Gearmore XB48 Guide

ROTARY TILLER
Assembly, Operation,
Service & Parts Manual
For
Model XB48
Form: XBTiller.PM7
April 2005

TABLE OF CONTENTS
Introduction ....................................................................................................... 1
Welcome ................................................................................................ 1
Safety ................................................................................................................. 2
Safety Alert Symbols ............................................................................ 2
Training .................................................................................................. 3
Equipment Safety Guidelines............................................................. 4
Operational Safety .............................................................................5-6
Starting and Stopping Safety .............................................................. 7
Transport Safety ................................................................................... 8
Safety Sign Locations..................................................................... 9-11
Assembly Instructions .................................................................................... 12
Before Putting Tiller Into Service ............................................. 13-14
Preparation ....................................................................................................... 15
Attaching to Tractor .................................................................................. 16-17
Sizing PTO Shaft................................................................................ 18
Operating Instructions ................................................................................... 19
Maintenance ..................................................................................................... 20
Maintenance Safety ............................................................................ 21
Storage Safety ...................................................................................... 22
Tiller Assembly .......................................................................................... 23-24
Side Gearbox Assembly............................................................................ 25-26
Top Gearbox Assembly ............................................................................ 27-28
Driveline Assembly ......................................................................................... 29
Limited Warranty ............................................................................................. 30

CUSTOMER INFORMATION
NAME:______________________________________________
PURCHASED FROM: _________________________________
DATE OFPURCHASE:________________________________
MODELNUMBER: ___________________________________
SERIALNUMBER: ___________________________________
INTRODUCTION
We welcome you as a new owner of a Gearmore Rotary Tiller. Please read the following
instructions and refer to them when required.
This manual contains valuable information about your Tiller. It has been carefully prepared to give
you helpful suggestions for operating, adjustments, servicing, and ordering repair parts.
Keep this manual in a convenient place for quick and easy reference. Study it carefully. You have
purchased a dependable and sturdy Tiller, but only by proper care and operation can you expect to
receive the service and long life designed and built into it.
It is the purchaser and/or operator's responsibility to....
Read and understand the information contained in this manual.
Operate, lubricate, assemble and maintain the equipment in accordance with
all instructions and safety procedures in this manual.
Inspect the equipment and replace or repair any parts that are damaged
or worn which under continued operation would cause damage, wear to
other parts, or cause a safety hazard.
Return the equipment or parts to the authorized Gearmore dealer, from where
it was purchased, for service or replacement of defective parts that are covered
by warranty. Gearmore may inspect equipment or parts before warranty claims
are honored.
Sometime in the future your Tiller may need new parts to replace those that are worn or broken. If
so, go to your dealer and provide him with the model and part number.
1

SAFETY
2
SAFETY ALERT SYMBOL
Why is SAFETY important to you?
Read and follow the instructions in
this manual and especially in the
Safety Section. Failure to do so can
result in serious injury or death.
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.
This Safety Alert symbol means
ATTENTION! BECOME
ALERT! YOUR SAFETY IS
INVOLVED!
Accidents Disable and Kill
Accidents Cost
Accidents Can Be Avoided
3 Big Reasons
DANGER - Indicates an imminently hazardous
situation that, if not avoided, will result
in death or serious injury. This signal
word is to be limited to the most
extreme situations typically for
machine components which, for
functional purposes, cannot be guarded.
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.
It may also be used to alert against
unsafe practices.
SIGNAL WORDS:
WARNING and CAUTION with the safety
messages. The appropriate signal word for
each message has been selected using the
following guide-lines:
SI NO LEE INGLES, PIDA AYUDA
A AIGUIEN QUE SI LO LEA PARA
QUE LE TRADUZCA LAS
MIDIDAS DE SEGURIDAD.
If you have any questions not answered in this manual or require additional copies or the manual is
damaged, please contact your local dealer.

