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BUSH HOG
ZERO TU RN
MO WERS
®
Operator’s Manual
ASSEMBLY ● OPERATION ● MAINTENANCE
199 $4.00
99221
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CONGRATULATIONS!
You have invested in the best implement of its type on the market today.
The care you give your Bush Hog implement will greatly determine your satisfaction
with its performance and its service life. We urge a careful study of this manual to provide
you with a thorough understanding of your new implement before operating, as well as
suggestions for operation and maintenance.
If your manual should become lost or destroyed, Bush Hog will be glad to provide you with
a new copy. Order from Bush Hog, P. O. Box 1039, Selma, Alabama 36702-1039.
As an authorized Bush Hog dealer, we stock genuine Bush Hog parts which are
manufactured with the same precision and skill as our original equipment. Our trained
service personnel are well informed on methods required to service Bush Hog equipment,
and are ready and able to help you.
Should you require additional information or assistance, please contact us.
YOUR AUTHORIZED
BUSH HOG DEALER
BECAUSE BUSH HOG MAINTAINS AN ONGOING
PROGRAM OF PRODUCT IMPROVEMENT, WE
RESERVE THE RIGHT TO MAKE IMPROVEMENTS IN
DESIGN OR CHANGES IN SPECIFICATIONS WITHOUT INCURRING ANY OBLIGATION TO INSTALL
THEM ON UNITS PREVIOUSLY SOLD.
BECAUSE OF THE POSSIBILITY THAT SOME
PHOTOGRAPHS IN THIS MANUAL WERE TAKEN OF
PROTOTYPE MODELS, PRODUCTION MODELS MAY
VARY IN SOME DETAIL. IN ADDITION, SOME
PHOTOGRAPHS MAY SHOW SHIELDS REMOVED
FOR PURPOSES OF CLARITY. NEVER OPERATE
THIS IMPLEMENT WITHOUT ALL SHIELDS IN PLACE.
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ZERO TURN SERIES
TABLE OF CONTENTS
SECTION PAGE
Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . 2
Dealer Preparation Check List . . . . . . . . . 3
Safety Precautions. . . . . . . . . . . . . . . . . . 4
Federal Laws and Regulations. . . . . . . . . 6
I INTRODUCTION AND DESCRIPTION . . 7
Introduction. . . . . . . . . . . . . . . . . . . . . . . . 7
Description . . . . . . . . . . . . . . . . . . . . . . . . 7
Specifications. . . . . . . . . . . . . . . . . . . . . . 8
II OPERATION. . . . . . . . . . . . . . . . . . . . . . . 9
General Safety . . . . . . . . . . . . . . . . . . . . . 9
Pre-Operation Checklist. . . . . . . . . . . . . 19
Operation . . . . . . . . . . . . . . . . . . . . . . . . . 9
Mowing Recommendations . . . . . . . . . . 11
Mower Deck Tilt-Up Procedure . . . . . . . 11
Lowering & Reattaching Deck . . . . . . . . 11
III MAINTENANCE. . . . . . . . . . . . . . . . . . . 13
Maintenance Schedule. . . . . . . . . . . . . . 13
SECTION PAGE
Engine . . . . . . . . . . . . . . . . . . . . . . . . . .14
Battery . . . . . . . . . . . . . . . . . . . . . . . . . .14
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Mower Blades . . . . . . . . . . . . . . . . . . . . .14
Checking Gearbox Fluid . . . . . . . . . . . . .14
Changing Gearbox Fluid . . . . . . . . . . . .14
Neutral Adjustment . . . . . . . . . . . . . . . . .15
Drive Adjustments . . . . . . . . . . . . . . . . .15
Test Drive Operations . . . . . . . . . . . . . . .15
Leveling The Deck . . . . . . . . . . . . . . . . .15
Deck Belt Adjustment . . . . . . . . . . . . . .16
Deck Belt Replacement . . . . . . . . . . . . .16
Start Up Maintenance . . . . . . . . . . . . . .18
Troubleshooting . . . . . . . . . . . . . . . . . . .19
IV ASSEMBLY . . . . . . . . . . . . . . . . . . . . . .20
Wiring Schematics . . . . . . . . . . . . . . . . .23
Safety Decals . . . . . . . . . . . . . . . . . . . . .25
Torque Specifications . . . . . . . . . . . . . . .27
RETAIL CUSTOMER’S RESPONSIBILITY
UNDER THE BUSH HOG WARRANTY
It is the Retail Customer and/or Operator’s responsibility to read the Operator’s Manual, to
operate, lubricate, maintain and store the product in accordance with all instructions and
safety procedures. Failure of the operator to read the Operator’s Manual is a misuse of this
equipment.
