Gearmore GCF41 Installation and operating instructions

HAMMER KNIFE
FLAIL MOWER
SHREDDER
Operation & Service
Manual For Models:
GCF41, 45, 53, 61,
69, & 79
February 2006
FORM: GCFMower.QXD

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Pre-operation Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Mower Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
Roller Height Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Drive Belt Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Troubleshooting & Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
GCF Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-11
GCF A-Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
GCF Rake Hatch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
GCF41-61 Rotor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
GCF69-79 Rotor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Quantity Matching Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
GCF Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-18
GCF Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19-22
GCF41-61 Gearbox Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
GCF69-79 Gearbox Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
GCF41-61 PTO Shaft (Bondioli & Pavesi) . . . . . . . . . . . . . . . . . . . . . . . . .25
GCF69-79 PTO Shaft (Bondioli & Pavesi) . . . . . . . . . . . . . . . . . . . . . . . . .26
GCF41-61 PTO Shaft (Weasler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
GCF69-79 PTO Shaft (Weasler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
TABLE OF CONTENTS
Date of Purchase:__________________________
Model Number:____________________________
Serial Number:____________________________

INSTALLATION
Page 1
BEFORE ATTACHING THE MOWER TO THE TRACTOR
1. Make sure that the mower is suitable for your tractor's horsepower.
YOUR TRACTOR's
MODELS MAX. H.P.
All 72
CAUTION: Please note that if these limits are exceeded, it will
invalidate your warranty.
2. Make sure the lower links and top link on the 3-point hitch arms of your tractor are
the correct size (Cat. I), so that they correspond to the size of the hitch on the
mower you have purchased.
3. P.T.O. Installation:
First, connect the P.T.O. shaft to the tractor. With the shaft in its shortest position,
there should be about a 2" clearance between the end of the gearbox shaft and the
end of the P.T.O. shaft. Should it be necessary to shorten the P.T.O. shaft, shorten
both male and female shafts equally, keeping the protective tube covers 1" shorter
than the steel tubes.
Particular attention should be given to carefully removing all burrs and to clean and
lubricate the steel tubes and protective covers. There must be sufficient telescopic
movement so that the two tubes do not touch the end of the P.T.O. shaft.
It is mot important to carefully raise and lower the mower with the tractor hydraulic
system, making sure that the P.T.O. shaft does not bottom or disengage the telescopic
shaft tubes, otherwise damage may occur.

SAFETY INFORMATION
Page 2
OPERATIONAL SAFETY:
Guards and safety shields are for your
protection. DO NOT operate equipment
unless they are in place.
Always operate tractor PTO (power-take-off)
at recommended RPM (revolutions per
minute).
Disengage tractor PTO and shift into neutral
before attempting to start engine.
Read and observe all safety decals on the
tractor and mower.
NEVER allow anyone within 25' of
machine while it is in operation.
DO NOT stop or start suddenly when
going uphill or downhill. Avoid operation
on steep slopes.
Be alert for holes in terrain and other hidden
hazards. Always drive slowly over rough
ground.
Reduce speed on slopes and in sharp turns
to prevent tipping or loss of control. Be
careful when changing direction on slopes.
Stop mower and tractor immediately upon
striking an obstruction. Turn off engine,
inspect mower and repair any damage before
resuming operation.
Disengage power to mower and stop engine
before dismounting from tractor, before
making any repairs or adjustments,
transporting or unclogging mower.
Take all possible precautions when leaving
tractor unattended: Disengage PTO, lower
mower, shift into neutral, set parking brake,
stop engine and remove key from ignition.
Front tractor weights or front tire ballast
should be used to enhance front end
stability on small tractors.
Check to make sur PTO is properly
connected and that the driveline is correct
to prevent bottoming out or pulling apart
during the full lift range of the hitch.
This implement is designed for a one-man
operation. It is the responsibility of the
tractor operator to see that no one is in the
proximity of the implement when it is
started. DO NOT operate the implement
with another person within 25' of the
implement.
NEVER operate mower with hatch in the
wrong working position.
NEVER run mower with rotorshaft out of
balance.

LUBRICATION
Page 3
Grease all fittings according to the following schedule:
1. ROLLER - Grease at both ends after 4 hours of operation, until excess
grease is visible (Ref. 1).
2. CUTTING SHAFT - Grease at both ends lightly after 8 hours of operation
(Ref. 2). DO NOT over grease.
3. P.T.O. SHAFT - Male and female telescopic tubes and universal joints
should be cleaned and greased monthly, or more frequently in extreme
operating conditions.

