Case IH GCX19 Grass Collector for DX18E & DX24E Tractors With MWX154S or MWX160S Mower Decks Operator’s Manual Instant Download (Publication No.87041311)

GCX19 Grass Collector For DX18E & DX24E Tractors With MWX154S or MWX160S Mower Decks OPERATOR S MANUAL 87041311 Rev. 1/04

INTRODUCTION IDENTIFICATION NUMBERS TO THE OWNER & OPERATOR The serial number plate, pictured below, is located on the right hand side of the blower fan housing. Record the numbers from it on the pictured plate below. Always refer to this information when requesting repair parts or dealer service. Congratulations on your decision to purchase a Case grass catcher. We recommend you read this manual before operating your new GCX19 three bag grass catcher. Your grass catcher has been designed to give many years of satisfactory service. Successful operation and long life depends on proper maintenance and correct operating technique. This operator s manual has been printed to provide you with safe operating techniques, proper maintenance procedures, correct unit assembly, and parts identifica- tion on your grass catcher. Please read this manual carefully, following all instructions. Keep this manual handy for future reference. All references to right and left, forward or rearward, used in this manual refer to that direction when seated on the tractor facing forward. Contact your Case dealer for authorized service parts. Substitute repair parts will void the product warranty, and will not meet the standards required for safe operation. If any assistance be required in understanding any sec- tion of this manual, contact your Case dealer. -1-

TABLE OF CONTENTS INTRODUCTION To the Owner and Operator....................................................................... Identification Numbers............................................................................... 1 1 SAFETY PRECAUTIONS Before Operation....................................................................................... During Operation........................................................................................ Maintenance............................................................................................... Transporting & Storage.............................................................................. 4 4 4 4 OPERATING INSTRUCTIONS General Bagging Information..................................................................... Clearing Plugged Ducts............................................................................. Emptying the Grass Bags.......................................................................... MAINTENANCE SECTION Scheduled Lubrication............................................................................... Cleaning Procedures................................................................................. Replacing the Grass Bag........................................................................... BOLT TORQUE CHART........................................................................................ Metric Hardware......................................................................................... Standard Hardware.................................................................................... 5 6 6 7 7 7 8 9 10 ASSEMBLY INSTRUCTIONS Mower Preparation..................................................................................... Tractor Preparation.................................................................................... Blower Installation...................................................................................... Bag Frame Installation............................................................................... Cover Assembly & Installation................................................................... Grass Bag Assembly.................................................................................. Chute and Boot Installation........................................................................ 19 11 12 13 17 20 21 -2-

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TABLE OF CONTENTS SPECIFICATIONS......................................................................................... 22 PARTS ILLUSTRATIONS Blower Drive Assembly.............................................................................. Plastic Lid Assembly.................................................................................. Grass Bag and Frame Components.......................................................... Driveline Components............................................................................... Gearbox Components............................................................................... Blower Components.................................................................................. Boot Components...................................................................................... 24 26 28 30 32 34 36 SAFETY DECALS......................................................................................... 38 39 SAFETY DECAL LOCATIONS...................................................................... PRE DELIVERY CHECKLIST....................................................................... 40 -3-