It is the Retail Customer and/or Operator’s responsibility to inspect the product and to have
any part(s) repaired or replaced when continued operation would cause damage or excessive wear to other parts or cause a safety hazard.
It is the Retail Customer’s responsibility to deliver the product to the authorized Bush Hog
Dealer, from whom he purchased it, for service or replacement of defective parts which are
covered by warranty. Repairs to be submitted for warranty consideration must be made within forty-five (45) days of failure.
It is the Retail Customer’s responsibility for any cost incurred by the Dealer for traveling to or
hauling of the product for the purpose of performing a warranty obligation or inspection.
DANGER: Indicates an imminently
hazardous situation which, if not avoided, will result in death or serious injury.
This signal word is to be limited to the
most extreme situations.
WARNING: Indicates a potentially
hazardous situation which, if not
avoided, could result in death or
serious injury.
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CAUTION: Indicates a potentially hazardous situation which, if not avoided,
may result in minor or moderate injury. It
may also be used to alert against
unsafe practices.
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®
BUSH HOG
ZERO TURN MOWER LIMITED WARRANTY
✯✯✯✯✯✯✯✯✯✯✯✯✯✯✯✯✯✯✯✯✯✯✯✯✯✯✯✯✯✯✯
Bush Hog warrants to the original purchaser of any new Bush Hog equipment, purchased from an
authorized Bush Hog dealer, that the equipment be free from defects in material and workmanship for a period
of two (2) years from date of retail sale. The obligation of Bush Hog to the purchaser under this warranty is limited to the repair or replacement of defective parts.
Replacement or repair parts installed in the equipment covered by this limited warranty are warranted
for ninety (90) days from the date of purchase of such part or to the expiration of the applicable new equipment warranty period, whichever occurs later. Warranted parts shall be provided at no cost to the user at an
authorized Bush Hog dealer during regular working hours. Bush Hog reserves the right to inspect any equipment or parts which are claimed to have been defective in material or workmanship.
DISCLAIMER OF IMPLIED WARRANTIES & CONSEQUENTIAL DAMAGES
Bush Hog’s obligation under this limited warranty, to the extent allowed by law, is in lieu of all war-
ranties, implied or expressed, INCLUDING IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS
FOR A PARTICULAR PURPOSE and any liability for incidental and consequential damages with respect to
the sale or use of the items warranted. Such incidental and consequential damages shall include but not be
limited to: transportation charges other than normal freight charges; cost of installation other than cost
approved by Bush Hog; duty; taxes; charges for normal service or adjustment; loss of crops or any other loss of
income; rental of substitute equipment, expenses due to loss, damage, detention or delay in the delivery of
equipment or parts resulting from acts beyond the control of Bush Hog.
THIS LIMITED WARRANTY SHALL NOT APPLY:
1. To transportation to and from dealership or service calls made by dealers, ie, driving time, towing,
pickup and delivery.
2. To vendor items which carry their own warranties, such as engines, batteries, tires, and tubes.
3. If the unit has been subjected to misapplication, abuse, misuse, negligence, fire or other accident.
4. If parts not made or supplied by Bush Hog have been used in connection with the unit, if, in the sole judge-
ment of Bush Hog such use affects its performance, stability or reliability.
5. If the unit has been altered or repaired outside of an authorized Bush Hog dealership in a manner
which, in the sole judgement of Bush Hog, affects its performance, stability or reliability.
6. To normal maintenance service and normal replacement items such as gearbox lubricant, hydraulic fluid,
worn blades, or to normal deterioration of such things as belts and exterior finish due to use or
exposure.
7. To expendable or wear items such as teeth, chains, sprockets, belts, springs and any other items that in the
company’s sole judgement is a wear item.
