John Deere Lawn Mower GM3054 User Manual

O P E R A T O R ’ S M A N U A L

GROOMING MOWERS

GM3054

GM3060

GM3072

5WPMAN0705 (Rev. 10/18/2012)

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TABLE OF CONTENTS

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

OWNER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

DEALER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

DEALER CHECK LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

PARTS LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

BOLT TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

BOLT SIZE CHART & ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 43

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

LEA EL INSTRUCTIVO!

Si no lee Ingles, pida ayuda a

alguien que si lo lea para que le

traduzca las medidas de seguridad.

5WPMAN0705 (Rev. 2/16/2009)

Introduction 3

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SPECIFICATIONS

MODEL

GM3054

GM3060

GM3072

3-Point Hitch

Limited Cat. 1

54"

Cat. 1

60"

Cat. 1

72"

Cutting Width

Cutting Height Range

1" - 4-1/2"

Operating Weight with

Chain Shielding

417 lbs.

521 lbs.

624 lbs.

Blade Speed (feet per minute)

Blade Spindles

16,200

18,000

18,100

Number of Blades

Universal Drive Series

Implement Code for Tractor Ballast

Caster Wheels

ASAE Cat. 3

25.4

ASAE Cat. 3

31.7

ASAE Cat. 3

38.0

3.5 x 4 x 10

540

3.5 x 4 x 10

540

3.5 x 4 x 10

540

Tractor PTO Speed RPM

Recommended Maximum

Tractor Horsepower

15-25

25-35

8 GA

25-35

8 GA

Mower Frame Thickness

10 GA

GENERAL INFORMATION

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.

„ 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 illustrations and data used in this manual were cur-

rent 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.

The purpose of this manual is to assist you in operating

and maintaining your mower. Read it carefully. It fur-

nishes information and instructions that will help you

achieve years of dependable performance. These

instructions have been compiled from extensive field

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

5WPMAN0705 (Rev. 2/16/2009)

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SAFETY RULES

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

„ Connect PTO driveline directly to power unit

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.

PTO shaft. Never use adapter sleeves or adapter

shafts. Adapters can cause driveline failures due to

incorrect spline or incorrect operating length and

can result in personal injury or death.

In addition to the design and configuration of

equipment, hazard control and accident preven-

tion are dependent upon the awareness, concern,

judgement, and proper training of personnel

involved in the operation, transport, maintenance

and storage of equipment.

„ Make sure driveline shield tether chains are

attached to the tractor and equipment 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 drive-

lines, repair and replace bearings before putting

equipment into service.

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. (Replace-

ment manuals and safety decals are available from

your dealer.) Failure to follow instructions or safety

rules can result in serious injury or death.

„ 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 systems in “locked up” position at all times.

„ Remove accumulated debris from this equip-

ment, power unit, and engine to avoid fire hazard.

„ Know your controls and how to stop engine and

attachment quickly in an emergency.

„ Make sure all safety decals are installed.

Replace if damaged. (See Safety Decals section for

location.)

„ If you do not understand any part of this manual

and need assistance, see your dealer.

„ Operators must be instructed in and be capable

of the safe operation of the equipment, its attach-

ments, and all controls. Do not allow anyone to

operate this equipment without proper instruc-

tions.

„ Make sure shields and guards are properly

installed and in good condition. Replace if dam-

aged.

„ 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

front wheel weights, ballast in tires or front tractor

weights. Weigh the tractor and equipment. Do not

estimate.

„ 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 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.

OPERATION

„ Inspect and clear area of stones, branches, or

other hard objects that might be thrown, causing

injury or damage.

„ Make sure attachment is properly secured,

adjusted, and in good operating condition.

„ Never direct discharge toward people, animals,

or property.

„ Make sure spring-activated locking pin or collar

slides freely and is seated firmly in tractor PTO

spline groove.

„ Keep bystanders away from equipment.

(Safety Rules continued on next page)

GM3054/GM3060/GM3072 (Rev. 6/1/2008)

Safety 5

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SAFETY RULES

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

„ 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

front wheel weights, ballast in tires or front tractor

weights. Weigh the tractor and equipment. Do not

estimate.

(Safety Rules continued from previous page)

„ Full chain shielding must be installed when

operating in populated areas or other areas where

thrown objects could injure people or damage

property.

• If this machine is not equipped with full chain

shielding, operation must be stopped when any-

one comes within 300 feet (92 m).

• This shielding is designed to reduce the risk

of thrown objects. The mower deck and protec-

tive devices cannot prevent all objects from

escaping the blade enclosure in every mowing

condition. It is possible for objects to ricochet

and escape, traveling as much as 300 feet (92 m).

„ Do not operate or transport on steep slopes.

„ Do not operate or transport equipment while

under the influence of alcohol or drugs.

„ Always comply with all state and local lighting

and marking requirements.

„ Do not operate or transport equipment while

under the influence of alcohol or drugs.

„ Operate only in daylight or good artificial light.

„ Never allow riders on power unit or attachment.

„ Keep hands, feet, hair, and clothing away from

equipment while engine is running. Stay clear of all

moving parts.

MAINTENANCE

„ Always comply with all state and local lighting

and marking requirements.

„ Before working underneath, carefully read Oper-

ator’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 hydrau-

lic leak down, hydraulic system failures, or

mechanical component failures.

„ Never allow riders on power unit or attachment.

„ 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.

„ Do not modify or alter or permit anyone else to

modify or alter the equipment or any of its compo-

nents in any way.

„ 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.

„ 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.

„ 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.

„ Make sure attachment is properly secured,

adjusted, and in good operating condition.

„ Stop power unit and implement immediately

upon striking an obstruction. Dismount power unit,

using proper procedure. Inspect and repair any

damage before resuming operation.

„ Keep all persons away from operator control

area while performing adjustments, service, or

maintenance.

TRANSPORTATION

„

Make certain all movement of equipment com-

„ Use additional caution and reduce speed when

under adverse surface conditions, turning, or on

inclines.

ponents has stopped before approaching for ser-

vice.

(Safety Rules continued on next page)

„ Do not operate PTO during transport.

GM3054/GM3060/GM3072 (Rev. 6/1/2008)

6 Safety

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SAFETY RULES

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

installed securely to ensure equipment is in a safe

condition before putting unit into service.

(Safety Rules continued from previous page)

„ 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 unexpect-

edly and cause severe injury or death. Follow Oper-

ator's Manual instructions for working underneath

and blocking requirements or have work done by a

qualified dealer.

„ 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 dam-

aged.

„ Wear gloves when installing belt. Be careful to

prevent fingers from being caught between belt

and pulley.

„ Use care when installing or removing belt from

spring-loaded idler. Springs store energy when

extended and, if released suddenly, can cause per-

sonal injury.

„ Frequently check blades. They should be sharp,

free of nicks and cracks, and securely fastened.

„ Do not handle blades with bare hands. Careless

or improper handling may result in serious injury.

STORAGE

„ Your dealer can supply genuine replacement

blades. Substitute blades may not meet original

equipment specifications and may be dangerous.

„ Follow manual instructions for storage.

„ Keep children and bystanders away from stor-

age area.

