O P E R A T O R ’ S M A N U A L
DISC/MOWER CADDY
DC1000
5TIDC611125 (Rev. 12/22/2010)
DEALER PREPARATION CHECK LIST
Frontier DC1000 Series Disc/Mower Caddy
THIS CHECKLIST IS TO REMAIN IN OWNER’S MANUAL
It is the responsibility of the dealer to complete the procedures listed below, then
review this checklist with the customer upon the delivery or the sale of this implement.
q 1. Implement is completely assembled.
q 2. All drivelines, bearings, and grease zerks are
properly lubricated. (See page 23)
q 3. All shields in place and in good condition.
q 4. Check PTO driveline. Make sure it is the
correct length to operate caddy with intended
tractor.
Dealer’s Signature ______________________________________________
Purchaser’s Signature ____________________________________________
IMPORTANT SAFETY MESSAGE FOR OWNERS/OPERATORS OF MOWER CADDIES
q 5. All decals in place and readable. (See page 8 - 9)
q 6. Overall condition good (i.e. paint, welds, hydraulic
hoses)
q 7 Operator’s manual has been given to owner and
the owner has been instructed on the safe and
proper use of the Disc/Mower Caddy.
Safety
Safety is a primary concern in the design, manufacture, sale, and use
of mower caddies. As manufacturers of mower caddies, we want to
conrm to you, our customers, our concern for safety. We also want to
remind you about the simple, basic, and common sense rules of safety
when using a mower caddy. Failure to follow these rules can result in
severe injury or death to operators or bystanders.
It is essential that everyone involved in the assembly, operation,
transport, maintenance, and storage of this equipment be aware,
concerned, prudent, and properly trained in safety. The majority of
accidents involve entanglement on the driveline or thrown objects.
These risks become greater when you do not use proper shielding
specied by the manufacturer.
Our current production machines include, as standard equipment,
guards or shields for drivelines and input shafts, safety signs and
operators manuals. If you have an older machine which does not have
current standard safety equipment, please contact your dealer about
bringing your machine up to the current level of safety.
Below are some of the most important safety rules to be understood
and followed by anyone who works with mower caddies:
Before operating a mower caddy, an operator must read and understand
all the information in the owner’s manual and in the safety signs
attached to the product. A person who has not read or understood the
owner’s manual and safety signs is not qualied to operate the unit.
Accidents occur often on machines that are loaned or rented to someone
who has not read the owner’s manual and is not familiar with the
equipment. If you do not have an owner’s manual or current production
safety signs, contact the manufacturer or your dealer immediately.
Mower caddies are designed for one-man operation. Never operate the
caddy with anyone near, or in contact with, any part of the implement or
PTO driveline. Be sure no one else, including bystanders, is near you
when you operate this product.
Following these simple, basic safety rules, as well as others identied
in the owner’s manual and in product safety signs, will help minimize
the possibility of accidents and increase your productivity in using this
product. Be careful and make sure that everyone who operates the caddy
knows and understands that it is a very powerful piece of machinery,
and if used improperly, serious injury or death may result. The nal
responsibility for safety rests with the operator of this machine.
2 Introduction
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 Preparation Check List in the Operator’s Manual are
completed before releasing equipment to the owner.
The dealer must complete the Product Registration form, located on the Frontier web site. Failure to complete
and return the form does not diminish customer’s warranty rights.
TO THE OWNER:
Read this manual before operating your Frontier equipment. Keep this manual
handy for ready reference. Require all operators to read this manual carefully
and become acquainted with all adjustments and operating procedures before
attempting to operate the equipment. 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 specied.
Please 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 of
your service needs.
Use only genuine Frontier service parts.
Throughout this manual, the term IMPORTANT is used to indicate that failure
to observe procedures 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!
Indicates an imminently hazardous situation that, if not avoided, will
result in death or serious injury.
Indicates a potentially hazardous situation that, if not avoided, could
WARNING
CAUTION
IMPORTANT
result in death or serious injury, and includes hazards that are exposed
when guards are removed.
Indicates a potentially hazardous situation that, if not avoided, may
result in minor or moderate injury.
Indicates that failure to observe can cause damage to equipment.
NOTE
Indicates helpful information.
Introduction 3
TABLE OF CONTENTS
Introduction ......................................................................................................... 4
Safety ............................................................................................................... 5-9
Description ................................................................................................... 10-11
Hardware Check Sheet .................................................................................... 12
Assembly & Setup ....................................................................................... 13-16
Attaching ...................................................................................................... 17-20
Operation and Detaching ............................................................................. 21-22
Detaching ......................................................................................................... 22
Lubrication & Maintenance .............................................................................. 23
Parts ............................................................................................................ 24-29
Torque Specications ......................................................................................... 30
All information, illustrations and specications in this manual are based on
the latest information available at the time of publication. The right is
reserved to make changes at any time without notice.
General Information
The purpose of this manual is to assist you in operating and maintaining your disc/mower caddy for years of
service. Read it carefully. The information and instructions in this manual have been compiled from extensive
eld 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.
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 change the
machines as may be necessary without notication.
WARNING: Some illustrations in this manual may show the disc/mower caddy with safety shields
removed to provide a better view. The disc/mower caddy 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.
4 Introduction
SAFETY RULES
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
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.