NO EMPLOYEE OR REPRESENTATIVE OF BUSH HOG IS AUTHORIZED TO CHANGE THIS LIMITED WARRANTY IN ANY WAY OR GRANT ANY OTHER WARRANTY UNLESS SUCH CHANGE IS MADE
IN WRITING AND SIGNED BY BUSH HOG’S SERVICE MANAGER, POST OFFICE BOX 1039, SELMA,
ALABAMA 36702-1039.
✯✯✯✯✯✯✯✯✯✯✯✯✯✯✯✯✯✯✯✯✯✯✯✯✯✯✯✯✯✯✯
Record the model number, serial number and date
purchased. This information will be helpful to your
dealer if parts or service are required.
MAKE CERTAIN THE WARRANTY REGISTRATION
CARD HAS BEEN FILED WITH BUSH HOG/
SELMA, ALABAMA
MODEL NUMBER
SERIAL NUMBER
DATE OF RETAIL SALE
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DEALER PREPARATION CHECK LIST
ZERO TURN
BEFORE DELIVERING MACHINE — The following check list should be completed.
Use the Operator’s Manual as a guide.
❒ 1. Engine has been serviced.
❒ 2. Battery fluid level is checked.
❒ 3. Low oil pressure warning buzzer checked for operation.
❒ 4. Kill switches checked for operation.
❒ 5. Assembly completed.
❒ 6. Gearbox filled with oil.
❒ 7. All fittings lubricated.
❒ 8. Hydraulic Reservoir filled with oil.
❒ 9. All shields in place and in good condition.
❒ 10. All fasteners torqued to specifications given in Torque Chart.
❒ 11. All decals in place and readable. (See decal page.)
❒ 12. Overall condition good (i.e. paint, welds)
❒ 13. Parking brake checked and adjusted, if necessary.
❒ 14. Steering checked and adjusted, if necessary.
❒ 15. Check tire pressure.
❒ 16. Operators manual has been delivered to owner and he has been instructed
on the safe and proper use of the cutter.
Dealer’s Signature
Purchaser’s Signature
THIS CHECKLIST T
It is the responsibility of the dealer to complete the procedures listed
above before delivery of this implement to the customer.
O REMAIN IN OWNER’S MANUAL
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IMPORTANT SAFETY PRECAUTIONS
This symbol is used to call attention to safety precautions that should be followed by
the operator to avoid accidents. When you
see this symbol, carefully read the message
that follows and heed its advice. Failure to
comply with safety precautions could result
in serious bodily injury.
In addition to the design and configuration of equipment, hazard control and accident prevention are dependent upon the awareness, concern, prudence and proper training of personnel in the operation, transport,
maintenance and storage of equipment. Lack of attention to safety can result in accident, personal injury,
reduction of efficiency and worst of all—loss of life. Watch for safety hazards and correct deficiencies promptly. Use the following safety precautions as a general guide to safe operations when using this machine.
Additional safety precautions are used throughout this manual for specific operating and maintenance procedures. Read this manual and review the safety precautions often until you know the limitations.
ACCIDENT PATTERNS TO AVOID
1. CONTACT WITH THE ROTATING BLADE - This accident usually happens when the operator is clear
ing the discharge chute of grass, (especially when the grass is wet), or when the operator adjusts the
machine without turning it off and waiting for the blades to completely stop.
2. PROPELLED OBJECTS - Sticks, rocks, wires, and other objects can be propelled out through the discharge chute or from under the mower housing. Bystanders are particularly vulnerable.
3. GRASS CATCHER OR GUARD - The mower shall not be operated without either the entire grass catcher or guard in place.
4. OVERTURNING - This happens when riding mowers are used on steep slopes, embankments or hills.
The operator in these cases can come in contact with blades or sustain injuries during a fall.
5. MOWER RUNNING OVER THE VICTIM - This usually happens when a riding mower is driven in reverse.
The accident victims are most often young children whom, unseen by the operator of the mower, were in
the area being mowed.
WE SHARE YOUR DESIRE TO PROTECT YOURSELF, YOUR FAMILY, YOUR FRIEND AND YOUR
NEIGHBORS FROM ACCIDENTAL INJURY. OBSERVING AND ENFORCING THE FOLLOWING GUIDE
LINES WILL HELP TO INSURE THE SAFETY OF EVERYONE.