„ Tighten all bolts, nuts, and screws to torque

chart specifications. Check that all cotter pins are

™

GM3054/GM3060/GM3072 (Rev. 6/1/2008)

Safety 7

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SAFETY & INSTRUCTIONAL DECALS

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Replace Immediately If Damaged!

2 - 5WP18867

DANGER

SHIELD MISSING

DO NOT OPERATE

PUT SHIELD ON

18867--B

PRODUCT IDENTIFICATION NUMBER

11 - 5WP20106 - Rear Reflector (GM3060 & GM3072 Only)

LENEXA, KS, U.S.A.

3 - Serial Number Plate

4 - 5WP1003751

1 - 5WP15503

DANGER

WARNING

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.

ROTATING BLADES AND

THROWN OBJECTS

ꢀ Operate tractor controls from tractor seat only.

ꢀ Do not put hands or feet under or into mower when

ꢀ Do not stand between tractor and implement

engine is running.

when tractor is in gear.

ꢀ Before mowing, clear area of objects that may be

ꢀ Make sure parking brake is engaged before

thrown by blade.

going between tractor and implement.

ꢀ Stand clear of machine while in operation or

ꢀ Keep bystanders away.

ꢀ Keep guards in place and in good condition.

when it is being raised or lowered.

FAILURE TO FOLLOW THESE

INSTRUCTIONS COULD RESULT IN

BLADE CONTACT OR THROWN OBJECTS CAN

CAUSE SERIOUS INJURY OR DEATH.

15503-C

SERIOUS INJURY OR DEATH.

1003751-A

(Safety Decals continued on next page)

8 Safety

5WPMAN0705 (Rev. 5/9/2008)

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SAFETY & INSTRUCTIONAL DECALS

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Replace Immediately If Damaged!

(Safety Decals continued from previous page)

WARNING

TO AVOID SERIOUS INJURY OR DEATH:

WARNING

5 - 5WP18866

ꢀ Read Operator's Manual before operating,

servicing or repairing equipment. Follow all

safety rules and instructions. (Manuals are

available from your selling dealer.)

540 RPM

ꢀ Never allow riders.

ꢀ Keep bystanders away from equipment during

operation.

ꢀ Operate from tractor seat only.

18866-D

ꢀ Keep all shields in place and in good condition.

ꢀ Lower equipment to ground, stop engine,

remove key and set brake before dismounting

tractor.

ꢀ Never allow children or untrained persons to

operate equipment.

6 - 5WP18864

DANGER

ꢀ Do not transport towed or semi-mounted units

over 20 MPH.

FAILURE TO FOLLOW THESE INSTRUCTIONS

1002423-B

CAN RESULT IN INJURY OR DEATH.

ROTATING DRIVELINE

CONTACT CAN CAUSE DEATH

7 - 5WP1002423

8 - 5WP18865

KEEP AWAY!

DO NOT OPERATE WITHOUT -

ꢀ All driveline guards, tractor and

equipment shields in place

WARNING

ꢀ Drivelines securely attached at both ends

ꢀ Driveline guards that turn freely on

driveline

18864-C

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.

10 - 5WP33347

„

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.

9 - 5WP1004114

DANGER

„

Securely blocking prevents equipment dropping from hydraulic leak-

down, hydraulic system failures or mechanical component failures.

If shaft connection is visible, shield

is missing. Replace shield before

FALLING OFF OR FAILING TO BLOCK SECURELY CAN

operating equipment.

RESULT IN SERIOUS INJURY OR DEATH.

18865--C

1004114

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.

33347E

Replacement safety decals can be ordered free from your dealer.

5WPMAN0705 (Rev. 5/9/2008)

Safety 9

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OPERATION

The operator is responsible for the safe operation of

the mower. The operator must be properly trained.

Operators should be familiar with the mower, the trac-

tor, and all safety practices before starting operation.

Read the safety rules and safety decals on page 5

through page 9.

CAUTION

„ Stop power unit and implement immediately

upon striking an obstruction. Dismount power unit,

using proper procedure. Inspect and repair any

damage before resuming operation.

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.

„ 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.

Recommended mowing speed for most conditions is

from 2 to 5 mph.

TRACTOR STABILITY

„ Full chain shielding must be installed when

operating in populated areas or other areas where

thrown objects could injure people or damage

property.

„ A minimum 25% 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. Weigh the tractor and equipment. Do not

estimate.

• If this machine is not equipped with full chain

shielding, operation must be stopped when any-

one comes within 300 feet (92 m).

• This shielding is designed to reduce the risk

of thrown objects. The mower deck and protec-

tive devices cannot prevent all objects from

escaping the blade enclosure in every mowing

condition. It is possible for objects to ricochet

and escape, traveling as much as 300 feet (92 m).

„ Never allow children or untrained persons to

operate equipment.

Figure 1. Tractor Stability

„ Keep bystanders away from equipment.

ATTACHING MOWER TO TRACTOR

„ 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.

„ Make sure spring-activated locking pin or collar

slides freely and is seated firmly in tractor PTO

spline groove.

„ Before working underneath, carefully read Oper-

ator’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 hydrau-

lic leak down, hydraulic system failures, or

mechanical component failures.

The standard 1-3/8" 6B-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.

„ Keep all persons away from operator control

area while performing adjustments, service, or

maintenance.

3. Attach tether chain to tractor drawbar (Figure 3).

10 Operation

5WPMAN0705 (Rev. 5/9/2008)

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4. Adjust the tractor lower 3-point arm anti-sway

devices to prevent mower from swinging side to

side during transport.

4. To raise rear of mower, move caster adjustment

spacers under rear caster arms.

5. To raise front of mower, move spacers under front

caster wheel arms.

Table 1: Cutting Height Chart

Spacers Required Under

Caster Arm Pivot Tube

Cut Height

1/2" Spacer

1" Spacer

1. Tractor Top Link

A. Mower Top Link

Attachment Point

1-1/2"

B. Mower Hitch Pin

2-1/2"

Figure 2. Attachment Points

3-1/2"

4-1/2"

TRACTOR TOP LINK ADJUSTMENT

Tether Chain

When the cutting height is set, adjust tractor top link

until mower top link attachment point (A), Figure 4, is

aligned vertically with mower hitch pin (B). The front

tires of the mower will lift off the ground before the rear

tires when the unit is raised. This will allow the mower

to follow the ground contour.

CM906

Figure 3. Attaching Mower to Tractor

A. Mower top link attachment point

B. Mower hitch pin

CUTTING HEIGHT ADJUSTMENT

C. Tractor top link

D. Mower hitch plate

attachment point

(GM3054 only)

„ 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

measuring distance from mower frame to the

ground at each deck rail.

Figure 4. Top Link Adjustment

GM3054 Only

2. Verify that the same amount of spacers are under

The GM3054 has two mower hitch plate attachment

points (D). It may be necessary to change the mower

hitch plate attachment point to obtain proper tire clear-

ance and/or lift height.

all caster arms.

3. Control cutting height by adjusting front and rear

caster wheels.