In addition to the design and conguration of equipment, hazard control and accident prevention are dependent
upon the awareness, concern, judgment, 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
Safety instructions are important! Read all attachment
and power unit manuals; follow all safety rules
and safety decal information. (Replacement manuals and
safety decals are available from your dealer.) Failure
to follow instructions or safety rules can result in
serious injury or death.
If you do not understand any part of this manual and
need assistance, see your dealer.
Know your controls and how to stop engine and
attachment quickly in an emergency.
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.
Never allow children or untrained persons to operate
equipment.
• Preparation
Check that all hardware is properly installed
and tightened.
Always wear relatively tight and belted clothing to avoid
getting caught in moving parts. Wear sturdy, rough-soled
work shoes and protective equipment for eyes, hair,
hands, hearing, and head; and respirator or lter mask
where appropriate.
Make sure attachment is properly secured, adjusted,
and in good operating condition.
Before putting equipment into service, check and adjust
driveline length. Driveline must not bottom out or pull
apart throughout the full range of the tractor hitch. Do
not operate until driveline length is correct.
Make sure driveline shield safety chain is attached as
shown in this manual. Replace if damaged or broken.
Check that driveline guards rotate freely on driveline
before putting equipment into service.
Before starting power unit, check all equipment
driveline guards for damage. Replace any damaged
guards. Make sure all guards rotate freely on all
drivelines. If guards do not rotate freely on drivelines,
repair and replace bearings before putting equipment
into service.
Remove accumulated debris from this equipment,
power unit, and engine to avoid re hazard.
Power unit must be equipped with cab and seat belt.
Keep seat belt securely fastened. Falling off power unit
can result in death from being run over or crushed.
A minimum 20% of tractor and equipment weight must
be on the tractor front wheels when attachments are 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.
Make sure collar slides freely and is seated rmly in
tractor PTO spline groove.
(Safety Rules continued on next page)
Safety 5
SAFETY RULES
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
(Safety Rules continued from previous page)
Make sure all safety decals are installed. Replace if
damaged. (See Safety Decals section for location.)
Make sure shields and guards are properly
installed and in good condition. Replace if damaged.
Inspect and clear area of stones, branches, or other
hard objects that might be thrown, causing injury
or damage.
• Transportation
Power unit must be equipped with cab and seat belt.
Keep seat belt securely fastened. Falling off power unit
can result in death from being run over or crushed.
A minimum 20% of tractor and equipment weight
must be on the tractor front wheels when attachments
are 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.
Always comply with all state and local lighting and
marking requirements.
Never allow riders on power unit or attachment.
Do not operate PTO during transport.
Watch for hidden hazards on the terrain.
Do not leave cutter bar in up position when parked.
Do not transport fully weighted caddy without a disc
mower installed.
Maximum Compatible Disc Mower Cutting Width =
10’ 2”.
• Operation
Do not allow bystanders in the area when operating,
attaching, removing, assembling, or servicing
equipment.
Never direct discharge toward people, animals, or
property.
Do not operate or transport equipment while under
the inuence of alcohol or drugs.
Keep hands, feet, hair, and clothing away from
equipment while engine is running. Stay clear of all
moving parts.
Operate only in daylight or good articial light.
Always comply with all state and local lighting and
marking requirements.
Never allow riders on power unit or attachment.
Power unit must be equipped with cab and seat
belt. Keep seat belt securely fastened. Falling off
power unit can result in death from being run over or
crushed.
Do not operate or transport on steep slopes.
Do not operate or transport equipment while under
the inuence of alcohol or drugs.
• Disc Mower Caddy Compatibility
The combined weight of disc mower and caddy should
not exceed 1.5 X weight of the tractor.
Base Disc Mower Caddy weight = 1750 Lbs.
Fully Ballasted Disc Mower weight = 2190 Lbs.
Maximum recommended Disc Mower weight to use with
caddy = 1421 Lbs.
Cab tractor is required when using Frontier Disc Mower
Caddy.
6 Safety
SAFETY RULES
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
Always sit in power unit 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 power unit engine.
Operate tractor PTO at 540 RPM. Do not exceed.
Do not operate PTO during transport.
Look down and to the rear and make sure area is
clear before operating in reverse.
Do not operate or transport on steep slopes.
Do not stop, start, or change directions suddenly
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 equipment immediately upon
striking an obstruction. Turn off engine, remove
key, inspect, and repair any damage before
resuming operation.
Leak down or failure of mechanical or hydraulic
system can cause equipment to drop.
• Maintenance
Before dismounting power unit or performing any
service or maintenance, follow these steps: disengage
power to equipment, lower the 3-point hitch and all
raised components to the ground, set parking brake,
stop engine, remove key, and unfasten seat belt.
Before performing any service or maintenance,
disconnect driveline from tractor PTO.
Do not modify or alter or permit anyone else to
modify or alter the equipment or any of its components
in any way.
Always wear relatively tight and belted clothing to
avoid getting caught in moving parts. Wear sturdy,
rough-soled work shoes and protective equipment
for eyes, hair, hands, hearing, and head; and respirator
or lter mask where appropriate.
Make sure attachment is properly secured, adjusted,
and in good operating condition.
Keep all persons away from operator control area
while performing adjustments, service, or
maintenance.
