John Deere GM1060, GM1072 User Manual
OPERATOR’S MANUAL
GM1060
GM1072
GROOMING MOWERS
SIDE DISCHARGE
5WPMAN0242 (Rev. 7/21/2008)
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 Dealer’s Pre-Delivery and Delivery Check Lists 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 website. 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. The information presented will prepare you to do a better
and safer job. Keep this manual handy for ready reference. Require all operators to read this manual carefully and
become acquainted with all the adjustment and operating procedures before attempting to operate. 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 specified.
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 your needs.
Use only genuine Frontier service parts. Substitute parts will void the warranty and may not meet standards required for
safe and satisfactory operation. Record the model number and serial number of your equipment in the spaces
provided:
Model: ______________________________ Date of Purchase: _____________________
Serial Number: (see Safety Decal section for location) ____________________________________
Provide this information to your dealer to obtain correct repair parts.
Throughout this manual, the term NOTICE is used to indicate that failure to observe 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.
2 Introduction
Frontier (Rev. 7/20/2007)
TABLE OF CONTENTS
Si no lee Ingles, pida ayuda a
alguien que si lo lea para que le
traduzca las medidas de seguridad.
LEA EL INSTRUCTIVO!
!
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OWNER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DEALER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
DEALER CHECK LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
PARTS INDEX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
BOLT TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
BOLT SIZE CHART & ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 47
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
PRODUCT WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
REPLACEMENT PARTS WARRANTY . . . . . . . . . . . . INSIDE BACK COVER
5WPMAN0242 (Rev. 5/2/2008)
Introduction 3
SPECIFICATIONS
WARNING
GM1060 GM1072
3-Point Hitch Category 1 Category 1
Cutting Width 60" (1524 mm) 72" (1829 mm)
Cutting Height Range 1.5" - 6" 1.5" - 6"
(38 - 152 mm) (38 - 152 mm)
Shipping Weight (Approximate) 500 lbs (226.8 kg) 550 lbs (249.5 kg)
Blade Speed (feet per minute) 15,200 16,600
Blade Speed (RPM) 2,795 2,571
Blade Spindles 3 3
Number of Blades 3 3
Universal Drive Series Category 3 Category 3
Caster Wheels 3.5" x 10.25" 3.5" x 10.25"
(89 - 260 mm) (89 - 260 mm)
Tractor PTO Speed RPM 540 540
Recommended Maximum
Tractor Horsepower 35 35
Mower Frame Thickness 8 GA 8 GA
GENERAL INFORMATION
Some illustrations in this manual show the
equipment with safety shields removed to provide
a better view. This equipment should never be
operated with any necessary safety shielding
removed.
The purpose of this manual is to assist you in operating
and maintaining your mower. Read it carefully. It furnishes information and instructions that will help you
achieve years of dependable performance. These
instructions have been compiled from extensive field
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. However, 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
notification.
Throughout this manual, references are made to right
and left directions. These are determined by standing
behind the tractor facing the direction of forward travel.
4 Introduction
5WPMAN0242 (Rev. 7/21/2008)
TRAINING
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 configuration of
equipment, hazard control and accident prevention are dependent upon the awareness, concern,
judgement, 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.
SAFETY RULES
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
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.
Always tighten to torque chart specifications
unless instructed otherwise in this manual.
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 filter mask where appropriate.
Make sure attachment is properly secured,
adjusted, and in good operating condition.
Make sure spring-activated locking pin or collar
slides freely and is seated firmly in tractor PTO
spline groove.
Power unit must be equipped with ROPS or
ROPS cab and seat belt. Keep seat belt securely
fastened. Falling off power unit can result in death
GM1060/1072 SD SR (Rev. 9/6/2005)
from being run over or crushed. Keep foldable
ROPS system in “locked up” position at all times.
Remove accumulated debris from this equipment, power unit, and engine to avoid fire hazard.
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.
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.
Inspect and clear area of stones, branches, or
other hard objects that might be thrown, causing
injury or damage.
OPERATION
Do not put mower into service unless discharge
chute is installed and in good condition. Replace if
damaged.