(Rev. 6/1/2008)

Operation 11

5WPMAN0705 (Rev. 5/9/2008)

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using proper procedure. Inspect and repair any

damage before resuming operation.

FRONT CASTER WHEEL INTERFERENCE

CHECK

NOTICE

Power for operating the mower is supplied by the trac-

tor PTO. Operate PTO at 540 rpm. Know how to stop

tractor and mower quickly in an emergency.

■ 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.

If mower becomes plugged causing belt to slip for over

two seconds, follow these steps:

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.

1. Maneuver equipment into a previously cut area

and allow mower to clear accumulated material.

2. Continue running at least two minutes, allowing

pulleys to cool. Stopping the mower when in

contact with a very hot pulley will bake and ruin

belt.

1. Raise mower with tractor hydraulics to 16" at

dimension C, Figure 5, or maximum height of

tractor lift, whichever is less.

Proper ground speed will depend upon the terrain, the

height, and type and density of material to be cut.

2. Pivot both front caster wheels forward and check

that there is clearance between caster wheels and

tractor tires.

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. Always operate tractor PTO at 540 rpm to main-

tain proper blade speed and produce a clean cut.

3. If there is interference on GM3054 model, adjust

mower hitch plate point as shown in Figure 4. On

model GM3060 and GM3072, the hitch plate is not

adjustable; see tractor operator’s manual and

adjust tractor wheels accordingly.

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 par-

tially rebound.

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 recom-

mendations for the suitable cutting height in your area.

Operating Tips

Figure 5. Front Caster Wheel Interference Check

„ Inspect and clear area of stones, branches, or

other hard objects that might be thrown, causing

injury or damage.

FRONT ROLLER (OPTIONAL)

The caster wheels 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 the mower to contact ground and

scalp. An optional front roller may be installed to mini-

mize scalping. See page 40.

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. Remem-

ber, sharp blades produce cleaner cuts and require

less power.

OPERATING TECHNIQUE

Analyze area to be cut to determine the best proce-

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.

CAUTION

„ Stop power unit and implement immediately

upon striking an obstruction. Dismount power unit,

12 Operation

5WPMAN0705 (Rev. 5/9/2008)

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Uneven Terrain

OWNER PRE-OPERATION CHECK LIST

(OWNER'S RESPONSIBILITY)

___ Review and follow all safety rules and safety

decal instructions on page 5 through page 9.

„ Do not operate or transport on steep slopes.

„ Do not stop, start, or change directions sud-

denly on slopes.

___ Check that all safety decals are installed and in

good condition. Replace if damaged.

„ Use extreme care and reduce ground speed on

___ Check that all shields and guards are properly

installed and in good condition. Replace if dam-

aged.

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. Prac-

tice will improve your skills in maneuvering rough ter-

rain.

___ Check that chain shielding is in good condition

and replace any damaged chain links.

___ Check that all hardware and cotter pins are prop-

erly installed and secured.

REMOVING MOWER FROM TRACTOR -

STORAGE

___ Check to ensure blades are sharp, in good condi-

tion, and installed correctly. Replace if damaged.

Follow cleaning procedure, page 17.

___ Check that equipment is properly and securely

attached to tractor.

1. Disengage tractor PTO and raise mower with the

3-point hitch.

2. Disconnect mower driveshaft from tractor PTO.

___ Make sure driveline spring-activated locking pin

or collar slides freely and is seated firmly in trac-

tor PTO spline groove.

3. Collapse driveshaft as far as possible and store it

in PTO hanger bracket to prevent ground contact.

4. Place blocks under mower side skids. Lower

mower onto blocks, disconnect mower from tractor

3-point hitch, and carefully drive tractor away from

mower.

___ 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.

„ Keep children and bystanders away from stor-

age area.

___ Do not allow riders.

___ Check all lubrication points and grease as

instructed in Lubrication Information, page 14.

Make sure the PTO slip joint is lubricated and that

the gearbox fluid levels are correct.

___ Set tractor PTO at 540 rpm.

___ 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 transmis-

sion in neutral or park, engage brake, and

disengage tractor PTO.

Figure 6. Mower Storage Position

Operation 13

5WPMAN0705 (Rev. 5/9/2008)

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OWNER SERVICE

The information in this section is written for operators

When blocking, you must consider overall stability of

the unit. Just blocking under the unit will not ensure

your safety. The working surface must be level and

solid to support the loaded weight of the jackstands.

Test jackstand stability before working under any por-

tion of the mower.

who possess basic mechanical skills. If you need help,

your dealer has trained service technicians available.

For your protection, read and follow the safety informa-

tion in this manual.

„ Never allow children or untrained persons to

operate equipment.

„ Keep bystanders away from equipment.

„ Before working underneath, carefully read Oper-

ator’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 hydrau-

lic leak down, hydraulic system failures, or

mechanical component failures.

„ Keep all persons away from operator control

area while performing adjustments, service, or

maintenance.

Figure 7. Jackstand Placement

„ Make sure spring-activated locking pin or collar

slides freely and is seated firmly in tractor PTO

spline groove.

LUBRICATION INFORMATION

Do not let excess grease collect on or around parts,

particularly when operating in sandy areas.

„ Operate tractor PTO at 540 RPM. Do not exceed.

Figure 8 shows the lubrication points. The accompany-

ing chart gives the frequency of lubrication in operating

hours, based on normal operating conditions.

CAUTION

„ 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.

Severe or unusual conditions may require more fre-

quent 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.

BLOCKING METHOD

Do not work underneath mower unless it is properly

attached to the tractor and blocked securely. When

properly attached, the unit will be anchored to minimize

front to rear movement.

Use SAE 80W or 90W gear lube in the gearbox. Fill to

plug on side of gearbox.

Raise mower completely, set tractor brakes, turn

engine off, remove key, block tractor wheels front and

rear, and disconnect mower driveline from tractor.

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.

The only approved blocking devices for this mower are

jackstands with a load rating of 1000 pounds or more.

One jackstand under each corner of the mower (four

total) must be installed before working underneath this

unit.

Overfilling the gearbox will cause the excess gear lube

to blow out vent plug and ruin the belt.

(Rev. 6/1/2008)

5WPMAN0705 (Rev. 5/9/2008)

14 Owner Service

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2. Remove front half of driveshaft.

Driveshaft Lubrication

3. Apply grease all around and along inner shaft.

4. Reassemble driveshaft halves.

Lubricate the driveshaft slip joint every 40 operating

hours. Failure to maintain proper lubrication could

result in damage to U-joints, gearbox, and driveshaft.

5. Raise and lower mower several times to distribute

1. Lower mower to ground.

grease.

Ref

No.

Description

Frequency

8 Hours

40 Hours

8 Hours

Front U-Joint

Caster Wheel (Four wheels)

Caster Pivot (Four wheels)

Left Spindle (Access through hole)

Shield Bearings

Rear U-Joint

Gearbox (Fill to center of horizontal shaft with

SAE 80W or 90W gear lube)

Check Daily

for Leakage

Right Spindle (Access through hole)

Center Spindle (Access through hole)

Slip Joint

40 Hours

Figure 8. Lubrication Points & Chart

5WPMAN0705 (Rev. 5/9/2008)

Owner Service 15

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3. Make sure belt is on drive pulley A and route

BELT SERVICE

around idler F.