Never go underneath equipment (lowered to the
ground or raised) unless it is properly blocked and
secured. Never place any part of the body under
neath equipment or between moveable parts even
when the engine has been turned off. Hydraulic system
leak down, hydraulic system failures, mechanical
failures, or movement of control levers can cause
equipment to drop or rotate unexpectedly and cause
severe injury or death. Follow Operator’s Manual
instructions for working underneath and blocking
requirements or have work done by a qualied dealer.
Make certain all movement of equipment components has
stopped before approaching for service.
Tighten all bolts, nuts, and screws to torque chart
specications. Check that all cotter pins are installed
securely to ensure equipment is in a safe condition
before putting unit into service.
Make sure all safety decals are installed. Replace if
damaged. (See Safety Decals section for location.)
Make sure shields and guards are properly
installed and in good condition. Replace if damaged.
• Storage
Block equipment securely for storage.
Keep children and bystanders away from storage area.
Follow manual instructions for storage.
Always use a tractor to position equipment for storage.
Never attempt to move equipment by hand.
Safety 7
SAFETY and INSTRUCTIONAL DECALS
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
Replace Immediately if Damaged!
5
4
3
1
7
8
2
3
4
5
6
8 Safety and Instruction Decals
9
1
540 RPM
SAFETY and INSTRUCTIONAL DECALS
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
Replace Immediately if Damaged!
4
PINCH POINT
RED REFLECTOR
2 Needed
1 Extra Supplied in Manual
Holder for Rear of Disc Mower
2
CAUTION INJURY
RED REFLECTOR
5
TIFC711207
6
HIGH PRESSURE HYDRAULICS
HITCH WARNING
7
SERIAL NUMBER
9
ENTANGLEMENT
3
Warning Label Sheet
Part Number 5TIDC611124
(Contains Label #s 1, 2, 3, 4, 6, 7 & 8)
TRANSPORT SPEED
8
Safety and Instruction Decals 9
GENERAL DESCRIPTION
Your Frontier DC1000 Disc/Mower Caddy has been carefully designed for easily moving your disc mower. This
manual is provided to give you the necessary operation and maintenance instructions for keeping your caddy in
excellent operating condition. Please read this manual thoroughly. Understand the purpose of the controls and
how to use them. Observe all safety precautions on the machine and as noted throughout this manual. If any
assistance or additional information is needed, contact your authorized Frontier dealer.
Major components
Front Tower
PTO Shield
Manual Tube
Hydraulic Cylinder
Rear Tower
PTO Shield
Driveline
Tire & Wheel Assembly
Top Link
A-Frame
Rear PTO
Tower
Adjustable
Tongue Clevis
Front PTO
Tower
Safety Chain
Jack
10 Description
Lift Arms
TECHNICAL DESCRIPTION
Model DC1000
Frame
Construction 4” x 6” tubing
Ballasting
Internal Internally weighted and counterbalanced
External Up to 5 tongue and 5 side weights as needed
Hitch
Type Adjustable Clevis Tongue
Operating Dimensions
Overall Length, in. (mm) 140 (3556)
Overall Width, in. (mm) 83 (2108.2)
Overall Height, in. (mm) 44 (1117.6)
Approx. Weight, lb. (kg) without suitcase weights 1750 (795.5)
Approx. Weight, lb. (kg) with suitcase weights 2190 (995.5)
Hydraulic Lift 3-point hitch
Category 2
Cylinder Stroke 6”
Hoses All hydraulic hoses (3) and tips included
Tires
Size 11L x 15SL ribbed implement tires
PTO
Type Equal angle Cat IV 540rpm
(20 spline double locking collar)
Jack
Type Screw Type
Shipping Dimensions
Overall Length, in. (mm) 85.75 (2178.05)
Overall Width, in. (mm) 90 (2286)
Overall Height, in. (mm) 21 (533.4)
Approx. Weight, lb. (kg) without suitcase weights 1975 (897.7)
Description 11
HARDWARE CHECK SHEET
Ref # Qty. Part # Description Picture
1 1 5TIDC611154 44” Double Splined Shaft
2 10 5TIDC611112 PTO HOUSING BOLTS
5/8” x 2” Grade 5 hex bolt with nylon
lock nut
3 1 5TIDC611101 Manual Holder with Hardware (1/46”
x 1” Grade 5 hex bolt with hardware),
Manual and red reector inside
4 1 5TIDC611132 Clevis Tongue
5 1 5TIDC611108 Cat 2 Pin with Lynch Pin
6 8 5TIDC611122 FLANGE BOLTS
5/8” x 2” Grade 5 with nylon lock nut
7 4 5TIDC611113 CROSSBAR BOLTS
3/4” x 2 1/2” Grade 2 with lock washer
and nut
8 8 5TIDC611115 PTO SHIELD BOLTS
1/4” x 1” Grade 5 with at washer, lock
washer and hex nut
9 1 5TIDC611146 Top Link Adjustment Handle (Included
for replacement with Top Link Only)
10 2 5TIDC611109 Cat 1 Pins with Lynch Pins
11 1 5TIDC611136 Safety Chain with 1/2” x 2” Grade 2 with
two washers and nylon lock nut
12 1 5TIDC611103 Hydraulic Cylinder
13 2 5TIDC611102 Eccentric Locking Collars w/ Bearings
14 1 5TIDC611118 Hydraulic Cylinder Safety Stop with
Locking Pin
15 2 5TIDC611120 Hydraulic Hoses with 90° Connecting
Tips
16 1 5TIDC611137 Hydraulic Hose with Straight Connector
17 2 5TIDC611148 &
5TIDC611149
18 1 5TIDC611114 Hose Clamp with 3/8” x 2” Grade 2 Hex
Front & Rear PTO Shields
Bolt and anged nylon lock nut
12 Hardware Check Sheet
ASSEMBLY & SET UP
TOOLS REQUIRED: rubber hammer, impact wrench, 1 1/8” socket & wrench, adj. wrench, 3/4” socket
& wrench, regular hammer, 1/2” socket, socket wrench, 15/16” socket, 9/16” socket, allen wrenches, 7/8”
socket, grease gun, and Teon tape or pipe compound.
