Page 2 - I n t r o d u c t i o n; NOTE
I n t r o d u c t i o n Frontier (Rev. 10/29/2004) 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 Manua...
Page 3 - TABLE OF CONTENTS
I n t r o d u c t i o n 1 WPMAN0142 (Rev. 9/1/2004) TABLE OF CONTENTS INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inside Front Cover SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . ....
Page 4 - SPECIFICATIONS; WARNING
2 I n t r o d u c t i o n WPMAN0142 (Rev. 9/1/2004) SPECIFICATIONS Hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-Point, Category 1 Cutting Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 in. (2.29 m) Cutting Height ...
Page 5 - S a f e t y; TRAINING; SAFETY RULES
S a f e t y 3 GM1190R SR (9/1/2004) 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 follow ...
Page 6 - TRANSPORTATION
4 S a f e t y GM1190 SR (9/1/2004) (Safety Rules continued from previous page) Remove accumulated debris from this equip- ment, power unit, and engine to avoid fire hazard. Make sure all safety decals are installed. Replace if damaged. (See Safety Decals section forlocation.) Make sure shields...
Page 7 - MAINTENANCE
S a f e t y 5 GM1190R SR (9/1/2004) (Safety Rules continued from previous page) Do not stop, start, or change directions sud- denly on slopes. Use extreme care and reduce ground speed on slopes and rough terrain. Watch for hidden hazards on the terrain during operation. Stop power unit and e...
Page 8 - STORAGE; SAFETY & INSTRUCTIONAL DECALS; Replace Immediately If Damaged!; Red Rear Reflector; Use a clean, damp cloth to clean safety decals.
6 S a f e t y GM1190 SR (9/1/2004) (Safety Rules continued from previous page) Your dealer can supply genuine replacement blades. Substitute blades may not meet originalequipment specifications and may be dangerous. Tighten all bolts, nuts, and screws to torque chart specifications. Check that a...
Page 9 - DO NOT EXCEED PTO SPEED OF; SHIELD MISSING; ROTATING COMPONENTS; DANGER; ROTATING DRIVELINE; CONTACT CAN CAUSE DEATH
S a f e t y 7 WPMAN0142 (Rev. 9/1/2004) FALLING OFF CAN RESULT IN BEING RUN OVER. Tractor must be equipped with ROPS (or ROPS CAB) and seatbelt. Keep foldable ROPS systems in “locked up” position at alltimes. Buckle Up! Keep seat belt securely fastened. Allow no riders. RAISED EQUIPMENT CAN DR...
Page 10 - ROTATING BLADES AND; DANG
8 S a f e t y WPMAN0142 (Rev. 9/1/2004) SAFETY & INSTRUCTIONAL DECALS ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Replace Immediately If Damaged! 9 - WP1003751 ROTATING BLADES AND THROWN OBJECTS Do not put hands or feet under or into mower when engine is running. Before mowing, clear area ...
Page 11 - O p e r a t i o n; OPERATION; ATTACHING MOWER TO TRACTOR
O p e r a t i o n 9 WPMAN0142 (Rev. 9/1/2004) OPERATION The operator is responsible for the safe operation ofthis mower. The operator must be properly qualifiedand trained. Operators should be familiar with themower, tractor and all safety practices before startingoperation. Read the Safety Rules an...
Page 12 - O p e ra t i o n; IMPORTANT
1 0 O p e ra t i o n WPMAN0142 (Rev. 9/1/2004) When driveline is attached to tractor, attach front drive-line shield tether chain to the tractor to prevent drive-line shield rotation. After mower is attached to tractor, carefully raisemower and check for driveline clearance between driveshielding an...
Page 13 - Top Link Adjustment; Tractor Stability; PRE-OPERATION CHECK LIST; STARTING AND STOPPING MOWER
O p e r a t i o n 11 WPMAN0142 (Rev. 9/1/2004) Top Link Adjustment (Figure 4) When the cutting height is adjusted, adjust tractor toplink until mower top link attachment point “A” is alignedvertically with mower hitch pin “B”. Figure 4 . Top Link Adjustment Tractor Stability (Figure 5) A minimum 2...