SAFETY PRECAUTIONS A careful operator is the best operator. Most accidents can be avoided by observing certain safety precautions. Read and understand these precautions before using the grass collector. This equipment should be operated by those who have been trained in its safe use. BEFORE OPERATION MAINTENANCE Read and understand all safety and instruction labels on this attachment, and the safety precautions found in the tractor, mower and grass collector operator s manuals, BEFORE operation. Keep the tractor, mower and grass collector clean. Dirt and grass buildup can cause fires that may lead to serious personal injury. Immediately replace any safety label that is damaged, lost or otherwise becomes illegible. Never allow anyone to operate the mower and grass collector until they are thoroughly familiar with basic tractor, mower and grass collector operation. To avoid injury, do not adjust, unclog or service this mower or grass collector with the tractor engine running. Disengage the PTO, place ALL CONTROLS IN NEUTRAL, set the parking brake, shut off the engine, remove the key, and make sure ROTATING MOWER AND BLOWER PARTS ARE STOPPED, before leaving the operator s seat. Always make sure all grass collector components are properly installed and securely fastened BEFORE mowing. Carefully check the area to be mowed, and remove any foreign objects, such as rocks, cans, toys, etc., that may cause personal or bystander injury, or equipment and property damage. Always wear eye protection when cleaning or servicing the grass collector. Do not work under any part of the tractor, mower, or grass collector, unless it is securely supported by safety stands. DURING OPERATION Hearing protection is recommended when operating the grass collector. Make sure all shields and guards are securely in place following all cleaning, or repair work. Do not allow passengers on the tractor, mower or grass collector at any time. The operator MUST sit in the tractor seat. The cloth grass bags are subject to wear and deterioration. Check them often. Use genuine replacement bags from Case. Inspect the mower and grass collector after striking any foreign object. This will assure that all mower and grass collector components are secure and not damaged. TRANSPORTING & STORAGE Be alert for all other traffic when driving on public roads or highways. Mow and bag only during daylight hours, or when the area is well lit. Moisture content in most grasses can damage mower and grass collector components. Also, dry grass and leaves left in the bags can be a fire hazard. Always make sure the bags are completely empty and the blower and chutes are fully cleaned before storage. All blower cleaning or service MUST be performed with the BLOWER REMOVED from the mower. WHEN YOU SEE THIS SYMBOL IT MEANS: ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! -4-

OPERATING INSTRUCTIONS GENERAL BAGGING INFORMATION CAUTION: ALWAYS MAKE SURE ALL GRASS COLLECTOR COMPONENTS ARE PROPERLY INSTALLED AND SECURELY FASTENED BEFORE MOWING. CAUTION: HEARING PROTECTION IS RECOMMENDED WHEN OPERATING THE GRASS COLLECTOR. Always mow at full engine speed. This will insure the most airflow into the grass bags. If the tractor engine lugs down while mowing, reduce the tractor ground speed. NOTE: Plastic lawn and leaf bags, 33 gallon size, can be used inside the cloth bags. Be sure to leave enough plastic bag hanging over the frame so the plastic bags can be twist tied before emptying. Grass and leaf collecting performance depends on air flow into the bags. Mow when the grass is dry. Chute and blower plugging can be more frequent in wet conditions. WARNING: INSPECT THE MOWER AND GRASS COLLECTOR AFTER STRIKING ANY FOREIGN OBJECT. THIS WILL ASSURE THAT ALL MOWER AND GRASS COLLECTOR PARTS ARE SECURE AND NOT DAMAGED. Tall grass clippings may also plug the blower and chute. Mow at the highest height of cut and re-mow the entire area at the final desired height to avoid plugging. Thoroughly clean the mower deck, the blower housing and chute, and the cover screen and tractor engine radiator screens, after each mowing. Grass buildup, left to dry, will be very difficult to remove, and if not removed, will affect future mowing and bagging performance. WARNING: DO NOT ALLOW PASSENGERS ON THE TRACTOR, MOWER, OR GRASS COLLECTOR AT ANY TIME. THE OPERA- TOR MUST SIT IN THE TRACTOR SEAT. NEVER mow with the mower raised in the transport position. When transporting the mower and grass collector, ALWAYS disengage the tractor PTO. WARNING: ALL BLOWER CLEANING OR SERVICE MUST BE PERFORMED WITH THE BLOWER REMOVED FROM THE MOWER. Mow up and down slopes, not across. Avoid all grass collector operation on steep slopes. Stay alert for holes or bumps that could affect stability of the tractor, mower and grass collector. -5-