Note: Ref # refers to the DC1000 Hardware Check
Sheet included at the end of this manual (pg. 12) and in
the hardware box that ships with caddy.
• Removing caddy from pallet
5. Cut weight retaining strap on end of frame
and rear wheel assembly.
1. Place pallet in open area to begin
assembly.
2. Remove box of
hardware and set
aside.
3. Remove tires and wheels from pallet
and set in assembly area.
4. Cut weight retaining
strap on end of the
main A-frame.
6. Remove bands from frame and rear wheel
assembly.
7. Using forklift, move frame and rear wheel
assembly and line up bolt holes with main
frame. Make sure wheel is to the inside. Use
caution as assembly is extremely heavy.
8. Using 15/16” socket, install eight 5/8” x
2” bolts and nylon locknuts into frame and
tighten. (Ref #6)
(continued on next page)
Assembly & Set Up 13
ASSEMBLY & SET UP
(continued from previous page)
9. Using forklift, remove large A-frame from
pallet and place in assembly area.
CAUTION: A-frame is extremely heavy and has
signicantly unbalanced weight. Use Extreme
Caution!
10. Remove all lugs from both hubs.
13. Your A-frame is now ready to have components
added to the frame.
• Crossbar Lift Arm Assembly
11. Install wheels and tires on both hubs.
12. Once tires and wheels are
in place, place chocks in
front and behind each wheel.
Using forklift or front end
loader, lift front of caddy and
swing front jack into down
position and lower A-frame
onto jack.
14. Using two people to lift the crossbar assembly,
place onto A-frame. Make sure that lift arms face
rear of caddy.
15. Install four 3/4” x 2 1/2” Grade 2 bolts with lock
washers and nuts from hardware box (Ref #7)
and tighten. Install all four bolts with nuts facing
toward outside of caddy.
Note: When installing the bolt in the right rear side,
with assistance, lift the arm to access the hole and
install the head of the bolt on the inside.
12. Cut zip-ties to remove top link from
A-Frame of caddy
14 Assembly & Set Up
(continued on next page)
ASSEMBLY & SET UP
• Installing PTO Shaft Shields and
Manual Holder
Note: There
are two PTO
shaft shields
to install.
(Ref #17)
16. Install the smaller PTO guard on the rear
bearing tower and the larger on the front
bearing tower using four (4) 1/4” x 1” hex
bolts, eight (8) 1/4” at washers, four (4) 1/4”
lock washers, and four (4) 1/4” hex nuts from
hardware box. (Ref #8) Use a 7/16” wrench to
secure all nuts and bolts.
19. Install hydraulic cylinder to frame and
crossbar lift assembly.
Port
17. Install manual holder on front PTO shield
using 1/4” x 1” bolts and nuts. (Ref #3)
Note: Manual Holder contains manual and a red
reector for installation on the rear of disc
mower, IF the mower obscures the view of the
red reector on the back, right-hand side of the
caddy cart. Install this red reector on the back
of the disc mower as close to the right-hand
outermost portion as practical.
• Installing Hydraulic Cylinder Assembly
Note: Be sure that hose hookup ports on
hydraulic cylinder face outside of caddy.
20. Install two hydraulic hoses with elbows to the
hydraulic cylinder. Be sure to use Teon tape
or pipe compound on these ttings. (Ref #15)
Note: The third hydraulic hose with straight
connector in the hardware box is extension
hose that will be used later on the disc mower
cylinder. (Ref #16)
18. Remove pin clips from hydraulic cylinder
pins and remove pins on both ends of
cylinder. (Ref #12)
21. Thread hydraulic lines through hole in base of
front bearing mount tower.
(continued on next page)
Assembly & Set Up 15
ASSEMBLY & SET UP
(continued from previous page)
22. Place hydraulic
lines into
hydraulic hose
clamp and
tighten.
23. Using Category 2 pin, install top link
adjustment arm on top of rear bearing
mount tower. (Ref #5)
24. Install top link adjustment
handle (Ref #9) into shaft
body on top link. Line
the handle up directly
over hole in top link. Use
hammer to drive handle
through top link.
27. Install safety chain on
tongue in bottom hole
of hitch. If tractor hitch
height requires hitch to
be in bottom hole, attach
safety chain to top hole.
(Ref #11)
28. Remove red Hydraulic Cylinder Safety Stop with
Locking Pin and install through hole on rear of
PTO shield. (Ref #14)
25. Using two pins and clevis
tongue, install tongue
assembly on front of
A-frame. (Ref #4 & Ref
#10)
PTO Shaft
26. Install PTO shaft on front bearing
mount tower.
16 Assembly & Set Up
29. Your caddy is now ready for your disc
mower.