Belt Replacement

4. 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.

One of the major causes of belt failure is improper

installation. Before installing a new belt, check the fol-

lowing:

1. Check pulley shafts and bearings for wear.

2. Check pulley grooves for cleanliness.

BLADE SERVICE

3. Make sure spindles turn freely and without wobble.

If grooves require cleaning, moisten a cloth with a non-

flammable, non-toxic degreasing agent or commercial

detergent and water.

„ 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 pres-

sure, set parking brake, stop engine, remove key,

and unfasten seat belt.

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

„ Keep all persons away from operator control

area while performing adjustments, service, or

maintenance.

Refer to Figure 9.

CAUTION

■ Use care when installing or removing belt from

spring-loaded idler. Springs store energy when

extended and, if released suddenly, can cause per-

sonal injury.

„ Frequently check blades. They should be sharp,

free of nicks and cracks, and securely fastened.

1. Inspect blades before each use to determine that

they are mounted securely and are in good condi-

tion.

2. Replace any blade that is bent, excessively nicked,

worn, or has any other damage.

3. Small nicks can be ground out when sharpening.

Blade Removal

„ Do not handle blades with bare hands. Careless

or improper handling may result in serious injury.

1. Remove bolt (1), Figure 11, which has right hand

threads.

2. Remove washer and blade.

Figure 9. Belt Routing

Blade Sharpening

1. Slide belt under drive pulley A and over idler arm.

NOTICE

Position belt around drive pulley A.

■ When sharpening blades, be sure to balance

them. Unbalanced blades will cause excessive

vibration that can damage blade spindle bearings.

Vibration may also cause structural cracks in

mower housings.

2. It may be necessary to remove front bolts (1) and

swing gearbox stand up to gain access to pulley A.

Route belt around pulley B, idler C, and pulley D as

shown.

(Rev. 6/1/2008)

5WPMAN0705 (Rev. 5/9/2008)

16 Owner Service

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1. Place blade over blade pilot on the bottom of the

shaft assembly.

2. Place bell washer (2) over blade and insert blade

bolt (1). Torque blade bolt to 100 lbs-ft.

CHAIN SHIELDING

„ Full chain shielding must be installed when

operating in populated areas or other areas where

thrown objects could injure people or damage

property.

Figure 10. Blade Balancing

1. Follow original sharpening pattern.

2. Do not sharpen blade to a razor edge, but leave

• If this machine is not equipped with full chain

shielding, operation must be stopped when any-

one comes within 300 feet (92 m).

approximately 1/64" blunt edge.

3. Do not sharpen back side of blade.

• This shielding is designed to reduce the risk

of thrown objects. The mower deck and protec-

tive devices cannot prevent all objects from

escaping the blade enclosure in every mowing

condition. It is possible for objects to ricochet

and escape, traveling as much as 300 feet (92 m).

4. Sharpen both cutting edges equally to keep blade

balanced. Balance blade using the method shown

in Figure 10.

Blade Installation

Check that chain shielding is in good condition and

replace any damaged chain links.

CAUTION

„ Your dealer can supply genuine replacement

blades. Substitute blades may not meet original

equipment specifications and may be dangerous.

CLEANING

After Each Use

●

Remove large debris such as clumps of dirt, grass,

crop residue, etc. from machine.

Inspect machine and replace worn or damaged

parts.

Replace any safety decals that are missing or not

readable.

NOTICE

■ When installing blade, the lift of the blade must

be toward the spindle blade housing as shown in

Figure 11. Torque bolt (1) into shaft assembly to

100 lbs-ft.

Periodically or Before Extended Storage

●

Clean large debris such as clumps of dirt, grass,

crop residue, etc. from machine.

Remove the remainder using a low-pressure water

spray.

●

1. Be careful when spraying near scratched or torn

safety decals or near edges of decals as water

spray can peel decal off surface.

2. Be careful when spraying near chipped or

scratched paint as water spray can lift paint.

3. If a pressure washer is used, follow the advice

of the pressure washer manufacturer.

●

Inspect machine and replace worn or damaged

parts.

Sand down scratches and the edges of areas of

missing paint and coat with spray paint of matching

color (purchase from your dealer).

1. 5/8 NF x 2 Cap screw GR5

2. Bell washer, 5/8 x 1-3/4 x .075

●

Replace any safety decals that are missing or not

readable (supplied free by your dealer). See Safety

Decals section for location drawing.

Figure 11. Blade and Spindle Assembly

5WPMAN0705 (Rev. 5/9/2008)

Owner Service 17

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TROUBLESHOOTING

MOWING CONDITIONS

PROBLEM

POSSIBLE CAUSE

SOLUTION

Grass cut higher in center of

swath than at edge

Height of mower higher at front

than at rear

Adjust mower height and attitude so

that mower rear and front are within

1/2 inch of same height. See

instructions on page 11.

Loose blade

Check blade hardware.

Grass cut lower in center of

swath than at edge

Height of mower lower at front

than at rear

Adjust mower height and attitude so

that mower rear and front are within

1/2 inch of same height. See

instructions on page 11.

Loose blade

Check blade hardware.

Streaking conditions in swath

Conditions too wet for mowing

Allow grass to dry before mowing.

Blades unable to cut that part of

grass pressed down by path of

tractor tires

Slow ground speed of tractor but keep

engine running at full PTO rpm.

Cutting lower will help. Adjust tractor

tire spacing if possible.

Dull blades

Sharpen or replace blades.

Check blade hardware.

Loose blade

Material discharges from mower

unevenly; bunches of material

along swath

Material too high and too much

material

Reduce ground speed but maintain

540 rpm at tractor PTO, or make two

passes over material. Raise mower

for the first pass and lower for the

second and cut 90-degrees to first

pass. Raise rear of mower high

enough to permit material discharge,

but not so high that conditions listed

above occur.

Grass is wet

Allow grass to dry before mowing.

Slow ground speed of tractor but keep

engine running at full PTO rpm.

5WPMAN0705 (Rev. 5/9/2008)

18 Troubleshooting

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TROUBLE SHOOTING

BELT CONDITIONS

PROBLEM

Belt slippage

POSSIBLE CAUSE

SOLUTION

Mower overloading; material too

tall or heavy

Reduce tractor ground speed but

maintain full PTO rpm. Cut material

twice, one high pass and then mow at

desired height. Cut at 90 degrees to

first pass.

Oil on belt from over lubricating

Belt hung up or rubbing

Be careful not to over lubricate. Clean

lubricant from belt and pulleys with

clean rag. Replace oil-soaked belt.

Check belt position in pulleys and

idlers. Check belt for free travel in

pulleys. Check under mower and

around blade spindle shaft for wire,

rags, or other foreign material. Clean

all material from under mower.

Frayed edges on belt cover

Belt is misaligned

Re-align belt. Be sure belt does not

rub any other part while running.

Pulley is misaligned

Inspect to ensure belt is running in

center of backside idler. Shim idler as

necessary to align.

Belt rollover

Pulley is misaligned

Damaged belt

Re-align.