SAFETY
Safety is a primary concern in the design and manufacturing of our product. Unfortunately,
our efforts to provide safe equipment can be wiped out by a single careless act of an operator
or bystander.
In addition to the design and configuration of equipment, hazard control and accident pre-
vention are dependent upon the awareness, concern, prudence and proper training of per-
sonnel involved in the operation, transport, maintenance and storage of this equipment.
It has been said, "The best safety device is an informed, careful operator." We ask you to be
that kind of operator. It is the operator's responsibility to read and understand all safety and
operating instructions in the manual and to follow them. Accidents can be avoided.
Working with unfamiliar equipment can lead to careless injuries. Read this manual, and the
manual for your tractor, before assembly or operating, to acquaint yourself with the ma-
chines. If this machine is used by any person other than you, or is loaned or rented, it is the
Rotary Tiller owner's responsibility to make certain that the owner's manual be available to
the operator prior to operating:
1. Reads and understands the operator's manuals.
2. Is instructed in safe and proper use.
Know your controls and how to stop the tractor, engine, and tiller quickly in an emergency.
Read this manual and the one provided with your tractor.
Train all new personnel and review instructions frequently with existing workers. Be certain
only a properly trained and physically able person will operate the machinery. A person who
has not read and understood all operating and safety instructions is not qualified to operate
the machine. An untrained operator exposes himself and bystanders to possible serious in-
jury or death. If the elderly are assisting with farm work, their physical limitations need to be
recognized and accommodated.
3
TRAINING

SAFETY
4
Safety of the operator and bystanders is one of the main concerns in designing and developing a
tiller. However, every year accidents occur which could have been avoided by a few seconds of
thought and a more careful approach to handling equipment. You, the operator, can avoid many
accidents by observing the following precautions and insist those working with you, or for you,
follow them.
In order to provide a better view, certain photographs or illustrations in this manual may show an
assembly with a safety shield removed. However, equipment should never by operated in this con-
dition. Keep all shields in place. If shield removal becomes necessary for repairs, replace the shield
prior to use.
Replace any safety sign that is not readable or missing. Location of such safety signs are indicated in
this manual.
Never use alcoholic beverages or drugs that can hinder alertness or coordination while operating
this equipment. Consult your doctor about operating this machine while taking prescription medi-
cations.
Under no circumstances should children under the age of 18 be allowed to work with this equip-
ment. Do not allow persons to operate or assemble this unit until they have read this manual and
have developed a thorough understanding of the safety precautions and how it works. Review the
safety instructions with all users annually.
This equipment is dangerous to children and persons unfamiliar with its operation. The operator
should be a responsible, properly trained and physically able person familiar with farm machinery
and trained in this equipment's operations. If the elderly are assisting with farm work, their physical
limitations need to be recognized and accommodated.
Use a tractor equipped with a Roll Over Protective System and seat belts. (ROPS)
Never exceed the limits of a piece of machinery. If its ability to do a job, or to do so safely, is in
question - DON'T TRY IT.
Do not modify the equipment in any way. Unauthorized modification could result in serious injury
or death and may impair the function and life of the equipment.
In addition to the design and the confirmation of this implement, including safety signs and safety
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 the machine. Refer also to safety messages and operation instruction in each of the
appropriate sections of the tractor and tiller manuals. Pay close attention to the safety signs affixed
to the tractor and the tiller.
EQUIPMENT SAFETY GUIDELINES

SAFETY
5
The use of this equipment is subject to certain hazards that cannot be protected against by the mechani-
cal 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. If there is some-
thing in this manual you do not understand, ask your supervisor, or your dealer, to explain it to you.
Most accidents occur because of neglect or carelessness. Keep all helpers and bystanders at least several
hundred feet from an operating rotary tiller. Only properly trained people should operate this machine.
When machine is operated in populated areas where thrown objects could injure persons or property,
operation must be stopped when anyone comes within several hundred feet.
The majority of the accidents involve entanglement on the driveline, injury of bystanders by the objects
thrown by the rotating tines, and operators being knocked off the tractor by low hanging limbs and then
being run over by the tiller. Accidents are most likely to occur with machines that are loaned or rented to
someone who has not read the owner's manual and is not familiar with a rotary tiller.
The rotary tiller is designed for use only on tractors with the power take-off (PTO) turning at 540-RPM.
Install and secure all guards and shields before starting or operating. The tiller tines, driveline guards and
tractor shields should be used and maintained in good working condition. They should be inspected
carefully, at least daily, for missing or broken chain links, shields, or guards. (Worn items must be replaced
at once to reduce possibility of injury.)
Disengage power take-off (PTO) and place transmission in neutral before attempting to start engine.
Many varied objects, such as wire, cable, rope, or chains, can become entangled in the operating parts of
the tiller. These items could then swing outside the housing at greater velocities than the tines. Such a
situation is extremely hazardous. Inspect the cutting area for such objects before tilling. Remove any like
objects from the site.
Never allow the tilling tines to contact such items. Never assume an area is clear. ALWAYS CHECK!
Always stop the tractor, disengage PTO, set brake, shut off the tractor engine, remove the ignition key,
lower implement to the ground and allow rotating pieces to come to a complete stop before dismounting
tractor. Never leave equipment unattended with the tractor running.
Never place hands or feet under tiller with tractor engine running or before you are sure all motion has
stopped. Stay clear of all moving parts.
OPERATIONAL SAFETY