Keep bystanders away from equipment.
Never direct discharge toward people, animals,
or property.
Do not operate or transport equipment while
under the influence of alcohol or drugs.
Operate only in daylight or good artificial light.
Keep hands, feet, hair, and clothing away from
equipment while engine is running. Stay clear of all
moving parts.
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 ROPS or
ROPS cab and seat belt. Keep seat belt securely
fastened. Falling off power unit can result in death
from being run over or crushed. Keep foldable
ROPS system in “locked up” position at all times.
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.
(Safety Rules continued on next page)
Safety 5
(Safety Rules continued from previous page)
SAFETY RULES
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
Operate tractor PTO at 540 RPM. Do not exceed.
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 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.
sturdy, rough-soled work shoes and protective
equipment for eyes, hair, hands, hearing, and head;
and respirator or filter mask where appropriate.
Keep all persons away from operator control
area while performing adjustments, service, or
maintenance.
Make certain all movement of equipment components has stopped before approaching for service.
Frequently check blades. They should be sharp,
free of nicks and cracks, and securely fastened.
Stop power unit and equipment immediately
upon striking an obstruction. Turn off engine,
remove key, inspect, and repair any damage before
resuming operation.
TRANSPORTATION
Power unit must be equipped with ROPS or
ROPS cab and seat belt. Keep seat belt securely
fastened. Falling off power unit can result in death
from being run over or crushed. Keep foldable
ROPS system in “locked up” position at all times.
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.
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 operate or transport equipment while
under the influence of alcohol or drugs.
MAINTENANCE
Use a new Nylok blade bolt and cup washers
when you replace the blade. Do not substitute any
bolt for the special blade bolt. It is self-locking,
meeting the non-loosening requirements for this
application.
Do not handle blades with bare hands. Careless
or improper handling may result in serious injury.
Your dealer can supply genuine replacement
blades. Substitute blades may not meet original
equipment specifications and may be dangerous.
Tighten all bolts, nuts, and screws to torque
chart specifications. 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.
Before performing any service or maintenance,
lower equipment to ground or block securely, turn
off engine, remove key, and 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
6 Safety
STORAGE
Block equipment securely for storage.
Keep children and bystanders away from stor-
age area.
Follow manual instructions for storage.
GM1060/1072 SD SR (Rev. 9/6/2005)
2 - 5WP18863
7 - Serial Number Plate
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
Driveline guards that turn freely on
driveline
18864-C
1 - 5WP18864
PRODUCT IDENTIFICATION NUMBER
LENEXA, KS, U.S.A.LE NEX A, K S, U .S. A.
(Safety Decals continued on next page)
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 discharge chute and guards in place and in good
condition.
BLADE CONTACT OR THROWN OBJECTS CAN
CAUSE SERIOUS INJURY OR DEATH.
DANGER
18863-B
GUARD MISSING.
DO NOT OPERATE.
DANGER
33347E
DANGER
DANGER
GUARD MISSING.
DO NOT OPERATE.
9 - 5WP33347
GM1060
Shown;
GM1072 Similar
SAFETY & INSTRUCTIONAL DECALS
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
Replace Immediately If Damaged!
4
10
3
2
7
1
1
3
8
CD3977B
9
12
3
6
5
5WPMAN0242 (Rev. 7/21/2008)
Safety 7
SAFETY & INSTRUCTIONAL DECALS
FALLING OFF CAN RESULT IN BEING RUN OVER.
Tractor must be equipped with ROPS (or ROPS CAB) and seat
belt. Keep foldable ROPS systems in “locked up” position at all
times.
Buckle Up! Keep seat belt securely fastened.
Allow no riders.
RAISED EQUIPMENT CAN DROP AND CRUSH.
Before working underneath, follow all instructions and safety rules in
operator’s manual and securely block up all corners of equipment
with jack stands.
Securely blocking prevents equipment dropping from hydraulic leakdown, hydraulic system failures or mechanical component failures.