SAFETY INSTRUCTIONS AND RECOMMENDATIONS
1. PEOPLE WHO OPERATE, SERVICE, OR ARE OTHERWISE ASSOCIATED with the Zero Turning
Radius Mower should be trained in its proper use and warned of its dangers. Before operating, adjusting,
or servicing the Zero Turning Radius Mower they should read and understand this entire manual and the
owner’s engine manual.
2. AVOID CONTACT WITH MOVING PARTS. Keep hands and feet from under mowing deck and away
from blades at all times. Turn engine (motor) off if you must unclog the chute.
3. AVOID HILLS AND SLOPES. Use extreme caution when mowing up or down slopes. NEVER mow
across the face of a slope. If a slope must be ascended, drive up the slope; back down when descending. Reduce speed and use caution to start, stop and maneuver. To prevent loss of control on a slope,
avoid sharp turns, sudden changes in direction, and sudden stops and starts.
4. DISENGAGE POWER TO MOWER BEFORE BACKING UP. Do not mow in reverse unless absolutely
necessary and then only after turning around and observing the entire area behind the mower. Go slowly.
Most “running over victim” accidents occur in reverse.
5. BEGINNING OPERATORS SHOULD LEARN HOW TO STEER the Zero Turning Radius Mower before
attempting to mow. Start with slow engine speed and drive without the blades engaged in open area until
comfortable with the machine.
6. KNOW HOW TO STOP QUICKLY. Know the location and operation of every control, especially how to brake and
how to disengage the mower blades.
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SAFETY CONTINUED
7. DO NOT MOVE THE CONTROL LEVERS from forward position to reverse position rapidly. The speed
and/or direction of travel is affected instantly by movement of the Control Levers.
8. DO NOT ALLOW CHILDREN TO OPERATE MOWER. Do not allow others who have not had instructions to operate mower.
9. ALWAYS TURN ENGINE OFF AND REMOVE KEY before leaving mower to prevent children and
inexperienced operators from starting the engine. Never leave the mower unattended with engine run
ning. Always wait for all moving parts and all sounds to stop before leaving operator’s seat. Always set
the parking brake on an unattended mower.
10. WEAR STURDY, ROUGH-SOLED WORK SHOES AND CLOSE-FITTING SLACKS AND SHIRTS.
Never operate mower in bare feet, sandals or sneakers.
11. WEAR PERSONAL PROTECTIVE EQUIPMENT such as, but not limitied to, protection for eyes, ears, feet, hands
and head when operating or repairing equipment. Do not wear loose clothing or jewelry that may catch on equipment moving parts.
12. NEVER CARRY PASSENGERS.
13. KNOW THE AREA YOU ARE TO MOW. Watch for hidden dangers such as rocks, roots, sticks, holes,
bumps, and drop-offs, etc. Before mowing, pick up all debris in area to be mowed. Sharp and hard
objects can be propelled at a high speed and can act like shrapnel. Walk through tall grass BEFORE
MOWING to make sure there are no hidden dangers. Mow higher than desired in tall grass to expose
any hidden objects and/or obstacles, clean the area, and then mow to the desired height.
14. BE SURE THE AREA IS CLEAR of other people before mowing. Stop machine if anyone enters the area.
15. NEVER REFUEL A MOWER INDOORS. Allow the engine time to cool before refueling. Unseen vapors may be
ignited by a spark. Always clean up spilled gasoline. Never run the engine indoors in a garage
or any other closed building. Allow engine to cool before storing in any enclosure. The engine exhaust
and gasoline fumes are dangerous.
16. NEVER REMOVE THE FUEL CAP or add gasoline to a running or hot engine or an
engine that has not been allowed to cool for several minutes after running. Always make sure the gas
cap is in place.
17. DO NOT SMOKE AROUND THE MOWER or the gasoline storage container. Gasoline fumes can easily ignite.
18. KEEP GASOLINE IN A WELL-VENTILATED AREA away from your living quarters and in tightly
capped safety cans. Never store mower with gasoline in the tank inside a building where fumes may
reach open flame or spark.
19. DISENGAGE BLADE, STOP ENGINE, ENGAGE PARKING BRAKE AND REMOVE IGNITION KEY before any servicing. Be sure all moving parts and all sounds have stopped. Let engine cool and disconnect the spark plugs so the
engine cannot start by accident. A SLIGHT ROTATION OF THE BLADES COULD START THE ENGINE.