Page 15 - O w n e r S e r v i c e; OWNER SERVICE; BLOCKING METHODS; LUBRICATION INFORMATION
O w n e r S e r v i c e 1 3 WPMAN0142 (Rev. 9/1/2004) OWNER SERVICE Before servicing, adjusting, repairing or unplug- ging, stop tractor engine, place all controls in neu-tral, set park brake, remove ignition key, and waitfor all moving parts to stop. Keep all persons away from operator control ...
Page 16 - BELT REPLACEMENT
1 4 O w n e r S e r v i c e WPMAN0142 (Rev. 9/1/2004) Figure 7 . Lubrication Points Use a lithium grease of No. 2 consistency with a MOLY(molybdenum disulfide) additive for all locations. Besure to clean fittings thoroughly before attachinggrease gun. When applied according to the lubricationchart, ...
Page 17 - SHEAR BOLT REPLACEMENT; CHAIN SHIELDING REPAIR
O w n e r S e r v i c e 1 5 WPMAN0142 (Rev. 9/1/2004) Figure 8 . Belt Installation IMPORTANT Use care when installing or removing belt from spring-loaded idler in step 6. Springs store energywhen extended and, if released suddenly, cancause personal injury. Belt replacement is accomplished in thes...
Page 18 - CAUTION
1 6 O w n e r S e r v i c e WPMAN0142 (Rev. 9/1/2004) BLADE SERVICING Your dealer can supply genuine replacement blades. Substitute blades may not meet originalequipment specifications and may be dangerous. Make certain all movement of equipment com- ponents has stopped before approaching for se...
Page 19 - Tro u b l e S h o o t i n g; TROUBLE SHOOTING; MOWING CONDITIONS
Tro u b l e S h o o t i n g 1 7 WPMAN0142 (Rev. 9/1/2004) TROUBLE SHOOTING MOWING CONDITIONS PROBLEM POSSIBLE CAUSE SOLUTION Grass cut higher in center of swath than at edge Height of mower higher at rear than at front Adjust mower height and attitude so that mower rear and front are within 1/2"...
Page 20 - Tr o u b l e S h o o t i n g; BELT CONDITIONS
1 8 Tr o u b l e S h o o t i n g WPMAN0142 (Rev. 9/1/2004) TROUBLE SHOOTING 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 slippag...
Page 21 - D e a l e r S e r v i c e; DEALER SERVICE; BLADE SPINDLE
D e a l e r S e r v i c e 1 9 WPMAN0142 (Rev. 9/1/2004) DEALER SERVICE The information in this section is written for dealer ser-vice personnel. The repair described herein requiresspecial skills and tools. If your shop is not properlyequipped or your mechanics are not properly trained inthis type o...
Page 22 - Blade Spindle Removal; Blade Spindle Assembly
2 0 D e a l e r S e r v i c e WPMAN0142 (Rev. 9/1/2004) Blade Spindle Removal Remove belt. Remove blades from spindle. Removebolt and washer from top of spindle shaft. Remove split taper bushing (located on top of pulley)by removing the two bolts and inserting them into thethreaded holes in bushing ...
Page 23 - Blade Spindle Installation; UNIVERSAL JOINT REPAIR
D e a l e r S e r v i c e 2 1 WPMAN0142 (Rev. 9/1/2004) Lightly lubricate top seal, locate spring and place sealsquarely on housing with spring up away from housing.Follow installation instructions given for bottom seal.Top seal should be flush with, to 1/16" (2 mm) above,housing. Blade Spindle ...
Page 25 - GEARBOX MAINTENANCE
D e a l e r S e r v i c e 2 3 WPMAN0142 (Rev. 9/1/2004) GEARBOX MAINTENANCE Read all of this section before starting any repair. Manysteps are dependent on each other. Check gearbox for leakage and shaft side and endplay. If excessive shaft play is found, disassemblegearbox and inspect bearings and ...