FALLING OFF OR FAILING TO BLOCK SECURELY CAN
RESULT IN SERIOUS INJURY OR DEATH.
WARNING
18865--C
5 - 5WP18865
6 - 5WP18877
SHIELD MISSING
DO NOT OPERATE
PUT SHIELD ON
DANGER
18867--B
3 - 5WP18867
4 - 5WP18869
DO NOT EXCEED PTO SPEED OF
540 RPM
PTO speeds higher than 540 RPM can cause
equipment failure and personal injury.
WARNING
18866-D
8 - 5WP18866
BE CAREFUL!
Use a clean, damp cloth to clean safety decals.
Avoid spraying too close to decals when using a
pressure washer; high-pressure water can enter
through very small scratches or under edges of decals
causing them to peel or come off.
Replacement safety decals can be ordered free from
your dealer.
(Safety Decals continued from previous page)
CRUSHING AND PINCHING HAZARD
Be extremely careful handling various parts of
the machine. They are heavy and hands, fingers,
feet, and other body parts could be crushed or
pinched between tractor and implement.
Operate tractor controls from tractor seat only.
Do not stand between tractor and implement
when tractor is in gear.
Make sure parking brake is engaged before
going between tractor and implement.
Stand clear of machine while in operation or
when it is being raised or lowered.
FAILURE TO FOLLOW THESE
INSTRUCTIONS COULD RESULT IN
SERIOUS INJURY OR DEATH.
WARNING
1003751-A
WARNING
TO AVOID SERIOUS
INJURY OR DEATH:
Read Operator's Manual (available
from dealer) and follow all safety
precautions.
Keep all shields in place and in good
condition.
Operate mower from tractor seat only.
Lower mower, stop engine and remove
key before dismounting tractor.
Allow no children or untrained persons
to operate equipment.
Do not transport towed or
semi-mounted units over 20 mph.
FAILURE TO OPERATE SAFELY
CAN RESULT IN
INJURY OR DEATH.
18877-C
12 - 5WP1003751
If shaft connection is visible, shield
is missing. Replace shield before
operating equipment.
DANGNGERER
1004114
10 - 5WP1004114
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
Replace Immediately If Damaged!
DO NOT OPERATE - PUT SHIELD ON
DANGER
SHIELD MISSING
18869-B
8 Safety
5WPMAN0242 (Rev. 5/2/2008)
OPERATION
WARNING
CAUTION
WARNING
WARNING
1. Tractor top link
A. Mower top link
attachment point
B. Mower hitch pin
CM906
Tether Chain
The operator is responsible for the safe operation of
the mower. The operator must be properly trained.
Operators should be familiar with the mower, tractor,
and all safety practices before starting operation. Read
the safety rules and safety decals on pages 5 to 8.
This mower is designed for lawn and grass mowing. It
is not designed for rough conditions or heavy weed
mowing. It is equipped with suction type blades for best
results in lawn mowing.
Figure 1. Tractor Stability
Recommended mowing speed for most conditions is
from 2 to 5 mph.
Never allow children or untrained persons to
operate equipment.
Keep bystanders away from equipment.
Make sure spring-activated locking pin or collar
slides freely and is seated firmly in tractor PTO
spline groove.
Operate tractor PTO at 540 RPM. Do not exceed.
Stop power unit and implement immediately
upon striking an obstruction. Dismount power unit,
using proper procedure. Inspect and repair any
damage before resuming operation.
ATTACHING MOWER TO TRACTOR
Make sure spring-activated locking pin or collar
slides freely and is seated firmly in tractor PTO
spline groove.
The standard 1-3/8" 6-spline driveline with a QD yoke
is used to connect the mower to the tractor.
1. Attach the mower hitch pins to the lower tractor lift
arms and secure.
2. Attach tractor top link (1), Figure 2, to mower top
link bracket attachment point A. Connect the driveline to the tractor PTO shaft.
3. Attach tether chain to tractor drawbar (Figure 3).
4. Adjust the tractor lower 3-point arm anti-sway
devices to prevent mower from swinging side to
side during transport.
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 filter mask where appropriate.