OPERATING INSTRUCTIONS - Continued CLEARING PLUGGED DUCTS EMPTYING GRASS BAGS WARNING: TO AVOID INJURY, DO NOT AD- JUST, UNCLOG OR SERVICE THE MOWER OR GRASS COLLECTOR WITH THE TRAC- TOR ENGINE RUNNING. DISENGAGE THE PTO, PLACE ALL CONTROLS IN NEUTRAL, SET THE PARKING BRAKE, SHUT OFF THE ENGINE, REMOVE THE KEY, AND MAKE SURE ALL ROTATING PARTS ARE STOPPED BEFORE LEAVING THE OPERA- TOR S SEAT. Remove the cloth bag and frame by lifting and sliding rearward. Grasp the loop on the bottom of the bag, turn it upside down and empty collected debris, or the twist tied plastics bags. Repeat on the other bags. 1. Release the chute hook band, remove the chute and lay it aside. Release both cover hook bands and raise the cover, allowing the latch linkage to hold the cover open. Dump the chute into the grass bags and lay it aside. 2. Remove the wing nut and washer and remove the tethered guard that covers the gearbox lower pulley. Reinstall all grass bags, line with plastic bags if desired, close the cover and fasten both hook bands. 3. Remove the front handle pin and pivot the blower housing rearward. This will allow the drive belt to be easily disconnected from the bottom of the gearbox pulley. 4. Raise the blower out of its rear bracket and remove the blower. Dump and clear the fan and chute outlet area of clippings. 5. Empty the grass bags, close the cover, and reinstall the blower housing and chute by reversing steps 1 through 4 above. CAUTION: ALWAYS MAKE SURE ALL GRASS COLLECTOR COMPONENTS ARE PROPERLY INSTALLED AND SECURELY FASTENED BEFORE MOWING. -6-

MAINTENANCE SECTION SCHEDULED LUBRICATION The blower should be cleaned every time grass buildup is removed from the bottom of the mower deck. This should be accomplished daily if the grasses mowed were unusually lush or wet. The gearbox oil needs to be changed on scheduled intervals. The initial gearbox oil change needs to be completed after 100 hours of use. It is recommended that gearbox oil be changed at 200 hour intervals thereafter. Oil capacity for gearbox when changing oil is 5 oz. of AGMA 5EP oil (Amoco Permagear EP220 or equivalent). For gearbox replacement or repairs refer to the parts breakdown in the PARTS LIST section of this manual. Following any water washing, all grass collector components should be reassembled on the tractor and mower. Start the tractor, mower and blower and run at low idle for 1 to 2 minutes, allowing air flow to dry the wet components. WARNING: MAKE SURE ALL SHIELDS AND GUARDS ARE SECURELY IN PLACE FOLLOWING ALL SERVICE, CLEANING, OR REPAIR WORK. The driveline should also be greased on scheduled intervals. It is recommended that driveline U-joints be greased every 25 hours of use. Refer to PARTS LIST section of this manual for repair parts and assembly diagram. REPLACING THE GRASS BAG CAUTION: THE CLOTH GRASS BAGS ARE SUBJECT TO WEAR AND DETERIORATION. CHECK THEM OFTEN. USE ONLY GENUINE REPLACEMENT BAGS FROM Case. CLEANING PROCEDURES WARNING: ALWAYS WEAR SAFETY GLASSES OR OTHER EYE PROTECTION WHEN SERVICING OR CLEANING THE GRASS COLLECTOR. If the grass bags are unusually dirty or grass stained, they should be washed with a mild detergent and water and hung up to dry. Do not attempt to dry the cloth bags in a clothes dryer! WARNING: DO NOT WORK UNDER ANY PART OF THE TRACTOR, MOWER, OR GRASS COLLECTOR, UNLESS IT IS SECURELY SUPPORTED BY SAFETY STANDS. See page 20 for bag installation information. Bag removal is a reversal of those instructions. The grass collector should be washed regularly using a mixture of mild detergent and water. Use a soft rag on the see through chute so it does not get scratched. Wash grass buildup from the inside of the cover screen, and other chute parts, with a soft bristled brush. WARNING: ALL BLOWER CLEANING OR SERVICE MUST BE PERFORMED WITH THE BLOWER REMOVED FROM THE MOWER. -7-