Page 4
PRE-OPERATION CHECK
DCheck tightness of all bolts and nuts.
DCheck gearbox oil level (Grade SAE80W-90 gear oil).
DGrease all points, on all GCF mowers.
DP.T.O. (power take-off) speed should not exceed 540 RPM (revolutions per minute).
DCheck correct length of P.T.O. shaft. When fitted, there should be 3 3/4" free travel on
male and female tubing (check in fully raised and fully lowered positions).
DThe recommended cutting height, with the hammer or blade in its lowest position, is
between 2" and 4" (Ref. 1). Basically, the fine height adjustment is achieved with the top
link of the 3-point hitch. For a greater height adjustment, it is necessary to raise or lower
the roller (Ref. 2).
DDrive belt should flex 3/8" (1 cm.) when pushed firmly with the finger.
DIf your tractor does not have a double clutch, or has a hydraulic P.T.O., an overrunning
P.T.O. shaft is required.
DMower should be completely cleaned after use and before storage.

MOWER ADJUSTMENTS
Page 5
FOR VARIOUS TYPES OF MOWING
There is an adjustable rear hatch (Fig. 3) that can be set in one of seven
positions to control the amount of power needed to do the work.
FOR BEST MOWING OPERATION, OPEN REAR HATCH FULLY
TO ALLOW MATERIAL TO EXIT
1. Adjustment of the rear hatch can be made by removing the
two bolts at the side (Fig. 13, ref. 1). Loosen the nut (Fig.
13, ref. 2) until the hatch can be pivoted around bolt (Fig.
13, ref. 3). To fix the hatch in the desired position, align the
hole in the side of the casing of the machine with the appro-
priate hole in the hatch. Insert the bolt and tighten the self-
locking nut (Fig. 13, ref. 1). Tighten the pivot bolt (Fig. 13,
ref. 3) with the self-locking nut (Fig. 13, ref. 2).
2. The rear hatch should be in a completely closed position
(Fig. 4) when used for mulching of prunings, or pulverizing debris.
3. The hatch is used in position (Fig. 5) to allow the grass clippings to escape above
the roller.
4. The hatch should be in a completely open position when the mower is used for grass,
cover crop, weed abatement, vegetables, corn stalk and cotton cutting operations (Fig. 6).
An open hatch enables the clippings to be discharged quickly, thus allowing a faster
mowing speed and lower H.P. requirements.
DANGER: When the hatch is in the fully open position, objects may be thrown
out of the machine. Make sure that NO ONE is in the operation area.

MOWER ADJUSTMENTS
Page 6
1. Various roller
adjustments
3 positions
2. Used for mulching
of prunings
3. Used with rakes to
mulch prunings
4. Used for cutting
grass
5. Used to mulch
cornstalk

ROLLER HEIGHT CONTROL
Page 7
The roller can be adjusted for 2 or 3 cutting heights. By raising the roller, you get a shorter cut,
by lowering it, a longer cut is achieved. You can also fine adjust the cutting height with the top
link arm. By shortening the link arm, your cut is further from the ground.
A suggested cutting height is having the hammer tips about 2" from the ground.
You can control the power needed and the amount of wear on the hammers by this adjustment.
ADJUSTING REAR ROLLER:
To adjust roller, loosen (Fig. 1, ref. 1). Completely remove
(Fig. 1, ref. 2 &3). Align the appropriate hole in the support
bracket with the hole in the deck to achieve roller position
desired.
1. There is also an adjustment that can be made on the roller to control mulch size and
power needed. By moving the roller toward the cutting shaft (Fig. 7), a finer mulch is
produced, requiring less H.P. In this case, we suggest opening the hatch to cut grass,
vegetables, cornstalk, cotton, etc.
2. By moving the roller away from the cutting shaft (Fig. 7), a coarser mulch is produced,
requiring more H.P. In this case, we suggest closing the hatch to mulch prunings.
3. The third position, or furthest from the cutting shaft, is used only to allow room for
rakes on the mower, if needed. Rakes are used when the prunings are laying close to
the ground and have to be drawn out.
4. For more precise work and performance, we recommend spending 5 minutes adjusting
your mower for the job, this can be done according to the previous recommendations.
5. The roller scraper can be removed when cutting grass, because close positioning of the
roller to the cutting shaft permits the hammers to act as a roller cleaning device.