TRACTOR STABILITY
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.
5WPMAN0242 (Rev. 5/2/2008)
Figure 2. Attachment Points
Figure 3. Attaching Mower to Tractor
Operation 9
CUTTING HEIGHT ADJUSTMENT
WARNING
SPACERS REQUIRED UNDER
CASTER ARM PIVOT TUBE
Cut
Height
1/2"
Spacer
3/4"
Spacer
1"
Spacer
1-1/4"
Spacer
1-1/2"
2" 1
2-1/2" 1
3" 11
3-1/2" 2
4" 12
4-1/2" 111
5" 1111
5-1/2" 121
6" 1121
Table 1: Cutting Height Chart
1. Tractor top link
A. Mower top link
attachment point
B. Mower hitch pin
Keep all persons away from operator control
area while performing adjustments, service, or
maintenance.
NOTICE
■ Avoid low cutting heights. Striking the ground
with blades produces one of the most damaging
shock loads a mower can encounter. Allowing
blades to contact ground repeatedly will cause
damage to mower and drive.
1. Level mower from side to side. Check by measur-
ing from mower frame to the ground at each deck
rail.
2. Adjust, using tractor 3-point arm leveling device.
NOTE:
front of mower level with or slightly lower than the
rear.
3. Control cutting height with tractor 3-point arms and
front and rear caster wheel adjustment.
4. Raise rear of mower, move caster adjustment
spacers under caster arms. Hex opening of blade
wrench fits bolts on top of caster shaft.
5. Raise front of mower with tractor 3-point arms.
Move spacers under front caster wheel arms.
NOTE:
blade and the ground. The blades are 7-3/4" below
the top of the deck rail on the GM1060 and 8-3/4"
below the top of the deck rail on the GM1072. To
check cutting height, place a straight edge along top
edge of deck rail as shown in Figure 4.
6. Measure from bottom of straight edge to the
ground at locations A and B. Subtract 7-3/4" on
GM1060 (8-3/4" on GM1072) from measurement B
to determine cutting height.
NOTE: Remember, measurement at location A, Figure
4, should not be less than location B and should not be
over 1/2" greater than location B.
10 Operation
Best mowing results will be obtained with
Cutting height is the distance between the
Figure 4. Cutting Height Adjustment
TRACTOR TOP LINK ADJUSTMENT
When the cutting height is set, adjust tractor top link
until mower top link attachment point A is aligned vertically with mower hitch pin B.
Adjust tractor top link so mower is level between caster
wheel and ground (dimension C, Figure 6). This will
allow the mower to follow ground contour.
Figure 5. Top Link Adjustment
Figure 6. Gauge Wheel Distance
(Rev. 7/21/2008)
5WPMAN0242 (Rev. 5/2/2008)
FRONT CASTER WHEEL INTERFERENCE
CAUTION
WARNING
CHECK
NOTICE
■ Do not operate tractor and mower until this
interference check has been performed. If you
change tractors, you must perform the check for
that mounting.
Perform this check with all of the spacers and springs
above the caster wheel arm. This will place the caster
wheels in their highest position and provide the lowest
cutting height for the mower.
Raise mower with tractor hydraulics to 16" at dimension C or maximum height of tractor lift, whichever is
less.
Pivot both front caster wheels forward and check that
there is clearance between caster wheels and tractor
tires. If there is interference, you must not use front
caster wheels on the mower with this tractor.
2. Continue running at least two minutes, allowing
pulleys to cool. Stopping the mower in contact with
a very hot pulley will bake and ruin belt.
Proper ground speed will depend upon the terrain, the
height, and type and density of material to be cut.
Normally, ground speed will range from 2 to 5 mph. Tall
dense material should be cut at a low speed; thin
medium-height material can be cut at a faster ground
speed.
OPERATING TECHNIQUE
Stop power unit and implement immediately
upon striking an obstruction. Dismount power unit,
using proper procedure. Inspect and repair any
damage before resuming operation.
Always operate tractor PTO at 540 rpm to maintain
proper blade speed and produce a clean cut.