• Attaching Caddy to Tractor
CAUTION: To avoid bodily injury or machine
damage whenever an implement is attached,
put transmission in PARK position and check
the full range of hitch for interference, binding,
or PTO separation. Do not stand between
tractor and implement.
1. Ensure that disc mower caddy is on level
surface with wheels rmly blocked.
2. Back tractor up slowly until hitch is near
caddy tongue.
ATTACHING
5. Attach safety chain to tractor.
6. Slowly lower jack to let weight of caddy
down onto tractor.
3. Use caddy jack to adjust caddy tongue to
correct height.
4. Slowly back tractor hitch onto tongue and
align holes. Insert pin into hitch and secure
with R-pin in bottom of hitch pin.
7. Remove jack completely and store on rear of
caddy near rear tire.
8. Attach two hydraulic cylinder hoses on caddy
to rear of tractor.
9. Your caddy is now ready to have a disc
mower attached.
Attaching 17
ATTACHING
• Attaching Disc Mower to Caddy
1. Ensure that mower is on level surface and
stabilized.
Note: Inside measurements of caddy lift arm are
32 3/4”. If necessary, adjust hitch pins on disc
mower to accommodate caddy arm width.
2. Remove mounting brackets from caddy lift
arms.
7. Install top link on caddy to top of disc mower.
Note: Top link may have to be adjusted with
adjustment handle in order to t.
3. Position caddy arms under mower hitch pins
so that they are just below mower hitch pins.
4. Using hydraulic controls on tractor, slowly
raise the lift arms on caddy to “seat” mower
hitch pins in caddy arms.
8. Once adjusted, tighten lock ring on top link.
9. Install PTO shaft from the front of mower to
the rear bearing mount tower.
10. Install PTO driveline
safety chain to mower.
5. Reinstall mounting brackets and bolts,
tighten bolts.
6. Install lynch pins in end of each hitch pin.
18 Attaching
11. Remove quick coupler
hydraulic nipple from end of
mower disc cylinder line.
(continued on next page)
ATTACHING
(continued from previous page)
12. Attach teon tape or pipe compound to thread
ttings on hydraulic line.
WARNING: Cutter bar guard/cover must
be folded back into transport position before
attempting to raise mower blade.
16. Start tractor and slowly raise caddy lift arms.
17. If mower is equipped with it’s own stand,
raise or release stand on mower at this time.
18. Slowly raise cutter bar to full upright position using
hydraulic cylinder on mower.
13. Attach 9’ hydraulic line extension to end of
mower hydraulic cylinder hose to increase overall
length and tighten.
14. Reattach hydraulic nipple coupler to end of
lengthened hydraulic line. Be sure to use teon
tape or pipe compound on all ttings.
19. Remove hydraulic cylinder safety stop and place
stop in storage location.
15. Thread extended hydraulic line through opposite
hole in base of PTO housing tower and attach to
rear of tractor.
20. Install PTO shaft from front PTO housing
tower to rear of tractor.
(continued on next page)
Attaching 19
(continued from previous page)
21. If equipped, install mower blade release
handle and rope to tractor within easy and
safe reach of operator.
ATTACHING
Note: Please contact your John Deere Dealer
for assistance with ballasting your caddy cart. If
you are able to ballast your caddy cart without
assistance from your dealer, please follow the
proceeding ballasting procedure:
To ensure safe operation of your mower, ballast
your mower caddy to have positive tongue
weight and a maximum side-to-side weight
distribution ratio of 3.2. Side-to-side weight
distribution ratio should be calculated by
dividing the righthand caddy tire weight by the
lefthand caddy tire weight (RH tire wt./LH tire
wt.) when the mower is fully raised on the cart
and with the cutter bar lowered to the side but
not touching the ground.
22. If needed, install approved suitcase
weights for ballast on front and rear
weight racks of disc mower caddy to
achieve proper weight balance.
IMPORTANT: Unit must be properly
ballasted before operation. See
“Ballasting” in next section before use.
• Ballasting Disc Mower Caddy
Note: All references to RH/LH side of machine
are made with the operator facing the operating
direction of the machine.
Note: The R66949 John Deere suitcase weight
is the approved suitcase weight to use when
ballasting your Frontier Mower Caddy Cart.
Mower
blade
in down
position
but not
touching
ground.
Caddy arms
fully up.
20 Attaching
Scales under each
tire and jack.
OPERATION and DETACHING
• Disc Mower Operation
1. Before mowing, ensure that all mower guards
and covers are in place and are in good condition. Replace if necessary. (Consult your
mower’s operating manual.)
2. Raise caddy arm to full upright position and
remove hydraulic cylinder safety stop.
6. Lower disc mower safety guard/cover.
7. Slowly engage tractor PTO. Let mower run to
make sure all parts are working properly.
3. Slowly lower disc mower blade to fully down
position.
4. Slowly lower caddy arms until cutter bar is in its
working position.
5. Adjust top link on caddy to ensure that disc mower
blade is at desired operating level.
8. Put tractor in gear to mow at recommended speed
for your tractor and terrain. (Consult your disc
mower manual.)
• Detaching Caddy from Tractor
(with mower attached)
1. Ensure that disc mower caddy is on level surface
with wheels chocked. (Disc mower cutter bar
should be in full upright position at this point.)
2. With tractor in park, raise disc mower caddy
arms to full upright position.
