John Deere GM2109, GM2190 User Manual

OPE R AT O R’S MAN U A L

GROOMING MOWERS

GM2190 GM2109

Manual 5BP971379B

Date 10/10/2010

SAFETY

Take note! This safety alert symbol found throughout this manual is used to call your attention to instructions involving your personal safety and the safety of others. Failure to follow these instructions can result in injury or death.

This symbol means: ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Signal Words

Note the use of the signal words DANGER, WARNING and CAUTION with the safety messages. The appropriate signal words for each have been selected using the following guidelines:

DANGER: Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.

WARNING: Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury, and includes hazards that are exposed when guards are removed. It may also be used to alert against unsafe practices.

CAUTION: Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury.

INDEX

1 - GENERAL INFORMATION

2 - SAFETY PRECAUTIONS

3 - OPERATION

41.01 - General

41.02 - Warranty Information

51.03 - Model and Serial Number ID 6

62.01 - Preparation

72.02 - Starting and Stopping

72.03 - Messages and Signs

103.01 - Operational Safety

123.02 - Set Up

133.03 - Cutting Height Adjustment

143.04 - Pre-Operational Check

143.05 - Attaching to the Tractor

153.06 - Start Up

163.07 - Working Speed

173.08 - Operating Techniques

4 - MAINTENANCE

5 - REPAIR PROCEDURES

6 - TROUBLESHOOTING

183.09 - Uneven Terrain

183.10 - Removing Mower from the Tractor

183.11 - Quick Hitch Adapter Assembly and Operation 21

214.01 - Maintenance Safety

224.02 - Service

234.03 - Blade Maintenance

254.04 - Belt Tension

264.05 - Belt Replacement

274.06 - Driveline

284.07 - Transport

294.08 - Storage 31

315.01 - Gearbox

315.02 - Blade Spindle

335.03 - Suggested Spare Parts 34

7 - PRE-DELIVERY CHECKLIST

PARTS MANUAL

INDEX 3 FRONTIER

35 37

GROOMING MOWERS OPERATOR’S MANUAL

1 - GENERAL INFORMATION

Thank you and congratulations for having chosen our implement. Your new grooming mower is a technologically advanced machine constructed of high quality, sturdy components that will fulfill your working expectations. Read this manual carefully. It will instruct you on how to operate and service your mower safely and correctly. Failure to do so could result in personal injury and/or in equipment damage.

1.01 - General

The implement described in this manual is to be used with tractors with PTO at 540 rpm and clockwise rotation.

CAUTION: Always ensure that the coupling of the implement with the tractor is done at the same PTO speed and direction of rotation. Do not operate this implement at a PTO speed or direction of rotation other than that shown on the implement. Serious damage can occur to the machine and/or the operator.

CAUTION: Unless otherwise specified, all hardware is metric. Use only metric tools on metric hardware. Other tools that do not fit properly can slip and cause injury.

CAUTION: Right hand and left hand sides of the implement are determined by facing in the direction the implement will travel when going forward (see fig. 2).

1.02 - Warranty Information

Warranty coverage is provided by John Deere according to the terms of the Agricultural/Commercial & Consumer Equipment Warranty Statement. Carefully read the warranty statement on the back of your original purchase order for details on coverage and limitations of this warranty. Your Authorized Company Dealer has genuine parts in stock. Only these approved replacement parts should be used.

GENERAL INFORMATION 4 FRONTIER

GROOMING MOWERS OPERATOR’S MANUAL

1.03 - Model and Serial Number ID

Attached to the frame is an ID plate showing the model and the serial number. Record your implement model and serial number in the space provided below. Your dealer needs this information to give you prompt, efficient service when you order parts.

GENERAL INFORMATION 5 FRONTIER

ROOMING MOWERS OPERATOR’S MANUAL

2 - SAFETY PRECAUTIONS

Safety is the primary concern in the design and manufacture of our products. Unfortunately our efforts to provide safe equipment can be wiped out by a single careless act of an operator. In addition to the design and configuration of equipment, hazard control and accident prevention are dependent upon the awareness, concern, prudence and proper training of personnel involved in the operation, transport, maintenance and storage of equipment. It is the operator’s responsibility to read and understand all safety and operating instructions in the manual and to follow these. Allow only properly trained personnel to operate the mower. Working with unfamiliar equipment can lead to careless injuries. Read this manual, and the manual for your tractor, before assembly or operation, to acquaint yourself with the machines. It is the mower owner’s responsibility, if this machine is used by any person other than yourself, is loaned or rented, to make certain that the operator, prior to operating, reads and understands the operator’s manuals and is instructed in safe and proper use.