Under certain conditions, tractor tires may roll some
grass down and prevent it from being cut at the same
height as the surrounding area. When this occurs,
reduce your ground speed, but maintain PTO at 540
rpm. The lower ground speed will permit grass to partially rebound.
Figure 7. Front Gauge Wheel Interference Check
FRONT ROLLER (OPTIONAL)
The caster wheels and side skids effectively reduce
scalping in most cases. However, you may encounter
areas where the caster wheels and/or side skids drop
into depressions and allow center of mower to contact
ground and scalp. An optional front roller may be
installed to minimize scalping.
For Installation instructions See “Front Roller Installation (Optional)” on page 30.
Power for operating mower is supplied by tractor PTO.
Operate PTO at 540 rpm. Know how to stop tractor and
mower quickly in an emergency.
If mower becomes plugged causing belt to slip for over
two seconds, follow these steps:
In general, lower cutting heights give a more even cut
and leave less tire tracks. However, it is better to cut
grass frequently rather than too short. Short grass
deteriorates rapidly in hot weather and invites weed
growth during growing seasons. Follow local recommendations for the suitable cutting height in your area.
OPERATING TIPS
Inspect and clear area of stones, branches, or
other hard objects that might be thrown, causing
injury or damage.
NOTICE
■ Mower vibration tends to loosen bolts during
operation. All hardware should be checked regularly to maintain proper torque. It is a good practice
to check mower before each operation to ensure all
hardware is secure.
Extremely tall material should be cut twice. Set mower
at a higher cutting height for the first pass. Then cut at
desired height, 90 degrees to the first pass.
1. Maneuver equipment into a previously cut area and
allow mower to clear accumulated material.
5WPMAN0242 (Rev. 5/2/2008)
Remember, sharp blades produce cleaner cuts and
require less power.
Operation 11
Analyze area to be cut to determine the best proce-
WARNING
dure. Consider height and type of grass and terrain
type: hilly, level, or rough.
Plan your mowing pattern to travel straight forward
whenever possible. Mow with uncut grass to the right.
This will distribute the clippings over the cut area.
UNEVEN TERRAIN
Do not operate or transport on steep slopes.
2. Collapse driveshaft as far as possible and store it
in PTO hanger bracket to prevent ground contact.
3. Place blocks under mower side skids. Lower
mower onto blocks, disconnect mower from tractor
3-point hitch, and carefully drive tractor away from
mower.
PRE-OPERATION CHECK LIST
(OWNER'S RESPONSIBILITY)
___ Review and follow all safety rules and safety
decal instructions on pages 5 through 8.
___ Check that all safety decals are installed and in
good condition. Replace if damaged.
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.
Pass diagonally through sharp dips and avoid sharp
drops to prevent hanging up tractor and mower.
Practice will improve your skills in maneuvering rough
terrain.
STORAGE
___ Check that all shields and guards are properly
installed and in good condition. Replace if damaged.
___ Check that all hardware and cotter pins are prop-
erly installed and secured.
___ Check to ensure blades are sharp, in good condi-
tion, and installed correctly. Replace if damaged.
___ Check that equipment is properly and securely
attached to tractor.
___ Make sure driveline spring-activated locking pin
or collar slides freely and is seated firmly in tractor PTO spline groove.
___ Make sure the driveline guards and tether chains
are in good condition. Guards must rotate freely
on driveline. Fasten tether chains to the tractor
and the equipment as instructed.
___ Inspect area and remove stones, branches or
other hard objects that might be thrown, causing
injury or damage.
___ Do not allow riders.
Figure 8. Mower Storage Position
1. Disengage tractor PTO and raise mower with the
3-point hitch.
12 Operation
___ Check all lubrication points and grease as
instructed in Lubrication Information on page 14.
Make sure the PTO slip joint is lubricated and that
the gearbox fluid levels are correct.
___ Set tractor PTO at correct rpm for your equip-
ment.
___ Make sure tractor ROPS or ROPS cab and seat
belt are in good condition. Keep seat belt
securely fastened during operation.