Replace belt. *

Foreign object in pulley groove

Inspect all pulley grooves for rust,

paint, or weld spots and remove.

Worn pulley groove

Replace pulley.

Replace belt. *

Damaged belt

Belt breakage

Rollover, high shock loads or

installation damaged

High shock loads

Belt came off drive

Avoid abusive mowing. Avoid hitting

the ground or large obstructions.

Check pulleys for foreign material in

grooves. Avoid hitting solid objects or

ground.

* Check belt for damage by laying it flat on the floor. A belt that does not lie flat (has humps or twists, indicating broken

or stretched cords) must be replaced.

5WPMAN0705 (Rev. 5/9/2008)

Troubleshooting 19

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DEALER SERVICE

The information in this section is written for dealer ser-

vice personnel. The repair described here requires

special skills and tools. If your shop is not properly

equipped or your mechanics are not properly trained in

this type of repair, you may be time and money ahead

to replace complete assemblies.

„ Before working underneath, read manual

instructions, securely block up, and check stability.

Secure blocking prevents equipment from drop-

ping due to hydraulic leak down, hydraulic system

failure, or mechanical component failure.

„ Keep all persons away from operator control

area while performing adjustments, service, or

maintenance.

CAUTION

„ 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.

BLOCKING METHOD

CD6308

See instructions on page 14.

BLADE SPINDLE REPAIR

Spindle repair requires special skills and tools. If your

shop is not properly equipped or your mechanics are

not trained in this type of repair, you may be time and

money ahead to use a new spindle assembly.

1. 3/8 NF x 1 HHCS GR5

2. Cup washer

3. Sheave

4. Spacer

For reference, the grease fitting is in the top of the spin-

dle shaft.

5. Spindle bearing

6. 3/8 NC Flange lock nut

7. 1/4 Tapered grease fitting

8. Spindle housing

9. 3/8 NC x 1-1/2 HHCS GR5

10. Spacer

Permatex^®3D Aviation Form-A-Gasket or equivalent is

recommended as a sealant.

Remove Spindle

11. Square key

12. Shaft assembly

13. Blade kit

1. Remove belt shields from deck.

2. Remove belt.

14. Cup washer

15. 5/8 NF x 2 HHCS GR5

3. Remove blade from spindle assembly.

4. Remove nuts (6) and bolts (9) that secure spindle

to mower. (See Figure 12.)

Figure 12. Blade Spindle Assembly

20 Dealer Service

5WPMAN0705 (Rev. 5/9/2008)

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Disassemble Spindle

Seal Replacement

1. Remove bolt (1) and washer (2) from the top of the

Recommended sealant for gearbox repair is Perma-

tex^®Aviation 3D Form-A-Gasket or equivalent.

spindle.

2. Remove sheave (3) and spacer (4).

Leakage can occur at the vertical or horizontal gaskets

and shaft seals.

NOTE: A wheel puller may be needed if sheave

can not be removed by hand. Retain key (11).

3. Slide shaft assembly (12), lower bearing (5), and

long spacer (10) out the bottom of spindle housing

(8).

Leakage at the horizontal gasket or seal can be

repaired without removing the gearbox from the mower.

4. Remove upper bearing (5) and spacer (4) from top

Seal Installation

of spindle housing.

5. Inspect parts and replace as needed.

NOTE: Proper seal installation is important. An improp-

erly installed seal will leak.

Assemble Spindle

1. Clean area in housing where seal outer diameter

1. Slide lower bearing (5) over shaft assembly (12)

(OD) seats. Apply a thin coat of Permatex.

with seal down.

2. Inspect area of shaft where seal seats. Remove

2. Slide long spacer (10) on shaft assembly.

any burrs or nicks with an emery cloth.

3. Insert shaft assembly with bearing and spacer into

spindle housing from the bottom.

3. Lubricate gear shaft and seal lips.

4. Install upper bearing (5) over shaft with the seal

4. Place seal squarely on housing, spring-loaded lip

toward housing. Select a piece of pipe or tubing

with an OD that will sit on the outside edge of the

seal but will clear the housing. Tubing with an OD

that is too small will bow seal cage and ruin seal.

facing up.

5. Install spacer (4) and sheave (3) over shaft.

6. Align keyways in shaft and sheave and insert key

(11).

7. Install washer (2), and bolt (1). Torque bolt to 35

5. Carefully press seal into housing, avoiding

lbs-ft.

distortion to the metal seal cage.

8. Rotate sheave and check for free movement.

9. Lubricate spindle.

GEARBOX REPAIR

Read this entire section before starting any repair.

Many steps are dependent on each other.

Incorrect

Installation

Fill gearbox with SAE 80W or 90W gear lube until it

runs out the side level plug.

Repair to this gearbox is limited to replacing bearings,

seals, and gaskets. Replacing gears, shafts, and a

housing is not cost effective. It is more economical to

purchase a complete gearbox if repair to anything other

than replacement of bearings, seals or gaskets is

required.

CD1092

1. Seal

2. Pipe or tube

3. Seal seat

CD1094

Inspect gearbox for leakage and bad bearings.

4. Casting

Leakage is a very serious problem and must be cor-

rected immediately.

Pipe or tube must

press at outer edge of seal

Bearing failure is indicated by excessive noise and side

to side or end play in gear shafts.

Figure 13. Seal Installation

5WPMAN0705 (Rev. 5/9/2008)

Dealer Service 21

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1. Seal

2. Snap ring

3. Shim 55.4 mm x 61.7 mm

4. Ball bearing

5. Input shaft

6. Key 8 mm x 10 mm x 30

7. Input gear

8. Ball bearing

9. Shim 60.3 mm x 71.7 mm

10. Snap ring

11. Oil cap

12. Output shaft & gear

13. Ball bearing

14. Shim kit

15. Snap ring

16. Spacer

23. Castle nut M24 x 2

24. 3/16 x 2 Cotter pin

25. 3/8 Solid plug

17. Shim 60.3 mm x 71.7 mm

18. Snap ring

26. M10 x 22 mm Hex head

screw

19. Seal

20. Washer, 1.58 x 3.13 x .04

21. Snap ring

27. Vent plug

28. Cover

22. Washer 25 mm x 44 mm x

4 mm

29. Ball bearing

Figure 14. Gearbox Assembly

Vertical Shaft Seal Replacement (Figure 15)

1. Disconnect and remove the driveline from the

gearbox.

2. Remove vent plug (15) and siphon gear lube from

housing through this opening.

3. Remove gearbox stand from mower deck.

4. Remove gearbox and pulley from stand (2).

5. Remove vertical shaft seal. Replace with new seal

(see Seal Replacement, page 21).

Vertical seal should be recessed in housing. Hori-

zontal seal should be pressed flush with outside of

housing.

NOTE: Distortion to seal cage or damage to seal

lip will cause seal to leak.

CD6306

6. Fill gearbox with SAE 80W or 90W gear lube until it

runs out the level plug.

7. Assemble gearbox and pulley to gearbox stand.

Figure 15. Gearbox Stand Assembly

Attach gearbox stand to mower deck.