DRIVE BELT TENSION ADJUSTMENT
Page 8
1. Check belt tension before each use (Fig. 8). The tension is correct when you can depress
one belt 1 cm (3/8") between the two pulleys. It is possible for you to insert a tool through
the belt cover (Fig. 9), with mower stopped, to check the tension.
2. To adjust the belt tension, loosen bolts 1, 2, 3 & 4and locknut 6 (Fig. 9). To adjust tension,
move bolt 5. Do not forget to tighten all bolts after correct belt tension is achieved. If a belt
requires replacement, replace all other belts as well.

TROUBLESHOOTING
Page 9
1. Cutting shaft does not rotate properly:
a. Tighten drive belts to correct tension (see page 9).
b. Replace belts if they no longer can be adjusted properly.
2. Mower vibrates:
a. Check for loose or missing hammers or bolts.
b. Check for hammers that are unevenly worn. If one or more hammers is badly worn,
replace all the hammers the first time. Keep the hammers that are in good shape for
future replacement in worn series of hammers. For example: when replacing a worn
hammer, replace it with a hammer of similar shape and weight. This will insure a
balanced and vibration free cutting.
3. If the cutting shaft becomes jammed, reverse the rotation of the shaft to loosen and release
the obstruction.
4. If the hammer mounting ears break off, they must be welded back in their exact position,
otherwise the cutting shaft will be unbalanced.
5. If you have any questions or problems, it is always best to contact your dealer immediately.
6. When ordering spare parts, you must contact your authorized Gearmore dealer for original
replacement parts. When doing so, please include the following information:
a. Model Number
b. Serial Number
SAFETY PRECAUTIONS
1. All adjustments, inspections and repairs must be made with tractor and mower completely
stopped.
a. When the mower is in operation, make sure that there is no one near the flying debris
from the mower, to prevent the possibility of serious injuries.
b. ALWAYS keep hands and feet away from a mower that is in operation.
c. Check that all guards and safety features are in place and in good operating condition.
2. While mowing, take the necessary precautions to insure operator's and others safety.
3. DO NOT make height adjustment using only the top link. This will cause flying debris to
come out the front of the mower and toward the operator. Use the roller adjustment.
We thank you again for your choice of mowers and we remind you that the safety points outlined in
this manual will help you do your work in a safe and efficient manner.

GCF DECK ASSEMBLY
Page 10

GCF DECK ASSEMBLY
Page 11
REF# QTY. PART NO. DESCRIPTION
1 1 11001034 Deck Frame GCF41
1 1 11001035 Deck Frame GCF45
1 1 11001037 Deck Frame GCF53
1 1 11001038 Deck Frame GCF61
1 1 11001039 Deck Frame GCF69
2 1 15008022 Grass Hatch GCF41 (Optional)
2 1 15008023 Grass Hatch GCF45 (Optional)
2 1 15008025 Grass Hatch GCF53 (Optional)
2 1 15008026 Grass Hatch GCF61 (Optional)
2 1 13008019 Grass Hatch GCF69 (Optional)
3 2 96612421 Bolt M14 x 40
4 1 12010002 Belt Guard GCF41-61
4 1 12010003 Belt Guard GCF69 & 79
5 4 97495131 Washer M.15
6 1 13010033 Rubber Gasket
7 1 13010034 Side Plate
8 See Pg. 16 14310004 Deflector Chains From s/n 601100325
9 1 13010008 Shaft, Deflector Chain GCF41-69
9 1 13010012 Shaft, Deflector Chain GCF79
10 1 96612221 Bolt M14 x 30
11 1 97095511 Washer 15 x 28
12 1 97972321 Lock Nut M14
13 3 96605921 Bolt M8 x 40
14 3 97494831 Lock Washer M8
15 7 97971721 Lock Nut M8
16 4 97094911 Washer 8.4 x 16
17 2 96695723 Bolt M14 x 40
18 1 13011009 Parking Stand
19 1 11011001 Bracket
20 1 13011019 Cap, Plastic
21 1 97486611 Screw 6.3 x 19
22 2 96610021 Bolt M12 x 35
23 1 14311010 Pin
24 2 97495031 Lock Washer
25 2 97972031 Lock Nut
26 1 14311010 Lynch Pin