___ Before starting engine, operator must be in trac-
tor seat with seat belt fastened. Place transmission in neutral or park, engage brake, and
disengage tractor PTO.
5WPMAN0242 (Rev. 5/2/2008)
OWNER SERVICE
CAUTION
WARNING
The information in this section is written for operators
who possess basic mechanical skills. If you need help,
your dealer has trained service technicians available.
For your protection, read and follow the safety information in this manual.
Always wear relatively tight and belted clothing
to avoid entanglement in moving parts. Wear
sturdy, rough-soled work shoes and protective
equipment for eyes, hair, hands, hearing, and head;
and respirator or filter mask where appropriate.
Never go underneath equipment (lowered to the
ground or raised) unless it is properly blocked and
secured. Never place any part of the body underneath 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
qualified dealer.
BLOCKING METHOD
Jackstands, with a load rating of 1,000 pounds or
more, are the only approved blocking device for this
mower. A minimum of four jackstands, located under
the mower as shown in Figure 9, must be installed
before working underneath this unit. Do not position
jackstands under wheels, axles, or wheel supports
because these components can rotate.
Do not work underneath unless it is properly attached
to tractor (see Operation section), the brakes set, key
removed, and the mower blocked securely. Tighten
tractor lower 3-point arm anti-sway mechanisms to prevent side to side movement.
When blocking, you must consider overall stability of
the unit. Just placing jackstands under the unit will not
ensure your safety. The working surface must be level
and solid to support the weight on the jackstands.
Ensure jackstands are stable both top and bottom, and
mower is approximately level. With full mower weight
lowered on jackstands, test blocking stability before
working underneath mower.
Keep all persons away from operator control
area while performing adjustments, service, or
maintenance.
Before working underneath, carefully read Operator’s Manual instructions, disconnect driveline,
raise mower, securely block up all corners with
jackstands, and check stability. Secure blocking
prevents equipment from dropping due to hydraulic leak down, hydraulic system failures, or
mechanical component failures.
Make sure spring-activated locking pin or collar
slides freely and is seated firmly in tractor PTO
spline groove.
5WPMAN0242 (Rev. 7/21/2008)
Figure 9. Blocking Method
Owner Service 13
Ref
No.
Description Frequency
1 Front U-Joint 8 Hours
2 Slip Joint (1 location on shaft, access through slot) 8 Hours
3 Rear U-Joint 8 Hours
4 Right Spindle (Access through slot) 24 Hours
5 Center Spindle (Access through slot) 24 Hours
6 Left Spindle (Access through slot) 24 Hours
7 Gearbox (Fill to center of horizontal shaft with SAE 80W
or 90W gear lube)
Check Daily
8 Caster Wheel (Right and Left) 8 Hours
9 Caster Pivot (Right and Left) 8 Hours
10 Front Caster Wheel Pivot (Right and Left) 8 Hours
11 Front Caster Wheel (Right and Left) 8 Hours
Figure 10. Lubrication Points & Chart
LUBRICATION INFORMATION
Do not let excess grease collect on or around parts,
particularly when operating in sandy areas.
Figure 10Figure 10 shows the lubrication points. The
accompanying chart gives the frequency of lubrication
in operating hours, based on normal operating conditions. Severe or unusual conditions may require more
14 Owner Service
frequent lubrication. Some reference numbers have
more than one location; be sure you lubricate all locations.
Use a lithium grease of #2 consistency with a MOLY
(molybdenum disulfide) additive for all locations. Be
sure to clean fittings thoroughly before attaching
grease gun. When applied according to the lubrication
chart, one good pump of most guns is sufficient.
5WPMAN0242 (Rev. 7/21/2008)
Use SAE 80W or 90W gear lube in the gearbox. Fill to
plug on side of gearbox.
Check gearbox daily for evidence of leakage at both
seals and the gasket between the housing and cover. If
leakage is noted, repair immediately. There may be a
small amount of lube emitted from the vent plug; this is
not considered leakage.
Overfilling the gearbox will cause the excess gear lube
to blow out vent plug and ruin the belt.