Do not reach or place any part of your body under equipment until it is blocked securely.
Do not allow riders on the rotary tiller or tractor at anytime. There is no safe place for any riders.
Do not operate unless all personnel, livestock, and pets are several hundred feet away to prevent
injury by thrown objects.
Never operate tractor and rotary tiller under trees with low hanging limbs. Operators can be knocked
off the tractor and then run over by the rotating tines.
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 guardrails and concrete abutment. 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 tilling tines to contact
such obstacles.
Stop rotary tiller and tractor immediately upon striking an obstruction. Turn engine off, remove key,
inspect and repair any damage before resuming operation.
Stay alert for uneven terrain, holes, rocks, and roots and other hidden hazards. Keep away from drop-
offs and hazards that could cause roll over. Use extreme care and maintain minimum ground speed
when transporting or operating on hillsides, over rough ground and when operating close to ditches
or fences. Be careful and slow down when turning sharp corners and changing direction on slopes.
Do not start or stop suddenly on slopes. Avoid operation on steep slopes. In extremely uneven
terrain, rear wheels weights, front tractor weight, and/or tire ballast should be used to improve stabil-
ity.
Pass rotary tiller diagonally through sharp dips and avoid sharp drops to prevent "hanging up" tractor
and rotary tiller. Practice will improve your skills in maneuvering on rough terrain. Always cut down
slopes, never across the face. Always check tractor manual for proper use on slopes.
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 the 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!
SAFETY
6
OPERATIONAL SAFETY

SAFETY
7
STARTING AND STOPPING SAFETY
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.
All tractors that are not equipped with a "live" power take-off (PTO) need to be equipped
with an over-running PTO clutch. These are available through most farm equipment stores.
NOTE: The addition of an over-running PTO clutch may change the length of the PTO
driveline required. Pay extra attention to the instructions on the PTO Driveline Installa-
tion. Be sure that the driveline system guarding is adequate.
Tiller operating power is supplied from the tractor PTO. Refer to your tractor manual for
PTO engagement and disengagement instructions. Know how to stop tractor and tiller
quickly in case of an emergency.
When engaging PTO, the engine RPM should always be at idle speed. Once engaged and
ready to start tilling, raise PTO speed to 540-RPM and maintain throughout tilling opera-
tion.

SAFETY
8
TRANSPORT SAFETY
Comply with state and local laws governing highway safety and movement of farm
machinery on public roads.
The use of flashing amber lights is acceptable in most localities. However, some
localities prohibit their use. Local laws should be checked for all lighting and marking
requirements.
At all times, when driving the tractor and equipment on the road or highway under
20 m.p.h. (32 KPH) use flashing amber warning lights and a slow moving vehicle (SMV)
identification emblem. Do not exceed 20 m.p.h. (32 KPH). Reduce speed on rough
roads and surfaces.
Plan your route to avoid heavy traffic.
Always install transport locks, pins or brackets before transporting.
Do not drink and drive.
Be a safe and courteous driver. Always yield to oncoming traffic in all situations,
including narrow bridges, intersections, etc. Watch for traffic when operating near
or crossing roadways.
Turn curves or go up or down hills only at a low speed and at a gradual steering angle.
Make certain that at least 20% of the tractor's weight is on the front wheels to maintain
safe steerage. Slow down on rough or uneven surfaces. Always check tractor manual for
proper use on slopes.
Use extreme care and maintain minimum ground and when operating close to ditches
or fences. Be careful when turning sharp corners.
Never allow riders on either tractor or tiller.