BOLT TORQUE CHART STANDARD FASTENER TORQUES Mounting bolts and fasteners may work loose during operation due to vibration or stress. A visual check of the complete tractor/mower/grass catcher should be made daily. All fasteners should be checked for correct retention torque weekly, and more often if the unit is being operated in rough areas. All locally procured fastening hardware should be equivalent to those which are called out in the parts pages in this manual beginning on page 24. Use the charts on pages 9-10 for general torque specifications for Grade 5 and Grade 8 standard and metric fasteners. NOTE: All standard torque specifications apply to plated or oiled fasteners. When dry or non-plated fasteners are used, increase specified torque values by approximately 20%. -8-

BOLT TORQUE CHART - Continued -9-

BOLT TORQUE CHART - Continued -10-

ASSEMBLY INSTRUCTIONS NOTE: Assembly of grasscatcher will take approxi- mately 2 hours. Make sure the tractor and mower are completely set up and operational before grass collector installation. Locate the tractor and mower near where the grass col- lector is to be installed. The grass collector MUST be installed on a firm and level surface. Open and remove the crating from around the grass collector. Remove all cartoned components and hardware bags from the container and check the contents against their packing lists to insure they are complete. MOWER PREPARATION IMPORTANT: A MWX154S or a MWX160S mower deck must be installed prior to installation of the grass- catcher. 54" Hole Location 60" Hole Location 1. Remove and discard the discharge shield spring and the hardware attaching the discharge shield and the discharge shield stop to the deck. 2. Insert the boot baffle weldment under the deck as shown. Insert a single bolt through the boot baffle weldment and through the top of the deck shell. Secure in place with a nut. It is necessary to mark the second hole location with a metal punch. Re- move the boot baffle and drill a .406 hole through the deck. Drill .406 Hole Here 3. Insert the boot baffle weldment back under the deck and secure it in place by inserting a 3/8-16 x 3/4 bolt through the boot baffle weldment and through the hole drilled in step 2. Secure it in place with a 3/8-16 locknut. 4. Reinstall the discharge shield by adding the boot mount weldment and inserting four M10-1.25 x 35 bolts up through the deck and through the boot mount weldment. Secure with M10 flatwashers, M10 lockwashers, and M10 hex nuts. Reconnect the spring removed from step 1. -11-

ASSEMBLY INSTRUCTIONS - Continued TRACTOR PREPARATION 1. With tractor engine shut off and tractor in park, lower the tractor three point. 2. Remove snap pin and top link pin from tractor center link. Remove center link from tractor. Reinstall top link pin and snap pin in one end of the center link. Lay center link to the side as it will be installed in its storage position in later assembly steps. 3. Disconnect the lift arm links from the tractor by removing the lynch pin holding them in place. It is not necessary to disconnect the links from the tractor three point lift arms. 4. Tractor lift arms should be hanging freely. Lift arm sway linkages may need to be loosened at this time so that gearbox blower housing can be mounted to tractor lift arms. -12-

ASSEMBLY INSTRUCTIONS - Continued BLOWER INSTALLATION 1. Remove the single 5/16-18 x 5/8 flange head bolt (A) from the Gearbox Mount Assembly (D). Discard the bolt. F C B 2. Mount Top Link Support Weldment (E) to the Gear- box Mount Assembly (D) using four 5/16-18 x 1 flange head bolts (B). Do not tighten at this time. E 3. Before installing hitch pins (C) make sure that out- side nut is backed all the way out. Install the 7/8 Hitch Pins, with pins pointing outward, through ears of the Gearbox Mount Assembly and through straps of Top Link Support Weldment (F). Retain pins with the lockwashers and nuts provided. Tighten pins and four 5/16-18 x 1 flange head bolts at this time. Pins should be tightened so that the cross holes are vertical. A D 4. Attach stand legs to the Blower Drive Assembly by sliding the stand legs up through the bushings on the blower drive assembly. With legs in the lowered position and facing rearward, install the 1/2 x 2 1/2 clevis pins through the bushings and retain with wire rings. NOTE: Bolt tightening torques for all fasteners on the grass catcher are found on page 17 of this manual. -13-