Driveshaft Lubrication
Lubricate the driveshaft slip joint every 8 operating
hours. Failure to maintain proper lubrication could
result in damage to U-joints, gearbox, and driveshaft.
Avoid excessive force during installation. Do not use
tools to pry belt into pulley groove. Do not roll belt over
pulleys to install. This can cause hidden damage and
premature belt failure.
Belt Installation
Refer to Figure 11.
NOTICE
■ Use care when installing or removing belt from
spring-loaded idler at step 5. Springs store energy
when extended and, if released suddenly, can
cause personal injury.
1. Lower mower to ground.
2. Apply grease at the three locations as shown in
Figure 10.
3. Raise and lower mower several times to distribute
grease.
BELT
Belt Replacement
One of the major causes of belt failure is improper
installation. Before installing a new belt, check the following:
1. Check pulley shafts and bearings for wear.
2. Check pulley grooves for cleanliness.
3. Make sure spindles turn freely and without wobble.
If grooves require cleaning, moisten a cloth with a nonflammable, non-toxic degreasing agent or commercial
detergent and water.
1. Disconnect idler spring from deck lug.
2. Slide belt under drive pulley A and over idler arm.
Position belt around drive pulley A.
3. Loosen bolt holding belt guide G and swing it away
from pulley B. Route belt around pulley B, idler C
and pulley D as shown.
4. Make sure belt is on drive pulley A, route around
idler F, and connect idler spring to lug on deck.
5. Grasp belt between spindle pulley E, spring loaded
idler F and spindle pulley D. Pull spring loaded idler
with belt to obtain enough belt length to route it
over pulley E. Make sure spring-loaded idler pivots
freely with belt installed.
6. Adjust belt guide G to provide 1/16" to 1/8" clearance from belt. Tighten bolt to 85 lbs-ft.
5WPMAN0242 (Rev. 7/21/2008)
Figure 11. Belt Routing
Owner Service 15
BLADE
WARNING
CAUTION
1. Wrench, Blade spindle
2. Pulley
3. Washer, Shoulder .63 x 3.00 x .44
4. Blade
5. Washer, Flat 5/8 standard
6. Washer, Cup .63 x 1.75 x 14 Ga
7. Screw, HHCS Nylok 5/8 NC x 2 GR5
lead in clockwise rotation, as viewed from top of
mower.
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,
operate valve levers to release any hydraulic pressure, set parking brake, stop engine, remove key,
and unfasten seat belt.
Keep all persons away from operator control
area while performing adjustments, service, or
maintenance.
Inspect blades for condition and proper installation
each time before operation. Replace any blade that is
bent, excessively nicked, worn or has any other damage. Small nicks can be ground out when sharpening.
Blade Removal
NOTE:
washers to burn and lose their clamping force.
Inspect cup washers to determine if they are burned
or have lost their clamping force. Replace as necessary.
Excessive blade slipping can cause cup
Your dealer can supply genuine replacement
blades. Substitute blades may not meet original
equipment specifications and may be dangerous.
1. Remove belt shields.
2. Install blade spindle wrench (1) onto spindle pulley
as shown.
3. Remove cap screw (7) which has RIGHT HAND
THREADS, cup washers (6), washer (5), and blade
(4).
4. Shoulder washer (3) will not normally come off
unless intentionally removed.
Blade Installation
NOTICE
■ We recommend you install a new Nylok blade
bolt when you replace the blade.
■ Do not substitute any bolt for the special blade
bolt. It is self-locking, meeting the non-loosening
requirements for this application.
1. Install spindle lock wrench (1) onto spindle pulley
as shown.
2. Install shoulder washer (3) (if removed), small end
up. Make sure blade cutting edge is positioned to
16 Owner Service
Figure 12. Blade Assembly
3. Install two cup washers (6), washer (5) and blade
(4) on cap screw.
4. Install cap screw and blade assembly into spindle.
Torque cap screw to 170 lbs-ft.
5. Remove blade wrench from pulley.
6. Replace belt shields.
5WPMAN0242 (Rev. 7/21/2008)
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