SAFETY
9
SAFETY SIGN LOCATIONS
The types of safety signs and locations on the equipment are shown in the illustration below.
Good safety requires that you familiarize yourself with the various safety signs, the type of
warning and the area, or particular function related to that area, that requires your SAFETY
AWARENESS.
NOTE: The numbers represent the safety decals on the following pages.
REMEMBER: If safety signs have been damaged, removed, become illegible or parts have
been replaced without signs, new safety signs must be applied. New safety signs are available
from your authorized dealer or Gearmore.
TOP VIEW

SAFETY
10
SAFETY SIGN LOCATIONS
Safety Sign No. 1
Safety Sign No. 2
Safety Sign No. 3

SAFETY
11
SAFETY SIGN LOCATIONS
Safety Sign No. 4
Safety Sign No. 6
Safety Sign No. 7
Safety Sign No. 8

XB ROTARY TILLER ASSEMBLY
12
ASSEMBLY INSTRUCTIONS
STEP 1:
With rotary tiller still in crate, lay flat on a level surface. Cut banding straps on the two (2) upright
crate posts.
STEP 2:
Remove the top and upper side sections of the crate, leaving the rotary tiller resting on the bottom
section.
STEP 3:
Remove tie wire holding the PTO shaft and set aside PTO.
STEP 4:
Attach tiller according to your tractors manual and using the instructions on pages 16 and 17.
STEP 5:
Install tail back plate chain.
STEP 6:
Install PTO shaft as outlined in the Attaching to Tractor Section, Pgs 16-19.
NOTE: The safety chains on the PTO shaft should be attached to the tractor and tiller to
prevent the plastic safety shield from rotating.

XB ROTARY TILLER ASSEMBLY
13
BEFORE PUTTING ROTARY
TILLER INTO SERVICE
IMPORTANT - INSTRUCTIONS PRIOR TO START UP
SHIPPED WITHOUT OIL IN GEARBOXES AND WITHOUT GREASE IN GREASE
FITTINGS. UNIT MUST BE SERVICED BEFORE USING.
Fill gearbox using gear oil (type SAE-EP-80W 90).
For all grease fittings use TYPE/grade II tube grease.
STEP 1: Place rotary tiller so that the deck is secure
and level.
STEP 2: Remove oil plug located at top of transmission
gearbox (See Fig. A & B).
STEP 3: Fill gearbox using gear oil until gearbox is
approximately 1/2full (16 oz). The plug has
marks on it. (See Fig. C) Make sure oil level
is close to top line, but not over it.
DO NOT OVERFILL!
Fig. A
Fig. B
Fig. C

XB ROTARY TILLER ASSEMBLY
14
STEP 4: Replace and tighten the oil plug and clean
away any excess oil.
STEP 5: Remove oil plug located at top of side
gearbox (See Fig. D, ref. A), there is a
sight glass located in the side of the side
gearbox (Fig. D, ref. B and close-up
Fig. E). Fill oil until oil is to top of
glass (20 oz).
STEP 6: Replace and tighten the plug. Clean
away any excess oil.
STEP 7: Grease the grease fitting on the "outboard
hub", the two (2) grease fittings on the
PTO universal joints, the two (2) grease
fittings on the PTO safety shield, and the
inner surface portion of the PTO shaft.
(See Fig. F, G, & H).
CAUTION:
DO NOT overfill gearbox. This could cause damage
to oil seals and can cause permanent damage to the
gearbox. This issue will not be covered under warranty.
Fig. D
Fig. E
Fig. F Fig. G
Fig. H

PREPARATION
15
Never operate the tractor and tiller until you have read and completely understand this manual,
the Tractor Operator's Manual, and each of the safety messages found on the safety signs on
the tractor and tiller.
Personal protection equipment including hardhat, safety glasses, safety shoes, and gloves are
recommended during assembly, installation, operation, adjustment, maintenance, repairing,
removal, or moving the implement. Do not allow long hair, loose fitting clothing, or jewelry to
be around equipment.
PROLONGED EXPOSURE TO LOUD NOISE MAY CAUSE PERMANENT
HEARING LOSS! Tractors with or without tillers attached can often be noisy enough to
cause permanent, partial hearing loss. We recommend that you wear hearing protection on a
full time basis if the noise in the operator's position exceeds 80 db. Noise over 80 db on a
long-term basis can cause severe hearing loss. Noise over 90 db adjacent to the operator over
a long term basis may cause permanent, total hearing loss. NOTE: Hearing loss from loud
noise (from tractors, chain saws, radios, and other such sources close to the ear) is cumulative
over a lifetime without hope of natural recovery.
Operate the tiller only with a tractor equipped with an approved Roll-Over Protection System
(ROPS). Always wear your seat belt. Serious injury or even death could result from falling off
the tractor - particularly during turnover when the operator could be pinned under the ROPS
or the tractor.
Clear area to be tilled of stones, branches or other debris that might be thrown or entangled in
the tiller, causing injury or damage.
Operate only in daylight or good artificial light.
Ensure tiller is properly mounted, adjusted and in good operating condition.
Ensure that all safety shielding and safety signs are properly installed and in good condition.