(Rev. 6/1/2008)

22 Dealer Service

5WPMAN0705 (Rev. 5/9/2008)

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12. Inspect gears for broken teeth and wear. Some

wear is normal and will show on laded side. Forged

gear surfaces are rough when new. Check that

wear pattern is smooth.

Horizontal Shaft Seal Replacement

1. Disconnect and remove the driveline from the

gearbox.

2. Remove vent plug (27), Figure 14, and siphon gear

13. Inspect vertical and horizontal shafts for grooves,

nicks, or bumps in the areas where the seals seat.

Resurface any damage with emery cloth.

lube from housing through this opening.

3. If the leak occurred at either end of horizontal shaft,

remove oil cap (11) and/or oil seal (1). Replace

with new one (see Seal Replacement, page 21).

14. Inspect housing and caps for cracks or other

damage.

4. Fill gearbox with SAE 80W or 90W gear lube until it

runs out the level plug.

Reassemble Gearbox

(GM3060, GM3072 shown, GM3054 similiar)

Remove Gearbox from Mower

Refer to Figure 14.

1. Disconnect and remove the rear driveline from the

NOTE: Repair to this gearbox is limited to replacing

bearings, seals, and gaskets. Replacing gears, shafts,

and a housing is not cost effective. Purchasing a com-

plete gearbox is more economical.

gearbox.

2. Remove vent plug (15), Figure 15, and siphon gear

lube from housing through this opening.

1. Clean housing, paying special attention to areas

3. Remove gearbox stand (2) from mower deck by

where seals will be installed.

removing four hex screws (8).

2. Wash housing and component thoroughly. Select a

clean area for gearbox assembly. Replace all seals

and bearings. All parts must be clean and lightly

oiled before reassembling.

4. Remove four cap screws (14) and washers (13)

and remove shield (12) from gearbox.

5. Remove castle nut (6) and hardware from output

shaft of gearbox.

GM3060 & GM3072

6. Remove sheave (3) from gearbox.

3. Install upper output bearing (13), shims (14), and

snap ring (15) on output shaft (12). Use new shims

equal to the thickness of the original shims.

7. Remove four bolts (10) that attach gearbox to

gearbox stand and remove gearbox.

4. Press output shaft assembly into housing from the

Disassemble Gearbox

bottom opening.

1. Remove top cover (28), Figure 14, from housing.

Turn gearbox upside down and pour out remaining

gear oil from gearbox.

5. Install spacer (16), lower output bearing (13),

shims (17), and snap ring (18) in bottom of

housing.

2. Remove oil cap (11) (to be replaced).

GM3054

3. Remove snap ring (10) and shim (9) from input

1. Install shims (14), upper output bearing (8), spacer

(16), lower output bearing (8), shims (17), and

snap ring (15) on output shaft. Use new shims

equal to the thickness of the original shims.

shaft (5).

4. Support gearbox in hand press and push on input

shaft (5) to remove bearing (8).

5. Remove gear (7) from inside housing.

2. Press output shaft assembly into housing from the

bottom opening.

6. Remove oil seal (1) from front of housing (to be

replaced).

3. Install snap ring (18) in bottom of housing.

7. Remove snap ring (2) and shim (3) from front of

All Models

housing.

4. Apply grease to lower seal lips (19), and press seal

over output shaft (5), using a round tube of the

correct diameter. Be sure not to damage the seal

lip. Press in housing so that the seal is recessed.

8. Remove input bearing (4) by using a punch and

hammer from outside of housing.

9. Support housing in vise in a horizontal position.

10. The castle nut (23) and cotter pin (24) are already

removed with the drive sheave. Remove the snap

ring (18), washer (20), and seal (19).

5. Insert protective washer (20) (GM3060 & GM3072

only) by hand.

6. Install snap ring (21) and position it together with

seal (19) by pressing it into position. Verify that the

snap ring is seated properly.

11. Remove output shaft (12) and bearings by using a

punch and hammer and tap on top to drive down.

5WPMAN0705 (Rev. 5/9/2008)

Dealer Service 23

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7. Press bearing (8) into the housing, using a round

tube of the correct diameter and a hand press.

Secure with shims (9) and snap ring (10).

for proper belt life. Add or subtract shim washers

under idler pulley to align with drive pulley.

2. Tighten gear stand hardware.

8. Install key (6) on input shaft (5).

3. Fill gearbox half full with SAE 80W or 90W gear

9. Place gear (7) through top of housing and align the

lube.

two gears so they match.

4. Check level after waiting five minutes to permit

lube to work through bearings. Add lube, if

necessary, until gearbox is half full.

10. While holding gear (7) in place, slide input shaft (5)

through the gear and bearing (8).

11. Slide spacer (29) (GM3054 only) and bearing (4)

over input shaft (5) and press into housing, using a

round tube of the correct diameter and a hand

press.

5. Replace driveline shield. Attach driveline to

gearbox.

12. Slide shim (3) over input shaft and secure with

1. Shim

snap ring (2).

2. Idler arm

3. Idler pulley

4. Drive sheave

13. Check input shaft end float by moving the input

shaft by hand. If the end float is more than .012",

insert shim (9) between the rear bearing (8) and

snap ring (10).

5. Castle nut &

cotter pin

14. Check that gear backlash is between .006" and

6. Gearbox stand

.016". You should not have to adjust the backlash.

15. Press in input seal (1), using a round tube of the

correct diameter. Be careful not to damage the seal

lip.

16. Press oil cap (11) on to the rear cover of housing,

using a round tube of the correct diameter.

17. Check the gearbox housing for leaks by plugging

all holes except one. Apply 4 psi compressed air

and immerse the gearbox in water to verify that

there are no leaks.

Figure 16. Drive Sheave Installation

UNIVERSAL JOINT REPAIR

18. Remove the gearbox from water and dry off with

compressed air. Add SAE 80W or 90W EP oil until

it runs out of the side level hole. Tighten all plugs.

Install Gearbox

NOTE: Gearbox is heavy: do not attempt to move with-

out mechanical assistance.

1. Set gearbox on gearbox stand and fasten with

bolts and nuts. Torque bolts to 175 lbs-ft.

2. Attach drive sheave to output shaft. Secure using

castle nut and hardware previously removed.

3. Attach gearbox stand to mower using four hex

screws.

1. Yoke

2. Cup and bearings

3. Snap ring

Install Drive Sheave

1. When gear stand is installed on mower, dimension

A (from the top of the mower deck to the center line

of the drive pulley) must be 2-1/16" (±1/32"). This is

a critical dimension and must be carefully adjusted

4. Journal cross

Figure 17. U-Joint Exploded View

24 Dealer Service

5WPMAN0705 (Rev. 5/9/2008)

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U-Joint Disassembly

1. Remove external snap rings from yokes in four

locations as shown in Figure 18.

Figure 18

Figure 20

2. With snap rings removed, support drive in vise,

hold yoke in hand and tap on yoke to drive cup up

out of yoke. See Figure 19.

Figure 19

3. Clamp cup in vise as shown in Figure 20 and tap

on yoke to completely remove cup from yoke.

Repeat Step 2 and Step 3 for opposite cup.