2.01 - Preparation

1. Before operating equipment read and understand the operator’s manual and the safety signs (see fig. 2).

2. Thoroughly inspect the implement before initial operation to assure that all packaging materials, i.e. wires, bands, and tape have been removed.

3. Personal protection equipment including hard hat, safety glasses, safety shoes, and gloves are recommended during assembly, installation, operation, adjustment, maintaining and/or repairing the implement.

4. Operate the mower only with a tractor equipped with an approved Roll-Over-Protective-System (ROPS). Always wear your seat belt. Serious injury or even death could result from falling off the tractor.

5. Clear area to be cut of stones, branches or other debris that might be thrown, causing injury or damage.

6. Operate only in daylight or good artificial light.

7. Ensure mower is properly mounted, adjusted and in good operating condition.

8. Ensure that all safety shielding and safety signs are properly installed and in good condition.

SAFETY PRECAUTIONS 6 FRONTIER

ROOMING MOWERS OPERATOR’S MANUAL

2.02 - Starting and Stopping

1. Be sure that no one is near the machine prior to engaging or while the machine is working.

2. Be sure the tractor is in “Neutral” before starting engine.

3. Mower operating power is supplied from tractor PTO. Refer to your tractor manual for PTO engagement and disengagement instructions. Always operate PTO at 540 rpm. Know how to stop the tractor and mower quickly in case of an emergency.

4. When engaging PTO, the engine rpm should always be low. Once engaged and ready to start cutting, raise PTO speed to 540 rpm and maintain throughout cutting operation.

5. Check the tractor master shield over the PTO stub shaft. Make sure it is in good condition and fastened securely to the tractor. Purchase a new shield if old shield is damaged or missing.

6. After striking an obstacle, disengage the PTO, shut the tractor down and thoroughly inspect for damage before restarting.

7. Never engage the PTO until the mower is in the down position and resting on the ground. Never raise the mower until all blades have come to a complete stop.

8. To park the vehicle safely, stop vehicle on a level surface (not on a slope), disengage PTO, engage the parking brake, stop the engine, remove the key, and wait for engine and all moving parts to stop before leaving the operator’s seat.

9. Stay clear of rotating drivelines. Entanglement in rotating driveline can cause serious injury or death. Wear close fitting clothing. Stop the engine and be sure PTO driveline is stopped before getting near it.

2.03 - Messages and Signs

1. Read and adhere to all safety and operating decals on this machine (see fig. 2).

2. Before dismounting tractor: Allow moving parts to stop, stop engine, set brake and remove the key of unattended equipment.

3. Keep away from rotating blades and driveline.

4. Keep guards and shields in place and in good condition.

5. Do not mow with bystanders in area.

6. Allow no riders on tractor or mower.

7. Allow moving parts to stop before repair.

8. Securely support mower before working underneath.

Additional warning and operating decals are available at no extra charge. Please specify model and serial number when ordering.

SAFETY PRECAUTIONS 7 FRONTIER

ROOMING MOWERS OPERATOR’S MANUAL

Fig. 2 - Safety decals - implement; replace immediately if damaged.

right side left side

Red reflective decal Yellow reflective decal

SAFETY PRECAUTIONS 8 FRONTIER

ROOMING MOWERS OPERATOR’S MANUAL

Safety decals - driveline; replace immediately if damaged.