Page 26 - Gearbox Assembly; Drive Pulley Installation
2 4 D e a l e r S e r v i c e WPMAN0142 (Rev. 9/1/2004) Gearbox Assembly (Figure 22) NOTE: Repair of this gearbox is limited to replacing bearings, seals, and gaskets. Replacing gears, shafts,and a housing is not cost effective. Purchasing a com-plete gearbox is more economical. Clean housing, payin...
Page 28 - A s s e m b l y; ASSEMBLY; DEALER SET-UP INSTRUCTIONS; Rear Driveline Installation
2 6 A s s e m b l y WPMAN0142 (Rev. 9/1/2004) ASSEMBLY Always wear relatively tight and belted clothing t o a v o i d g e t t i n g c a u g h t i n m o v i n g pa r ts . We a rs tu rd y, rou gh - s ol e d wo rk s h o e s a n d p ro te c t i v eequipment for eyes, hair, hands, hearing, and head;and...
Page 29 - Chain Shielding Installation
A s s e m b l y 2 7 WPMAN0142 (Rev. 9/1/2004) Figure 24 . Hitch Installation Figure 25 . Chain Shielding Installation CD4594A 6 14 12 11 5 5 8 10 9 12 12 1 2 4 2 7 9 3 13 1. 5/8 x 3-1/2" Bolt 2. 5/8" Flat washer 3. .64 x 1.00 x 2.09" Sleeve 4. Hitch pin bracket 5. A-Frame bar 6. Hitch pi...
Page 30 - Optional Front Roller Installation
2 8 A s s e m b l y WPMAN0142 (Rev. 9/1/2004) Optional Front Roller Installation (Figure 26) The optional front roller is designed to carry the centerof the mower over uneven ground, minimizing scalping. Front roller mounting brackets use the four mountingbolts of the gear stand. Remove the gear sta...
Page 31 - Front Caster Wheel Installation; Rear Caster Wheel Installation; Initial Filling of Gearbox
A s s e m b l y 2 9 WPMAN0142 (Rev. 9/1/2004) Front Caster Wheel Installation (Figure 28) Figure 28 . Front Caster Wheel Installation Remove the front caster wheel and arm assembliesfrom shipping location along the outer deck rails. Attach adjustment lugs to frame with bolts (16) andnuts (18). Attac...
Page 32 - 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 0 D e a l e r C h e c k L i s ts WPMAN0142 (Rev. 9/1/2004) DEALER CHECK LISTS PRE-DELIVERY CHECK LIST (DEALER 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 toins...
Page 33 - P a r ts; INDEX TO PARTS LISTS; GM1190R Main Frame Assembly
P a r ts 3 1 WPMAN0142 (Rev. 9/1/2004) INDEX TO PARTS LISTS GM1190R Main Frame Assembly (Exploded View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 - 33 GM1190R Main Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Gearbox...
Page 34 - GM1190R MAIN FRAME ASSEMBLY
3 2 P a r ts WPMAN0142 (Rev. 9/1/2004) GM1190R MAIN FRAME ASSEMBLY (EXPLODED VIEW) CD3955D 60 61 62 30 41 40 39 9 29 28 28 29 9 1 2 6 8 10 11 12 13 14 15 2 23 21 20 19 18 17 55 54 49 48 46 56 58 53 59 57 44 43 45 50 51 38 37 36 47 35 42 33 43 47 51 39 56 52 27 24 - COMPLETE DECAL SET - ENGLISH 25 - ...
Page 37 - GEARBOX ASSEMBLY
P a r ts 3 5 WPMAN0142 (Rev. 9/1/2004) GEARBOX ASSEMBLY 15 12 1 13 3 14 9 12 23 16 20 5 15 6 11 4 7 21 19 10 18 17 25 8 27 15 2 26 11 22 REF PART NO NO NO USED DESCRIPTION 1 WP1001224 1 Gear, Bevel 22 Tooth 2 NS 1 Gearbox housing 3 WP57465 1 Shaft, Input 4 WP1001218 1 Shaft, Output 5 WP1001223 1 Gea...