4. Place universal cross in vise as shown in Figure 21

and tap on yoke to remove cup. Repeat Step 3 for

final removal. Drive remaining cup out with a drift

and hammer.

Figure 21

5WPMAN0705 (Rev. 5/9/2008)

Dealer Service 25

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U-Joint Assembly

1. Place seals securely on bearing cups. Insert cup

into yoke from outside and press in with hand

pressure as far as possible. Insert journal cross

into bearing cup with grease fitting away from

shaft. Be careful not to disturb needle bearings.

Insert another bearing cup directly across from first

cup and press in as far as possible with hand

pressure.

2. Trap cups in vise and apply pressure. Be sure

journal cross is started into bearings and continue

pressure with vise, squeezing in as far as possible.

Tapping the yoke will help.

3. Seat cups by placing a drift or socket (slightly

smaller than the cup) on cup and rap with a

hammer. See Figure 22. Install snap ring and

repeat on opposite cup.

4. Repeat Step 1 & Step 2 to install remaining cups in

remaining yoke.

5. Move both yokes in all directions to check for free

movement. If movement is restricted, rap on yokes

sharply with a hammer to relieve any tension.

Repeat until both yokes move in all directions

without restriction.

Figure 22

™

26 Dealer Service

5WPMAN0705 (Rev. 5/9/2008)

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ASSEMBLY INSTRUCTIONS

DEALER SET-UP INSTRUCTIONS

Install A-Frame Arms

Assembly of this mower is the responsibility of the

dealer. It should be delivered to the owner completely

assembled, lubricated, and adjusted for normal cutting

conditions.

1. Loosen lock nuts (52) at lower hitch point and

install A-frame arms (13) as shown.

2. Tighten nut securely.

Complete Dealer Check Lists on page 31 when you

have completed the assembly.

3. Repeat for opposite side.

The mower is shipped partially assembled. Assembly

will be easier if components are aligned and loosely

assembled before tightening hardware. Recommended

torque values for hardware are located on page 42.

Select a suitable working area. Open parts boxes and

lay out parts and hardware to make location easy.

Refer to illustrations, accompanying text, parts lists and

exploded view drawings.

„ Before working underneath, carefully read Oper-

ator’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 hydrau-

lic leak down, hydraulic system failures, or

mechanical component failures.

CD6497

13. A-Frame arms

CAUTION

14. Rear offset link arms

15. Top link U-bracket

„ 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.

16. Sleeve 1-1/4 x 1-3/4 x 2-3/4

25. Sleeve 5/8 x 1 x 7/16

51. 1/2 NC Flanged lock nut

52. 5/8 NC Flanged lock nut

53. 1/2 x 5 HHCS GR5

Uncrate Mower

55. 1/2 NC x 1-1/4 HHCS GR5

56. 5/8 NC x 2-1/2 HHCS GR5

1. Remove sides and top of mower shipping crate.

2. Remove lag screws and brackets that secure

mower to crate base.

3. Remove driveshaft wired to mower deck.

Figure 23. A-Frame Arms Installed

5WPMAN0705 (Rev. 5/9/2008)

Assembly 27

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Install Rear Offset Link Arms

Install Driveshaft

1. Loosen nut (51) and bolt (55) at rear frame lug and

attach rear offset link arm (14) as shown in Figure

24. (Do not use wheel tube bolt.)

1. Slide QD yoke of driveshaft assembly onto

gearbox shaft. Make sure QD yoke pin is seated

securely in groove of gearbox shaft.

2. Repeat for opposite side.

3. Do not tighten at this time.

2. Attach shield anti-rotation chain to drive shield.

Fill Gearbox

CD6497A-1

1. Make sure vent plug hole is clear. Fill gearbox half-

full with high quality gear oil that has a viscosity

index of 80W or 90W and an API service rating of

GL-4 or GL-5.

2. Fill gearbox until oil runs out the side plug on

gearbox.

3. Pour in one pint of gear lube, wait five minutes and

add additional gear lube until it just comes out of

side hole.

4. Allow an additional five minutes for the lube to flow

through bearings, then check to make sure oil level

is at bottom of side hole. Replace side plug. Install

vent plug.

14. Rear offset link arm

51. Nut, flanged lock 1/2 NC

55. 1/2 NC x 1-1/4 HHCS GR5

NOTICE

Figure 24. Right Rear Offset Link Installed

■ Gearbox is not filled at the factory. Prior to deliv-

ery, make sure each gearbox is filled half-full with

80W or 90W API GL-4 or GL-5 gear lube.

Install Top Link

1. Insert cap screw (54) through A-frame arms (13),

U-bracket (15), sleeve (16) and rear offset link

arms (14) and tighten securely with nut (51).

Install Chain Shielding (Optional)

2. Tighten hardware on rear frame lug and offset link.

CD6497-2

13. A-Frame arms

14. Rear offset link arms

15. Link, U-bracket

CM768

3. Shield, chain plate

14. Bolt, carriage 3/8 NC x 1

15. Nut, flanged lock 3/8 NC

16. Sleeve, .62 x .84 x 2.75

51. Nut,flanged lock 1/2 NC

53. 1/2 NC x 5 HHCS GR5

Figure 26. Chain Shielding Installed

CM757

Figure 25. Top Link Assembled

(GM3060 & GM3072 Only)

5WPMAN0705 (Rev. 5/9/2008)

28 Assembly

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NOTE: This kit allows mower to fit only Cat. 1 standard

ASAE quick hitch.

1. 1/4 Pin

2. 3-Link 1/4 proof chain

3. Shield, chain plate

4. Sleeve 1/2 x 3/4 x 1/2

5. 3/8 NC x 1-1/4 Carriage bolt

1. Offset link, .38 x 2 x 25.88 (A-frame bars)

2. 38" Long chain

3. Sleeve, .91 x 1.44 x 1.25

4. 1/2 NC x 6 Cap screw

5. 1/2 Flat washer

Figure 27. Chain Shield Installed (GM3054 Only)

6. Sleeve, .5 x .75 x 3.38

7. 1/2 NC Flange lock nut

8. Sleeve, .875 x 1.125 x .593 HT

9. 7/8 Flat washer

„ Full chain shielding must be installed when

operating in populated areas or other areas where

thrown objects could injure people or damage

property.

10. Sleeve, .81 x 1.25 x 1.81

Figure 28. Quick Hitch Kit Installation

• If this machine is not equipped with full chain

shielding, operation must be stopped when any-

one comes within 300 feet (92 m).

• This shielding is designed to reduce the risk

of thrown objects. The mower deck and protec-

tive devices cannot prevent all objects from

escaping the blade enclosure in every mowing

condition. It is possible for objects to ricochet

and escape, traveling as much as 300 feet (92 m).

1. Attach offset link (1) to mounting pins, using 7/8"

sleeve (8) and flat washer (9). Do not tighten

hardware.

2. Attach upper end of offset link to pivot link, using

flat washer (5), sleeves (6 & 10), flange lock nut

(7), and 1/2" x 4-3/4" cap screw.

3. Remove rear offset links and replace with chains

1. Install chain shielding plate (3) to rear mower frame

(2).

as shown.