placed on outer tube

placed on outer shield

SAFETY PRECAUTIONS 9 FRONTIER

ROOMING MOWERS OPERATOR’S MANUAL

3 - OPERATION

You have purchased a three spindle mower designed especially for the mowing of grassy areas where a highly professional cut is required without wasting time. This mower is perfect for the maintenance of parks, private lawns, industrial parks, airports, hospital grounds, schools, highways, golf courses, sport complexes, etc. The GM21 series, for tractors up to 70 HP, come in working widths of 90” and 110”. The mower can be either tractor front or rear mounted. On your mower, the tractor PTO transmits its power through a driveline to a speed multiplier gearbox. A pulley is attached to the pinion gear shaft of the gearbox which, via high resistance belts, transmits power to pulleys coupled to the three individual spindle shafts. Blades are secured to these shafts which turn at a high blade tip speed to cut the grass. Our grooming mower comes equipped with 4 swivel wheels. Aside from regulating the cutting height, the wheels are set in such a way as to allow the mower to follow the contour of the terrain and give a precise, level cut even in undulating conditions.

3.01 - Operational Safety

CAUTION: Our mowers are designed considering safety as the most important aspect and are the safest available in today’s market. Unfortunately, human carelessness can override the safety features built into our machines. Injury prevention and work safety, aside from the features on our mowers, are very much due to the responsible use of the equipment. It must always be operated prudently following with great care, the safety instructions laid out in this manual.

1. The use of this equipment is subject to certain hazards which cannot be prevented by mechanical means or product design. All operators of this equipment must read and understand this entire manual, paying particular attention to safety and operating instructions, prior to using.

2. Do not operate the tractor and mower when you are tired, sick or when using medication.

3. Keep all helpers and bystanders at least several feet from a rotary mower. Only properly trained people should operate this machine.

4. When this machine is operated in populated areas where thrown objects could injure persons or property, standard equipment safety chain shielding (which is designed to reduce the possibility of thrown objects) must be installed.

5. The majority of accidents involve entanglements on the driveline, injury of bystanders by objects thrown by the rotating blades, and operators being knocked off the tractor by low hanging limbs and then being run over by the mower. Accidents

OPERATION 10 FRONTIER

ROOMING MOWERS OPERATOR’S MANUAL

are most likely to occur with machines that are loaned or rented to someone who has not read the operator’s manual and is not familiar with a rotary mower.

6. Always stop the tractor, set brake, shut off the tractor engine, remove the ignition key, lower implement to the ground and allow mower blades to come to a complete stop before dismounting tractor. Never leave equipment unattended with the tractor running.

7. Never place hands or feet under mower with tractor engine running or before you are sure all motion has stopped. Stay clear of all moving parts.

8. Do not allow riders on the mower or tractor at any time. There is no safe place for riders.

9. Do not operate unless all personnel, livestock and pets are several feet away to prevent injury by thrown objects.

10.Before backing up, disengage the mower and look behind carefully.

11.Install and secure all guards and shields before starting or operating.

12.Keep hands, feet, hair and clothing away from moving parts.

13.This rotary mower is designed for use only on tractors with 540 rpm power take off.

14.Never operate tractor and mower under trees with low hanging limbs. Operators can be knocked off the tractor and then run over by the rotating blades.

15. The rotating parts of this machine have been designed and tested for rugged use. However, they could fail upon impact with heavy, solid objects such as steel guard rails and concrete abutments. Such impact could cause the broken objects to be thrown outward at very high velocities. To reduce the possibility of property damage, serious injury, or even death, never allow the cutting blades to contact such obstacles.

16.Frequently check mower blades. They should be sharp, free of nicks and cracks and securely fastened.

17. Stop mower immediately upon striking an obstruction. Turn engine off, remove key, inspect and repair any damage before resuming operation.

18. Stay alert for holes, rocks and roots in the terrain and other hidden hazards. Keep away from drop-offs.

19.Use extreme care and maintain minimum ground speed when transporting on hillside, over rough ground and when operating close to ditches or fences. Be careful when turning sharp corners.

20. Reduce speed on slopes and sharp turns to minimize tipping or loss of control. Be careful when changing directions on slopes. Do not start or stop suddenly on slopes. Avoid operation on steep slopes.

21. When using a unit, a minimum 20% of tractor and equipment weight must be on tractor front wheels. Without this weight, tractor could tip over, causing personal injury or death. The weight may be attained with a front end loader, front wheel weights, ballast in tires or front tractor weights. When attaining a minimum 20% of tractor and equipment weight on the front wheels, you must not exceed the ROPS weight certification. Weigh the tractor and equipment. Do not guess or estimate!