(continued on next page)
Operation and Detaching 21
DETACHING
(continued from previous page)
3. Remove hydraulic cylinder safety stop from
hydraulic cylinder.
Note: The safety stop should be loose on the
cylinder arm with no pressure on the stop.
7. Turn tractor off.
8. Remove jack from rear
position on frame and place
on tongue of mower caddy.
Raise jack until weight of
caddy is resting on jack
rather than tractor tongue.
9. Remove
hydraulic lines
from tractor.
4. Place safety stop in storage location on PTO shield.
5. Slowly lower cutter bar of disc mower to side to
be parallel with ground.
10. Remove
PTO shaft
from
tractor.
11. Remove rope for blade arm release if so
equipped.
12. Remove pin from hitch.
13. Remove
safety chain
from tractor.
6. Then, slowly lower the disc mower caddy arms
down until cutter bar rests on ground.
22 Detaching
14. Slowly pull tractor away from caddy.
LUBRICATION and MAINTENANCE
• Lubrication Before Each Use
1. Driveline Universal Joints
a. Apply multi-purpose grease with a grease gun.
2. Driveline Guard
b. Apply 2-3 shots of multipurpose grease with
grease gun to plastic tting.
3. Driveline Prole
c. Disconnect PTO Driveline.
d. Pull the two sections about half way apart and
rotate until the holes in the plastic guards align
with the exposed spline in the shaft.
e. Apply thin coat of multi-purpose grease to the
spline section in several locations around the
spline. Contract and expand the shaft several
times to distribute the grease.
f. Reconnect the PTO Driveline.
Note: Pull each driveline section to be sure driveline
and shields are securely connected. Make certain
PTO shielding is in good condition. Do not grease
outer or inner plastic shields.
4. PTO Housing Bearings
g. Apply multi-purpose grease with a grease gun.
5. Crossbar Lift Arm Assembly
h. Apply multi-purpose grease with a grease gun.
6. Wheel Bearings
i. Check monthly and repack as necessary.
(4) PTO Housing Bearings - On Each Tower,
Before Each Use
(1) Before Each Use
(2) Before
Each Use
(1) Before Each Use
(6) Monthly
(5) On Each Side,
Before Each Use
(3) Before Each Use
Lubrication and Maintenance 23
PARTS
Back Front
9
18
10
4
5
13*
3
1
11
2
17
* For complete Safety Decals listing and
locations refer to pages 8 and 9 of Disc/
Mower Caddy Operator’s Manual.
Item Number Qty.
Qty. Shipped
1 1 1 5TIDC611101 Black Manual Holder w/ Hardware
2 1 1 5TIDC611145 610MM 20 Spline PTO Shaft
3 1 1 5TIDC611151 PTO Tube Guard
4 1 1 5TIDC611146 29” Top Link
5 2 1 5TIDC611106 Wheel & Tire Combo
6 2 1 5TIDC611109 Cat #1 Hitch Pin w/ Lynch Pin
7 6 6 5TIDC611112 PTO Housing Mount Assembly Hardware
8 7 1 5TIDC611116 5/8” U-Bolts w/ Nylon Lock Nuts
9 2 1 5TIDC611148 Front PTO Shild Plate
10 1 1 5TIDC611149 Rear PTO Shield Plate
11 1 1 5TIDC611154 44” Double Spline Shaft
12 2 1 5TIDC611123 Model Number Decal Label
13 1 1 5TIDC611124 Warning Decal Sheet (see pages 8 & 9)*
14 2 1 TIFC711172 Frontier Logo Decal
15 1 1 5TIDC611136 Disc Caddy Safety Chain w/ Hook & Latch
16 2 1 5TIDC611120 9’ Hydraulic Hoses w/ 90° Ends
17 2 1
18 1 1 5TIDC611114 Hydraulic Line Holder w/ Hardware Kit
19 1 1 5TIDC611103 Hydraulic Cylinder
19
8
16
14
12
7
15
6
Parts Overall View
Double Tower Style
Part Number Description
5TIDC611139 Hub Kit (Hub, Lug Bolts, Dust Cap & Bearings)
19
Use this parts list if serial number is XFDC10X001400 or greater.
24 Parts
PARTS
BackFront Front
8
5
3
1
14
7
12
2
11
13
19
9
4
6
15
18
1
10
Parts Overall View
Double Tower Style
Item Number Qty.
1 2 1 5TIDC611102 Eccentric Locking Collar Bearings (hardware not included)
2 1 1 5TIDC611107 Jack
3 1 1 5TIDC611108 Cat #2 Top Link Pin w/ Lynch Pin
4 4 2 5TIDC611110 Hitch Tab Hardware
5 4 4 5TIDC611150 Bearing Hardware
6 4 2 5TIDC611113 Disc Caddy Hitch Adjustment Beam Hardware
7 8 4 5TIDC611115 PTO Shield Hardware
8 1 1 5TIDC611118 Hydraulic Cylinder Safety Stop w/ Clinch Pin
9 2 1 5TIDC611138 Disc Caddy Hydraulic Hose End Attachment
10 8 8 5TIDC611122 Frame Plate Hardware
11 1 1 5TIDC611147 Disc Caddy Frame
12 1 1 5TIDC611152 Front Bearing Mount Tower
13 1 1 5TIDC611153 Rear Bearing Mount Tower
14 1 1 5TIDC611132 Disc Caddy Hitch Clevis Tongue
15 2 1 5TIDC611134 Disc Caddy Hitch Tab
16 1 1 5TIDC611135 Rear Frame and Axle Attachment (Frame & Spindle Only)
17 3 1 TIFC711207 Red Reector Decal
18 2 1 5TIDC611119 Weight Retaining Bar w/ R-Pin
19 1 1 5TIDC611133 Disc Caddy Hitch Adjustment Beam
20 2 1 5TIDC611137 (Not Shown) Disc Caddy Hydraulic Extension Hose w/
Qty. Shipped
Part Number Description
Straight End
17
16
Use this parts list if serial number is XFDC10X001400 or greater.