4. Attach chain to top of A-frame as shown, using cap

screw (4), flat washer (5), and nut. Attach opposite

end of chain (2) to rear mower frame as shown.

2. Secure with carriage bolts (14) and flanged lock

nuts (15).

3. Insert carriage bolts from bottom upward as

5. Cut chain to length (GM3060 - 40", GM3072 45").

Vary length slightly as desired. Twist chain to make

finite adjustments in length until unit lifts level.

shown.

Install Quick Hitch Kit (Optional)

(GM3060 & GM3072 Only)

NOTE: Do not bottom out the drive on front of

deck.

NOTE: Figure 28 shows GM3060. Other models use

6. Install sleeve (3) on mounting pins and retain with

the same assembly instructions.

klik pin.

5WPMAN0705 (Rev. 5/9/2008)

Assembly 29

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Install Front Roller (Optional)

NOTES

1. Insert four carriage bolts (8) through the front

mower frame from inside out.

2. Place roller bracket (2) over bolts; then install

flange lock nuts (9) on bolts and tighten.

3. Place front roller (1), sleeve (3), bearings (4), and

washers (5) in roller bracket as shown in Figure 29.

4. Insert cap screw (3) through bracket and roller.

5. Secure with flanged lock nut (2). Do not

overtighten, roller must spin freely.

CD6310

1. Roller

2. Roller bracket

3. Spacer

4. Bearing

5. 1/2 Flat washer SAE

6. 1/2 NC x 9 HHCS GR5

7. 1/2 NC Flanged locknut

8. 3/8 NC x 1-1/4 Carriage bolt

9. 3/8 NC Flanged locknut

Figure 29. Front Roller Installation

5WPMAN0705 (Rev. 5/9/2008)

30 Assembly

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DEALER CHECK LISTS

DEALER PRE-DELIVERY CHECK LIST

(DEALER’S RESPONSIBILITY)

Inspect the equipment thoroughly after assembly to

ensure it is set up properly before delivering it to the

customer.

___ Check all bolts to be sure they are properly

torqued.

___ Check that all cotter pins and safety pins are

properly installed. Replace if damaged.

The following check lists are a reminder of points to

inspect. Check off each item as it is found satisfactory

or after proper adjustment is made.

___ Check and grease all lubrication points as iden-

tified in “lubrication information” on page 14.

___ Check that all safety decals are installed and in

good condition. Replace if damaged.

___ Gearboxes are not filled at the factory. Prior to

delivery, fill as specified in the "Service, lubrica-

tion information" on page 14 and check to see

that there are no leaking seals.

___ Check that shields and guards are properly

installed and in good condition. Replace if dam-

aged.

___ Check that blades have been properly installed.

DEALER DELIVERY CHECK LIST

(DEALER’S RESPONSIBILITY)

___ Show customer how to make adjustments and

select proper PTO speed.

___ Explain to customer the potential crushing haz-

ards of going underneath raised equipment.

Instruct that before going underneath to discon-

nect the driveline, securely block up all corners

with jackstands and to follow all instructions in

the "Service, blocking methods" section of the

Operator’s Manual. Explain that blocking up

prevents equipment dropping from hydraulic

leak down, hydraulic system failures, or

mechanical component failures.

___ Instruct customer how to lubricate and explain

importance of lubrication.

___ Point out the safety decals. Explain their mean-

ing and the need to keep them in place and in

good condition. Emphasize the increased safety

hazards when instructions are not followed.

___ Present Operator's Manual and request that

customer and all operators read it before oper-

ating equipment. Point out the manual safety

rules, explain their meanings and emphasize

the increased safety hazards that exist when

safety rules are not followed.

___ For mounted units, add wheel weights, ballast in

front tires, and/or front tractor weight to enhance

front end stability. A minimum 25% of tractor

and equipment gross weight must be on front

tractor wheels. When adding weight to attain

25% of tractor and equipment weight on front

tractor wheels, you must not exceed the ROPS

weight certification. Weigh the tractor and

equipment. Do not estimate!

___ Show customer how to make sure driveline is

properly installed and that spring-activated lock-

ing pin or collar slides freely and is seated in

groove on tractor PTO shaft.

___ Make customer aware of optional equipment

available so that customer can make proper

choices as required.

___ Show customer the safe, proper procedures to

be used when mounting, dismounting, and stor-

ing equipment.

___ Point out all guards and shields. Explain their

importance and the safety hazards that exist

when not kept in place and in good condition.

5WPMAN0705 (Rev. 5/9/2008)

Dealer Check Lists 31

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NOTES

5WPMAN0705 (Rev. 5/9/2008)

32 Dealer Check Lists

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PARTS INDEX

Grooming Mowers:

GM3054

GM3060

GM3072

MAIN FRAME ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 & 35

GEARBOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

DRIVELINE ASSEMBLY

GM3054 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

GM3060 & GM3072 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

BLADE & SPINDLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

BELT GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

REAR CHAIN SHIELDING ASSEMBLY (OPTIONAL). . . . . . . . . . . . . . 40

FRONT ROLLER ASSEMBLY (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . 41

QUICK HITCH KIT (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

(Rev. 8/6/2012)

5WPMAN0705 (Rev. 5/9/2008)

Parts 33

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GM3054, GM3060 & GM3072 MAIN FRAME ASSEMBLY

36 - COMPLETE DECAL SET

REF GM3054 PART GM3060 PART

GM3072 PART QTY

DESCRIPTION

-----

Main frame (not sold separately)

Idler arm

5WP1008044

5WP1008022

5WP1008023

5WP1008024

5WP1008044

5WP1008069

5WP1008167

5WP1008044

5WP1008166

5WP1008167

Right shield

Left shield

Center shield

34 Parts

5WPMAN0705 (Rev. 5/9/2008)

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GM3054, GM3060 & GM3072 MAIN FRAME ASSEMBLY

REF GM3054 PART GM3060 PART

GM3072 PART QTY

DESCRIPTION

5WP1008025

5WP1008028

5WP1008030

5WP1008032

5WP1008045

5WP1008056

-----

5WP1008085

5WP1008169

5WP1008030

5WP1008032

5WP18824

5WP1008056

-----

5WP1008125

5WP1008169

5WP1008030

5WP1008032

5WP18824

5WP1008056

-----

Caster tube

Gearbox stand

Caster yoke (pneumatic tire)

Caster yoke (solid tire)

Hitch

Gearbox sheave

Spindle (see page 39)

5WP1006649

5WP19579

5WP19056

5WP19605

5WP64814

5WP1008097

5WP1008096

5WP19749

5WP29368

5WP24993

5WP65578

5WP65130

5WP65129

5WP27542

5WP20409

-----

5WP1006648

5WP19579

5WP55331

5WP19605

5WP64814

5WP1008097

5WP1008096

5WP19749

5WP29368

5WP24993

5WP65578

5WP65130

5WP65129

5WP27542

-----

5WP1006648

5WP19579

5WP19578

5WP19605

5WP64814

5WP1008097

5WP1008096

5WP19749

5WP29368

5WP24993

5WP65578

Gearbox (see page 36)

A-frame arm

Rear offset link arm