 9 Cap screw GR5 4 * 2 1/2 Fl...
Page 53 - LIGHTING KIT
P a r ts 5 3 5WPMAN0183 (Rev. 7/9/2008) FM1012, FM1015 & FM1017 REAR & WING DECK DRIVES (WALTERSCHEID) LIGHTING KIT REF PART QTY DESCRIPTION A 5WP1004486 - Lighting kit 1 5WP90401149 1 Lighting 4 pin LH 2 5WP90401150 1 Lighting 4 pin RH 3 5WP1004481 1 Light bracket LH 4 5WP1004480 1 Light br...
Page 54 - CV DRIVE ASSEMBLY
5 4 P a r ts 5WPMAN0183 (Rev. 7/9/2008) CV DRIVE ASSEMBLY (WALTERSCHEID PROFILE) PAGE 54 PAGE 55 REF PART QTY DESCRIPTION 5WP44625 Drive, Walterscheid complete CV 2480, 35.8 x 48.4 1 5WP44671 1 Yoke, 1-3/8 - 6 Spline QD 2 5WP44674 1 U-Joint repair kit 2480 3 5WP38394 1 Slide lock collar repair kit 4...
Page 57 - REAR CHAIN SHIELDING ASSEMBLY
P a r ts 5 7 5WPMAN0183 (Rev. 7/9/2008) REAR CHAIN SHIELDING ASSEMBLY REF PART QTY DESCRIPTION - 5WP55348 Chain shield assembly, 5 ft. deck - 5WP53566 Chain shield assembly, 6 ft. deck - † Chain shield assembly, 4 ft. deck 1 5WP1007854 1 Pin, 40 to 42 chains (5 ft) -or- 1 5WP1007856 1 Pin, 52 to 54 ...
Page 58 - HYDRAULIC CYLINDERS
5 8 P a r ts 5WPMAN0183 (Rev. 7/9/2008) HYDRAULIC CYLINDERS Note: The center deck uses a 3 x 8 cylinder. The wing decks use 3 x 10 cylinders. Verifycylinder size before ordering replacement parts. 3 x 8 3 x 10 REF PART PART QTY DESCRIPTION 1 5WP29547 5WP1019460 Complete cylinder 2 5WP19810 5WP19810 ...
Page 59 - HYDRAULIC HOSE ASSEMBLY
P a r ts 5 9 5WPMAN0183 (Rev. 7/9/2008) HYDRAULIC HOSE ASSEMBLY REF PART QTY DESCRIPTION 14 5WP1019460 2 Cylinder, Hydraulic 3 x 10 (See pg 58) 15 5WP29547 1 Cylinder, Hydraulic 3 x 8 (See pg 58) 16 5WP8346 4 Pin, Headless 1.00 x 4.58 17 5WP1631 2 Pin, Headless 1.00 x 3.63 18 * Pin, Cotter 1/4 x 1-3...
Page 60 - A p p e n d i x; BOLT TORQUE CHART
6 0 A p p e n d i x 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 61 - BOLT SIZE CHART; SAE Bolt Thread Sizes; MM
A p p e n d i x 6 1 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 62 - I n d e x; INDEX
6 2 I n d e x 5WPMAN0183 (Rev. 7/9/2008) INDEX ASSEMBLY Dealer Set-up Instructions 34 DEALER CHECK LISTS Delivery (Dealer’s Responsibility) 36Pre-Delivery (Dealer’s Responsibility) 36 DEALER SERVICE Blade Spindle Assembly 27Disassembly 27Installation 28Removal 26Servicing 26 Blocking Method 26Drive ...
Page 64 - WARRANTY
W-07011-V (Rev. 6/13/2008) (cf. F-3079) WARRANTY Please enter information below and save for future reference. Date Purchased: ______________________ From (Dealer): _________________________ Model Number: ______________________ Serial Number: _________________________ Woods Equipment Company (“WOODS...
Page 65 - for Replacement Parts
W-07012-V Rev. 3/24/2005 (cf. F-8494) WARRANTY for Replacement Parts Woods Equipment Company (“WOODS”) warrants this product to be free from defect in material andworkmanship for a period of ninety (90) days from the date of delivery of the product to the original purchaserwith the exception of V-be...
Page 66 - PART NUMBER
©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 thismanual are the property of the...