Page 39 - BLADE SPINDLE ASSEMBLY
P a r ts 3 7 WPMAN0142 (Rev. 9/1/2004) BLADE SPINDLE ASSEMBLY QUICK HITCH KIT (OPTIONAL) REF PART NO NO NO USED DESCRIPTION 1 WP24520 1 Spindle, Assembly Complete 2 WP18359 1 Sleeve, 1.38 x 1.75 x .63 3 WP2715 2 Seal, 1.75 x 2.56 x .50 4 WP2717 2 Bearing, Cone 5 WP18361 1 Spindle, Housing w/Cups 6 W...
Page 40 - CHAIN SHIELDING ASSEMBLY
3 8 P a r ts WPMAN0142 (Rev. 9/1/2004) REF PART NO NO NO USED DESCRIPTION - ------ 1 Chain shield bundle complete 1 WP19552 1 Shield, Plate Right Front Chain 2 WP19553 1 Shield, Plate Left Front Chain 3 WP20792 1 Shield, Plate Right Rear Chain 4 WP20793 1 Shield, Plate Left Rear Chain 5 WP4763 60 Ch...
Page 41 - FRONT CASTER ARM ASSEMBLY
P a r ts 3 9 WPMAN0142 (Rev. 9/1/2004) FRONT CASTER ARM ASSEMBLY REF PART NO NO NO USED DESCRIPTION 1 WP20718G 2 Solid tire, wheel & hub, 13.00 x 5.00 x 10 Gray (includes item 5) -or- -or- 1 WP19744G 2 Pneumatic tire, wheel & hub, Gray 13 x 5-6 (includes item 5) 3 WP20777 2 Plate, Front Cast...
Page 42 - REAR CASTER ARM ASSEMBLY
4 0 P a r ts WPMAN0142 (Rev. 9/1/2004) REAR CASTER ARM ASSEMBLY REF PART NO NO NO USED DESCRIPTION 1 WP20776 2 Plate, Rear Caster Support 2 WP20781 2 Caster Arm Asy w/Bearing 3 WP24589 2 Washer, Cap Caster Wheel 4 WP24588 2 Seal, Felt 1.25 x 1.88 x .38 5 WP23609 4 Washer, Flat 1.25 x 2.38 x .19 9 WP...
Page 43 - A p p e n d i x; BOLT TORQUE CHART
A p p e n d i x 4 1 Bolt Torque & Size Charts (Rev. 8/14/02) 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 par...
Page 44 - BOLT SIZE CHART; SAE Bolt Thread Sizes; MM; ABBREVIATIONS
4 2 A p p e n d i x Bolt Torque & Size Charts (Rev. 8/14/2002) BOLT SIZE CHART NOTE: Chart shows bolt thread sizes and corresponding head (wrench) sizes for standard SAE and metric bolts. 5/16 3/ 8 1/2 5/ 8 3/4 7/ 8 SAE Bolt Thread Sizes MM 25 50 75 100 125 150 175 IN 1 7 Metric Bolt Thread Size...
Page 45 - I n d e x; INDEX
I n d e x 4 3 WPMAN0142 (Rev. 10/29/2004) INDEX ADJUSTMENTS Cutting Height Adjustment Mounted Mowers 10With Front and Rear Caster Wheels 10 Top Link 11 ASSEMBLY Dealer Set-Up Instructions 26 DEALER CHECK LISTS Delivery (Dealer Responsibility) 30Pre-Delivery (Dealer Responsibility) 30 DEALER SERVICE ...
Page 46 - WARRANTY; 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 48 - PART NUMBER
PART NUMBER WPMAN0142 ©2001 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-ual...