GCF A-FRAME ASSEMBLY
Page 12
REF# QTY. PART NO. DESCRIPTION
1 1 11011001 CPL Sleeve For Small Support
2 1 13011019 Cap F.Small Support QUIA 30 x 30
3 1 13011009 Support Foot
4 1 97486611 Bolt AUTOF. Type C 6.3 x 19 UNI 8117
5 1 96610021 Bolt TE M12 x 035 UNI 5739 8.8 ZN
6 1 97972021 Low Selfblock Nut M12-6S UNI 7474
7 1 14311010 Pin For Support (VS.COD. 33541)
8 1 97495034 Washer ELSP ASA B-27 12.2 x 21.2 x 2.5 N
9 1 97095311 Smooth Washer UNI 6592 12 x 24 x 2.5 ZN
10 1 96612721 Bolt TE M14 x 055 UNI 5739 8.8 ZN
11 1 97972321 Low Selfblock Nut M14-6S UNI 7474
12 1 97093311 Smooth Washer M14 UNI 5714 ZN
13 1 97495134 Washer ELSP ASA B-27 14.2 x 24.1 x 3 N
14 1 11004095 3-Point Linkage (Mod. 99)
14 1 11004102 3-Point Linkage (Mod. 99) I and II Cat
15 1 13004060 Converter Bushing 25 x 2.5 x 50
16 1 19704005 Cat. I Pin 3oPoint +Chain+Pin 19
17 1 13004147 Cat. I & II Pin 1oE 2oPoint '96
17 1 16004020 Cat. I Pin 1oE 2oPoint RIMA 33481
18 1 13004139 Boccola Per P.T.O. Shaft Support
19 1 14404021 P.T.O. Shaft Support
20 1 96609621 Bolt TE M12 x 050 UNI 5737 8.8 ZN
21 1 97495034 Washer ELSP ASA B-27 12.2 x 21.2 x 2.5 N
22 1 97972021 Low. Selfblock Nut M12-6S UNI 7474
23 1 16004014 Pin D.10
24 1 97096211 Smooth Washer UNI 6592 25 x 44 x 4.0 ZN

RAKE HATCH ASSEMBLY
Page 13
REF# QTY. PART NO. DESCRIPTION
1 1 15008032 Rake Hatch GCF41
1 1 15008033 Rake Hatch GCF45
1 1 15008035 Rake Hatch GCF53
1 1 15008036 Rake Hatch GCF61
1 1 13008027 Rake Hatch GCF69
1 1 13008028 Rake Hatch GCF79
2 As Req'd 13008050 Rake 1/2x 1-9/16 x 20
3 As Req'd 91009060 Hair Pin
4 2 96695723 Bolt M14 x 40
5 2 97095511 Washer 15 x 28
6 4 97972321 Lock Nut M14
7 2 97495131 Lock Washer
8 2 96612421 Bolt M14 x 40

ROTOR ASSEMBLY GCF41-61
Page 14
REF# QTY. PART NO. DESCRIPTION
1 1 15002003 Complete Rotor Assy GCF41
1 1 15002004 Complete Rotor Assy GCF45
1 1 15002006 Complete Rotor Assy GCF53
1 1 15002007 Complete Rotor Assy GCF61
2 See Pg. 16 48020001 Flail Knife SMW
3 2 15002103 Rotor Support (Less Ref. 8, 11, & 14)
4 8 96609821 Bolt M12 x 25
5 8 97495031 Lock Washer
6 2 40x62x7 Oil Seal
7 2 22208 Bearing
8 2 98045516 Spacer 40 x 50 x 2.5
9 2 15002044 2 pcs. Metal Seal 40 x 80 x 6
10 2 47280 Circlip 80 x 2.5 Int.
11 2 15002046 Spacer
12 2 15002042 Support Hub
13 2 97036711 Grease Zerk M8
14 1 47140 Circlip 40 x 1.75 R.H. Only Ext.
15 See Pg. 16 13002075 Special Bolt M16 x 1.5 x 90
16 See Pg. 16 13002076 Special Lock Nut M16 x 1.5
17 See Pg. 16 15002039 Hex Ear Flail Knife
18 See Pg. 16 15002038 Ear Flail Knife