Parts 25
PARTS
9
8
16
3
4
11*
2
1
15
* For complete Safety Decals listing and
locations refer to pages 8 and 9.
Item Number Qty.
Qty. Shipped
1 1 1 5TIDC611101 Black Manual Holder w/ Hardware
2 1 1 5TIDC611104 60” PTO Shaft
3 1 1 5TIDC611105 50” Top Link
4 2 1 5TIDC611106 Wheel & Tire Combo
5 2 1 5TIDC611109 Cat #1 Hitch Pin w/ Lynch Pin
6 6 6 5TIDC611112 PTO Housing Mount Assembly Hardware
7 7 1 5TIDC611116 5/8” U-Bolts w/ Nylon Lock Nuts
8 2 1 5TIDC611117 PTO Shield Plate (Rev A)
8 2 1 5TIDC611142 Single Tower PTO Shield Plate (Rev B) (For DC1000 with
9 1 1 5TIDC611121 15” Six-Spine PTO Adapter Shaft
10 2 1 5TIDC611123 Model Number Decal Label
11 1 1 5TIDC611124 Warning Decal Sheet (see pages 8 & 9)*
12 2 1 TIFC711172 Frontier Logo Decal
13 1 1 5TIDC611136 Disc Caddy Safety Chain w/ Hook & Latch
14 1 1 5TIDC611120 9’ Hydraulic Hoses w/ 90° Ends
15 2 1
16 1 1 5TIDC611114 Hydraulic Line Holder w/ Hardware Kit
17 2 1 5TIDC611137 (Not Shown) Disc Caddy Hydraulic Extension Hose w/
15
7
12
Parts Overall View
10
6
14
5
13
Single Tower Style
Part Number Description
serial number XFDC10X001234 or after)
5TIDC611139 Hub Kit (Hub, Lug Bolts, Dust Cap & Bearings)
Straight End
Use this parts list if serial number is before XFDC10X001400.
26 Parts
PARTS
14
4
19
2
5
7
15
11
16
18
8
2
9
13
10
3
18
12
9
1
6
17
Parts Overall View
Single Tower Style
Item Number Qty.
1 2 1 5TIDC611102 Eccentric Locking Collar Bearings (hardware not included)
2 1 1 5TIDC611103 Hydraulic Cylinder
3 1 1 5TIDC611107 Jack
4 1 1 5TIDC611108 Cat #2 Top Link Pin w/ Lynch Pin
5 4 2 5TIDC611110 Hitch Tab Hardware
6 4 4 5TIDC611111 Bearing Hardware
7 4 2 5TIDC611113 Disc Caddy Hitch Adjustment Beam Hardware
8 8 4 5TIDC611115 PTO Shield Hardware
9 1 1 5TIDC611118 Hydraulic Cylinder Safety Stop w/ Clinch Pin
10 2 1 5TIDC611138 Disc Caddy Hydraulic Hose End Attachment
11 8 8 5TIDC611122 Frame Plate Hardware
12 1 1 5TIDC611130 Disc Caddy Frame
13 1 1 5TIDC611141 Single Tower Disc Caddy Mount Assy w/PTO Shield
14 1 1 5TIDC611132 Disc Caddy Hitch Clevis Tongue
15 2 1 5TIDC611134 Disc Caddy Hitch Tab
16 1 1 5TIDC611135 Rear Frame and Axle Attachment (Frame & Spindle Only)
17 3 1 TIFC711207 Red Reector Decal
18 2 1 5TIDC611119 Weight Retaining Bar w/ R-Pin
19 1 1 5TIDC611133 Disc Caddy Hitch Adjustment Beam
Qty. Shipped
Part Number Description
Plates (Rev B)
Use this parts list if serial number is before XFDC10X001400.