ASSEMBLY INSTRUCTIONS - Continued BLOWER INSTALLATION - Continued 5. Install the bored yoke end of the driveline onto the gearbox input shaft. Using a 90 snap-ring plier, install the external snap ring. Align the driveline hole with the gearbox input shaft hole and install the 1/4-20 x 1 1/2 shear bolt and retain with a 1/4-20 locknut. SHEAR BOLT SNAP RING WARNING: Make sure the snap ring is in place. As a missing snap ring will allow the driveline to come off when the shear bolt breaks, which could severely damage mower and tractor components or could cause seri- ous injury. 6. Mount the Blower Drive Assembly to the tractor lift arms, installing hitch pins through the ball sockets of the tractor lift arms. Retain pins to tractor lift arms using lynch pins provided. Align the Top Link Support with the center link ears of the tractor, and install 3/4 x 4 1/2 top link pin provided with grass catcher. Install pin from left to right. -14-

ASSEMBLY INSTRUCTIONS - Continued BLOWER INSTALLATION - Continued 7. Install the driveline to the tractor PTO shaft by pulling back on the lock collar as it is installed. Release the lock collar and pull on the shaft to make sure it is locked to the tractor PTO. TRACTOR PTO PULL BACK COLLAR 8. Pin will protrude through ears. Tractor center link is to be slid over the remainder of pin and hooked in the tractor center link hook. Retain center link to pin using the snap pin provided. NOTE: This is a storage position only. Tractor center link is not to be used in this position. -15-

ASSEMBLY INSTRUCTIONS - Continued BLOWER INSTALLATION - Continued 9. Raise the stand legs up in the transport position, rotate leg 90 inward and reinstall 1/2 x 2 1/2 clevis pins and retain with wire rings. NOTE: Be sure to raise stand legs in transport position before moving tractor. Damage to stand legs or possibly grass catcher could occur. 10. Level the blower drive assembly by loosening or tightening the lift arm sway linkages. After adjusting linkage as needed to level the blower drive assembly, tighten jam nut on linkage. EQUAL DISTANCE -16-

ASSEMBLY INSTRUCTIONS - Continued BAG FRAME INSTALLATION 1. Place the vertical mainframe onto the blower drive assembly and retain with four 3/8-16 x 1 flange head bolts. Tighten bolts to specified torque. IMPORTANT: DO NOT tighten any fasteners until the entire bag frame is installed. 2. Install the bag support frame to the rear edge of the vertical mainframe with four 5/16-18 x 5/8 flange head bolts, and 5/16-18 flange lock nuts. 3. Fasten the top of the frame brace rods to the bag support frame with two 5/16-18 x 5/8 flange head bolts and 5/16-18 flange lock nuts. Fasten the bot- tom of the rods to the mainframe with two 5/16-18 x 5/8 flange head bolts and 5/16-18 flange lock nuts. 4. Tighten all loose frame fasteners. -17-

ASSEMBLY INSTRUCTIONS - Continued BAG FRAME INSTALLATION - Continued 5. Install the catch all plate by inserting a 1/2-13 x 1 bolt through the catch all bracket and through the catch all plate. Secure with a 1/2-13 crown lock- nut. Do not overtighten. The bolts should be tight enough to secure the bracket, but not so tight as to restrict movement. 6. The tractor lift links can now be installed in their storage positions. Insert the two 3/4 x 2 3/4 2 1/2 clevis pins through the catch all plate and through the tractor lift links. Secure with two 1/8 x 2 1/2 hair pins. The adjustable lift link should be stored on the right upright, the solid lift link should be stored on the left upright. See figure to the right. -18-

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ASSEMBLY INSTRUCTIONS - Continued COVER ASSEMBLY & INSTALLATION 1. Install the cover over the bag support frame and engage the hinge pin with the brackets on the mainframe. Retain with two 5/16 flatwashers and 1/8 x 1 cotter pins. 2. Raise the cover, allowing access to the inside and hold in the up position with a block, safety wire, or a small length of rope. 3. Assemble the latch links as shown, with three 5/16 x 1/2 clevis pins and 1/8 x 1 cotter pins. 4. Remove the means of holding the cover open and allow this latch to support the cover. -19-

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