ATTACHING TO TRACTOR
16
WARNING
Never stand between tractor and rotary
tiller while backing up tractor to the hitch
STEP 1: Attach to tractor's Cat. I, 3-point hitch as described in the Tractor's Operator's Manual.
STEP 2: Determine if the PTO shaft needs to be shortened.
NOTE: Due to the many variations in the tractor hitch points and distances between
equipment gearbox input shaft and tractor PTO output shafts, some combinations may
require PTO shafts to be shortened as described by the following steps.
STEP 3: Raise and lower rotary tiller in order to locate the shortest distance between
equipment gearbox input shaft and tractor PTO output shaft. With the rotary
tiller in the shortest distance position, shut down the tractor and SECURELY
BLOCK ROTARY TILLER IN POSITION.
WARNING: IF TILLER IS RAISED UP SO THAT PTO SHAFT IS AT AN
ANGLE SHARPER THAN 35 DEGREES, PTO MUST BE STOPPED!
STEP 4: Pull apart PTO shaft and attach outer section to tractor PTO output shaft.
NOTE: Be sure to pull on PTO shaft section to ensure yoke has locked into place.

ATTACHING TO TRACTOR
17
STEP 5: Place and hold inner PTO shaft section
next to outer section and check if PTO
shaft is too long. Each section should end
approximately 1" short of reaching u-joint
shield on the opposite section. If the shaft
is too long, measure 1" back from each
u-joint shield and mark the other shaft
section. (Measure 1" from arrow on Fig. C).
Be sure to do this for both PTO shaft halves.
NOTE: Do not cut PTO shaft sections at this time.
STEP 6: Raise rotary tiller and remove blocking. Raise and lower rotary tiller in order to
locate the longest distance between equipment input shaft and the tractor PTO
output shaft. With the rotary tiller in the longest distance position shut down the
tractor and SECURELY BLOCK THE ROTARY TILLER IN POSITION.
STEP 7: As in Step 5, hold PTO shaft sections together and check for a minimum of 6"
of overlap. If PTO shaft has been marked for cutting the overlap is the distance
measured between the two marks. If the PTO shaft has less than a 6" overlap,
DO NOT USE. Contact your authorized Gearmore dealer.
NOTE: If the PTO shaft length is too long, go to SIZING PTO SHAFT Pg. 18.
STEP 8: Apply any multipurpose grease to the outside of the male (inner) PTO shaft
section. Assemble PTO shaft and install on rotary tiller and tractor.
STEP 9: Pull on tractor side of PTO shaft yoke to be sure it has locked in place. Make
certain PTO shaft shielding is in place and good working condition.
STEP 10: The PTO shaft shield is a non-rotating design and must be secured prior to
equipment use. Using the chain on each yoke shield, attach to a fixed object on
the tractor and equipment ends that will not allow the PTO shaft shield to rotate
during operation.

SIZING PTO SHAFT
18
STEP 1:
Cutting the PTO shaft to length.
NOTE: Be sure to cut equal lengths
of each PTO shaft section. Clamp end
of PTO shaft in a vice and cut off
shield where marked. (Fig. 1-A
& 1-B)
STEP 2:
Using cut section of the shield as a
guide, cut shaft off the same amount
(Fig. 2)
STEP 3:
Repeat steps 1 and 2 for other PTO
shaft section.
STEP 4:
Use a file to deburr PTO shafts. Clean
up all chips, burrs, and fillings from
both ends of the PTO shaft.
Figure 1-A
Figure 1-B
Figure 2