Parts 27
PARTS
5
4
3
1
2
3
8
9
7
10
6
1
2
PTO Driveline Assembly
Double Tower Style
Item Number Qty. Qty. Shipped Part Number Description
1 1 1 5TIDC611155 Yoke ASGE
2 1 1 TIFC711178 ASGE Collar Kit
3 2 2 5TIDC611156 Cross & Bearing Kit (2pk)
4 1 1 5TIDC611157 Inner Pinned Assembly
5 1 1 5TIDC611158 Outer Shield Kit
6 1 1 TIFC711179 Decal Outer
7 1 1 5TIDC611159 Inner Shield Kit
8 1 1 5TIDC611160 Outer Pinned Assembly
9 1 1 TIFC711180 Decal Inner
10 1 1 5TIDC611145 610MM 20 Spline PTO Shaft
28 Parts
PARTS
5
4
3
1
2
8
7
9
10
3
6
1
2
PTO Driveline Assembly
Single Tower Style
Item Number Qty. Qty. Shipped Part Number Description
1 1 1 5TIFC711233 Yoke ASGE
2 1 1 TIFC711178 ASGE Collar Kit
3 2 2 5TIFC711234 Cross and Bearing Kit
4 1 1 5TIDC611126 Inner Pinned Assembly
5 1 1 5TIDC611127 Outer Shield Kit
6 1 1 TIFC711179 Decal Outer
7 1 1 5TIDC611128 Inner Shield Kit
8 1 1 5TIDC611129 Outer Pinned Assembly
9 1 1 TIFC711180 Decal Inner
10 1 1 5TIDC611104 60” PTO Shaft
Parts 29
AMERICAN
Bolt Head Markings
Wrench
Size “A”
SAE Grade 2
(No Dashes)
SAE Grade 5
(3 Dashes)
Diameter “B”
SAE Grade 8
(6 Dashes)
Bolt
TORQUE SPECIFICATIONS
Proper torque for American fasteners used on manufactured implement.
Recommended Torque in Foot Pounds (Newton Meters).*
WRENCH
SIZE(IN.)”A”
7/16 1/4 -20 UNC 6 (7) 8 (11) 12 (16)
7/16 1/4 - 24 UNF 6 (8) 10 (13) 14 (18)
1/2 5/16 -18 UNC 11 (15) 17 (23) 25 (33)
1/2 5/16 - 24 UNF 13 (17) 19 (26) 27 (37)
9/16 3/8 - 16 UNC 20 (27) 31 (42) 44 (60)
9/16 3/8 -24 UNF 23 (31) 35 (47) 49 (66)
5/8 7/16 -14 UNC 32 (43) 49 (66) 70 (95)
5/8 7/16 - 20 UNF 36 (49) 55 (75) 78 (106)
3/4 1/2 - 13 UNC 49 (66) 76 (103) 106 (144)
3/4 1/2 - 20 UNF 55 (75) 85 (115) 120 (163)
7/8 9/16 -12 UNC 70 (95) 109 (148) 153 (207)
7/8 9/16 - 18 UNF 79 (107) 122 (165) 172 (233)
15/16 5/8 - 11 UNC 97 (131) 150 (203) 212 (287)
15/16 5/8 - 18 UNF 110 (149) 170 (230) 240 (325)
1-1/8 3/4 - 10 UNC 144(195) 266 (360) 376 (509)
1-1/8 3/4 - 16 UNF 192 (260) 297 (406) 420 (569)
1-5/16 7/8 - 9 UNC 166 (225) 430 (583) 606 (821)
1-5/16 7/8 - 14 UNF 184 (249) 474 (642) 668 (905)
1-1/2 1-8 UNC 250 (339) 644 (873) 909 (1232)
1-1/2 1 - 12 UNF 274 (371) 705 (955) 995 (1348)
1-1/2 1-14 UNF 280 (379) 721 (977) 1019 (1381)
1-11/16 1-1/8 - 7 UNC 354 (480) 795 (1077) 1288 (1745)
1-11/16 1-1/8 -12 UNF 397 (538) 890 (1206) 1444 (1957)
1-7/8 1-1/4 - 7 UNC 500 (678) 1120 (1518) 1817 (2462)
1-7/8 1-1/4 - 12 UNF 553 (749) 1241 (1682) 2013 (2728)
2-1/16 1-3/8 - 6 UNC 655 (887) 1470 (1992) 2382 (3228)
2-1/16 1-3/8 -12 UNF 746 (1011) 1672 (2266) 2712 (3675)
2-1/4
2-1/4
BOLT DIAMETER
(IN.)”B” AND
THREAD SIZE
1-1/2 - 6 UNC
1-1/2 - 12 UNF
SAE
GRADE 2
870 (1179)
979 (1327)
SAE
GRADE 5
1950 (2642)
2194 (2973)
SAE
GRADE 8
3161 (4283)
3557 (4820)
Proper torque for metric fasteners used on manufacturer implement.
METRIC
Bolt
Diameter “B”
Wrench
Size “A”
Numbers appearing on bolt heads
indicate ASTM classes.
*Use 75% of the specied torque value for
plated fasteners. Use 85% of the specied
torque values for lubricated fasteners.
WRENCH SIZE
(mm) “A”
8 5 1.8 (2.4) 5.1 (6.9) 6.5 (8.8)
10 6 3 (4) 8.7 (12) 11.1 (15)
13 8 7.3 (10) 21.1 (29) 27 (37)
16 10 14.5 (20) 42 (57) 53 (72)
18 12 25 (34) 74 (100) 73 (99) 93 (126)
21 14 40 (54) 118 (160) 116 (157) 148 (201)
24 16 62 (84) 167 (226) 181 (245) 230 (312)
30 20 122 (165) 325 (440) 449 (608)
33 22 443 (600) 611 (828)
36 24 211 (286) 563 (763) 778 (1054)
31 27 821 (1112) 138(1542)
46 30 418 (566) 1119 (1516) 1547(2096)
30 Torque Specications
Recommended Torque in Foot Pounds (Newton Meters).*
BOLT DIA.
(mm) ”B”
ASTM
4.6
ASTM
8.8
ASTM
9.8
ASTM
10.9
NOTES
Notes 31
PART NUMBER
5TIDC611125
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