ROTOR ASSEMBLY GCF69 & 79
Page 15
REF# QTY. PART NO. DESCRIPTION
1 1 12002001 Complete Rotor Assembly
2 See Pg. 16 48020001 Flail Knife SMW
3 1 13002035 L.H. Rotor Support Assembly
4 1 13002034 R.H. Rotor Support Assembly
5 See Pg. 16 96612221 Bolt M14 x3 0
6 See Pg. 16 97495131 Lock Washer M14
7 1 13002014 Support Hub L.H.
8 2 50x90x10 Oil Seal
9 2 22209 Bearing
10 1 98045816 Spacer 45 x 55 x 2.5
11 2 13002037 2 pcs. Metal Seal 50 x 85 x 6
12 2 47285 Snap Ring 85 x 3 Int.
13 1 96867676 Circlip 45 x 1.75 R.H. Only
14 1 13002013 Support Hub R.H.
15 2 97036711 Grease Zerk
16 See Pg. 16 13002075 Special Bolt M16 x 1.5 x 90
17 See Pg. 16 13002076 Special Lock Nut M16 x 1.5

QUANTITY MATCHING CHART
Page 16
PART NO. DESCRIPTION
MODELS
GCF41 GCF45 GCF53 GCF61 GCF69 GCF79
14310004 Deflector Chain 29 32 40 48 56 64
48020001 Flail Knife 9 12 12 15 18 21
13002075 Bolt, Knife 9 12 12 15 18 21
13002076 Lock Nut, Knife 9 12 12 15 18 21
15002039 Hex Knife Ear 9 12 12 15 18 21
15002038 Knife Ear 9 12 12 15 18 21

ROLLER ASSY (Prior to s/n 701100007)
Page 17
REF# QTY. PART NO. DESCRIPTION
1 1 11005004 Roller Assy. w/Bearings GCF41
1 1 11005005 Roller Assy. w/Bearings GCF45
1 1 11005007 Roller Assy. w/Bearings GCF53
1 1 11005008 Roller Assy. w/Bearings GCF61
1 1 11005009 Roller Assy. w/Bearings GCF69
1 1 13005005 Roller Assy. w/Bearings GCF79
2 1 11005021 Roller w/Bearings GCF41
2 1 11005022 Roller w/Bearings GCF45
2 1 11005024 Roller w/Bearings GCF53
2 1 11005025 Roller w/Bearings GCF61
2 1 11005026 Roller w/Bearings GCF69
2 1 71114200 Roller w/Bearings GCF79
3 1 11005029 Roller GCF41
3 1 11005030 Roller GCF45
3 1 11005032 Roller GCF53
3 1 11005033 Roller GCF61
3 1 11005034 Roller GCF69
3 1 13005019 Roller GCF79
4 2 UC207-35 Bearing
5 2 11005061 Washer 48 x 25 x 5
6 2 96607521 Bolt M10 x 20
7 2 97494931 Lock Washer M10
8 2 11005035 Bearing Support
9 2 11005065 Labyrinth 70/92/5
10 2 11005071 Bushing
11 2 11005037 Roller Support
12 2 97036711 Grease Zerk 8 x 5.8
13 4 96612221 Bolt M14 x 30
14 4 97495131 Lock Washer M15
15 6 96610021 Bolt M12 x 35
16 6 97972021 Lock Nut M12
17 6 97495031 Lock Washer M13

ROLLER ASSY (After s/n 701100007)
Page 18
REF# QTY. PART NO. DESCRIPTION
1 1 11005104 Complete Roller Assembly GCF41
1 1 11005105 Complete Roller Assembly GCF45
1 1 11005107 Complete Roller Assembly GCF53
1 1 11005108 Complete Roller Assembly GCF61
1 1 11005109 Complete Roller Assembly GCF69
1 1 11005110 Complete Roller Assembly GCF79
2 2 13005000 Hub Assembly
3 2 13005163 Bearing Hub Support Weld-on
4 2 13005160 Hub
5 8 96692223 Bolt M10 x 30
6 2 13005165 Spacer
7 As Req'd 11005069 Shim 0.5 mm
7 As Req'd 11005068 Shim 1.0 mm
8 2 13005143 Axle
9 2 58X72X8 Oil Seal
10 2 30205 Bearing
11 8 97494934 Washer D.10
12 2 32207 Bearing
13 2 13005088 Nut M25 x 1.5
14 2 13005162 Dust Cap
15 2 11005037 Roller Support
16 8 97495031 Washer
17 8 97972021 Lock Nut M12
18 8 96610021 Bolt M12 x 30
19 4 96612221 Bolt M14 x 30
20 4 97495131 Washer M15