22. Inspect the entire machine periodically

. Look for loose fasteners, worn or broken

parts, and leaky or loose fittings.

OPERATION 11 FRONTIER

See Chapter 4 - Maintenance.

ROOMING MOWERS OPERATOR’S MANUAL

23. Use only the driveline supplied with the mower. Do not use it if it is missing any shield or safety protection.

24. Pass diagonally through sharp dips and avoid sharp drops to prevent “hanging up” tractor and mower.

25.Avoid sudden starts and stops while traveling up or downhill.

26. Always cut down slopes; never across the face. Avoid operation on steep slopes. Slow down on sharp turns and slopes to prevent tipping and/or loss of control.

3.02 - Set Up

Notice to dealer: Pre-delivery setup and service including lubrication is the responsibility of the authorized dealer. It is up to him to assure that the machine is in perfect condition and ready to be used. It is his responsibility to ensure that the customer is aware of all safety aspects and operational procedures for the mower. He must also fill out the Pre-Delivery Checklist

prior to delivering the mower.

Fig. Front mounted mower.

Fig. 4 Rear mounted mower.

OPERATION 12 FRONTIER

See Chapter 7 - Pre-Delivery Checklist.

ROOMING MOWERS OPERATOR’S MANUAL

CAUTION: Stand clear of bands when cutting as they could be under sufficient tension to cause them to fly loose. Take care in removing bands and wire, they often have extremely sharp edges and cut very easily.

As mentioned above, all our grooming mowers may be either tractor front or rear mounted. Changing our mowers from front mount to rear, or vice versa, can be easily done at our authorized dealerships. This is accomplished by simply turning the three point hitch and the gearbox 180 degrees (see fig. 3 & 4).

3.03 - Cutting Height Adjustment

WARNING: Keep hands and feet away from moving blades. Be sure tractor engine is off, parking brake is locked, and key is removed before making any adjustments. Never rely on the tractor lift system. Install blocks or stands under the mower deck to prevent it from falling.

Fig. 5 The cutting height is adjusted by moving the height adjustment spacers on the wheel yokes above or below the wheel arm.

The cutting height is the distance from the blades to the ground. The cutting height is adjusted by moving the spacers on the wheel yokes. Placing spacers between the wheel arm and the wheel yoke raises the cutting height by the size of the spacer. Removing the spacers lowers it by the same height (see fig. 5). Be sure all wheel arms are adjusted equally. This is the only way to ensure a completely uniform cut.

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IMPORTANT: Very low cutting heights should be avoided. Damaging shock loads occur when the blades strike the ground repeatedly. This can cause damage to the mower.

Cutting lower than 2” under most circumstances should be avoided.

The cutting height is adjustable from 1.3” to 5.3”.

The mower comes equipped with a front anti-scalping roller. The roller is particularly helpful when cutting over uneven terrain.

3.04 - Pre-Operational Check

IMPORTANT: Check each of the following, carefully, prior to engaging the equipment:

1. The spindle bearings have been greased.

2. The belts for proper tension.

3. The oil in the gearbox.

4. The driveline cross and bearings have been greased.

5. No wrappings or foreign objects are around the blades, belts or driveline.

6. The blades are properly installed and the blade bolts properly torqued3.

7. All hardware is tight.

8. The tractor, to ensure correct direction of PTO and rpm speed.

9. All safety shields and guards are in place and tightly attached.

10.No people or animals are in the work area.

11. When working, make sure the tractor hitch is in the “float” position, in order to allow the mower to follow the contour of the ground.

DANGER: Stay clear of rotating driveline. Entanglement in rotating driveline can cause serious injury. Disengage PTO, engage parking brake or place transmission in “Park”, shut off the tractor and remove the key before working around hitch, attaching or detaching driveline, making adjustments, servicing or cleaning the machine.

3.05 - Attaching to the Tractor

Unit may be used on tractors ranging from 30 to 70 HP equipped with a standard PTO and category 1 three point hitch4. Never use this mower with tractors over 70 HP.

CAUTION: Check the tractor PTO rpm to ensure it is set at 540 and turns clockwise.

3 4

See Table 1, page 30. See Table 2, page 30.

OPERATION 14 FRONTIER

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CAUTION: Always ensure that the tractor tire pressure is correct according to the tractor operator’s manual.

DANGER: Failure to ensure a secure coupling of the implement to the tractor can cause injury and damage to the implement or tractor.

To attach the mower to the tractor do the following:

1. Back the tractor up to the mower in order to slip the tractor hitch arms over the hitch pins welded to the mower hitch arms. Turn off the tractor engine. Secure them in place with the lynch pins.

2. Adjust the tractor sway blocks or chains to remove all side movement.

3. Attach the top link. Adjust tractor top link to allow the mower to follow the ground contour and yet remain as level as possible when raised to transport position.

4. Install the shielded driveline to the tractor by first lining up the splines and depressing the snap pin. Push the yoke onto the PTO shaft as far as it will go. Release the pin and pull back slowly until the pin clicks in place. Repeat this operation on the implement end.

5. Ensure that the driveline has at least 2” from bottoming out in its shortest working position and has the minimum 6” overlap in its longest working position. Refer to

Section 4.065 of this manual, if it is determined that the driveline is too long and

needs to be shortened. Contact your local dealer if it is determined that the driveline is too short for your tractor.

6. Attach the driveline chains to the tractor and to the mower to keep the driveline protection from turning. The chains should not be too tight.

3.06 - Start Up

DANGER: The mower must always be lowered to the ground before starting tractor engine or engaging PTO lever.

Lower mower to the ground with the tractor rock shaft control lever. With the engine idling, slowly engage the PTO drive. Move the throttle lever until the PTO speed indicated on the mower is obtained. The mower is set for a PTO speed of 540 rpm. Shift the transmission to a slow speed gear and start forward, increase the ground speed by shifting upward until the desired speed is obtained. Do not mow in reverse unless absolutely necessary and only after careful observation of the area behind the mower.

procedures for shortening the driveline.

OPERATION 15 FRONTIER

See Section 4.06 - Driveline, for instructions on how to determine correct driveline length and

ROOMING MOWERS OPERATOR’S MANUAL

CAUTION: Do not operate this mower at a PTO speed or direction of rotation other than that shown on the mower. Serious damage can occur to the machine and/or the operator.

Before starting to mow, never forget that the operator is responsible for the following:

1. Safe and correct driving of the tractor and mower.

2. To learn precise safe operating procedures for both the tractor and the mower.

3. To ensure all maintenance and lubrication has been performed on the mower.

4. To have read and understood all safety aspects for the mower in the operator’s manual.

5. To have read and understood all safety decals on the mower.

6. Checking the condition of the blades. Worn or damaged blades should be changed before starting6.

7. Checking to ensure that the cutting edge is the leading edge of the blade7.

8. Checking that there is no wire, weed, grass or other material wrapped around blades.

9. Checking to see if front weights need to be added to the tractor in order to maintain balance.

10.Checking the tractor tires for the proper pressure in accordance with the tractor operator’s manual.

11. Checking that the PTO shield, belt shields and all other shielding are on the machine and securely in place.

12.Making sure the proper attire is worn. Avoiding loose fitting clothing which can become entangled. Wearing sturdy, tough-soled work shoes and protective equipment for eyes, hands, ears and head. Never operate tractor or implements in bare feet, sandals or sneakers.

13.Checking area for stones, branches and other debris that might be thrown.

14.Ensuring proper lighting is available, sunlight or good artificial lighting.

3.07 - Working Speed

The mowing speed depends on ground conditions, tractor HP, mowing height, and grass thickness. Only a test run will enable you to gauge the optimal working speed for your conditions. Under most conditions a 3 to 8 mph ground speed is best. As a rule of thumb, and if the conditions permit, grass dispersion is increased by higher ground speeds. In order to obtain the best cut possible, always keep the tractor rpm up to the speed indicated on the mower. When increasing or decreasing mowing ground speed, always use gear selection, not engine speed. This will maintain the constant maximum blade speed necessary for a clean cut.

6 7

OPERATION 16 FRONTIER

See Section 4.03 - Blade Maintenance. See Section 4.03 - Blade Maintenance.

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