20. KEEP ALL NUTS, BOLTS, AND SCREWS TIGHT to be sure equipment is in safe working condition, especially blade bolts.
21. VEHICLE SHOULD BE STOPPED AND INSPECTED FOR DAMAGE after striking a foreign object and
the damage should be repaired before restarting and operating the equipment. Stop immediately and
check for damage or loose parts if mower should start vibrating.
22. DISENGAGE BLADES BEFORE DRIVING ACROSS WALKS or projecting objects.
23. KEEP SAFETY DEVICES AND GUARDS IN PLACE. If any of the safety switches become inoperable,
have them repaired immediately.
24. DO NOT STEP OR STAND ON THE MOWER HOUSING. Step or stand only on the tread areas on the deck.
25. WATCH OUT FOR TRAFFIC near roadways and when crossing roads.
26. THIS MACHINE IS NOT MEANT FOR HIGHWAY OR STREET USE. It is not a recreational vehicle and it should not
be operated as such.
27. DO NOT USE MOWER WHEN GRASS IS WET OR SLIPPERY.
28. MOW ONLY DURING DAYLIGHT.
29. ALWAYS DISENGAGE THE MOWER BLADE CLUTCH when transporting.
30. If your tractor is equipped with ROPS (Roll-Over Protection Structure), you must wear your seat belt.
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IMPORTANT FEDERAL LAWS AND REGULATIONS* CONCERNING
EMPLOYERS, EMPLOYEES AND OPERATIONS.
*(This section is intended to explain in broad terms the concept and effect of the following federal laws and
regulations. It is not intended as a legal interpretation of the laws and should not be considered as such).
U.S. Public Law 91-596 (The Williams-Steiger Occupational and Health Act of 1970) OSHA
This Act Seeks:
“...to assure so far as possible every working man and woman in the nation safe and healthful working
conditions and to preserve our human resources...”
DUTIES
Sec. 5 (a) Each employer—
(1) shall furnish to each of his employees employment and a place of employment
which are free from recognized hazards that are causing or are likely to cause
death or serious physical harm to his employees;
(2) shall comply with occupational safety and health standards promulgated under
this Act.
(b) Each employee shall comply with occupational safety and health standards
and all rules, regulations and orders issued pursuant to this Act which are
applicable to his own actions and conduct.
OSHA Regulations
Current OSHA regulations state in part: “At the time of initial assignment and at least annually thereafter, the
employer shall instruct every
employee is, or will be involved.” These will include (but are not limited to) instructions to:
employee in the safe operation and servicing of all equipment with which the
Keep all guards in place when the machine is in operation;
Permit no riders on equipment;
Stop engine, disconnect the power source, and wait for all machine movement to stop before
servicing, adjusting, cleaning or unclogging the equipment, except where the machine must be
running to be properly serviced or maintained, in which case the employer shall instruct employees
as to all steps and procedures which are necessary to safely service or maintain the equipment.
Make sure everyone is clear of machinery before starting the engine, engaging power, or operating
the machine.
Child Labor Under 16 Years Old
Some regulations specify that no one under the age of 16 may operate power machinery. It is your
responsibility to know what these regulations are in your own area or situation. (Refer to U.S. Dept. of
Labor, Employment Standard Administration, Wage & Home Division, Child Labor Bulletin #102.)
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SECTION I
INTRODUCTION AND DESCRIPTION
INTRODUCTION
We are pleased to have you as a Bush Hog customer. Your Bush Hog Zero Turn Mower has been
carefully designed to give maximum service with
minimum down time. This manual is provided to give
you the necessary operating and maintenance
instructions for keeping your mower in top operating
condition. Please read this manual thoroughly.
Understand what each control is for and how to use
it. Observe all safety precautions decaled on the
machine and noted throughout the manual for safe
operation of implement. If any assistance or additional information is needed, contact your authorized
Bush Hog dealer. Optional equipment such as Roll
Over Protection Systems, Seat Belts or Front Blade
Assemblies are covered in their individual instructions, which come with the kits.
NOTE:
All references made to right, left, front, rear, top or bottom is as viewed facing the direction of forward travel
with implement properly attached to power unit.
DESCRIPTION
The Zero Turn is intended for use on large lawns and
other maintained areas where a smooth, even cut is
desired and superior maneuverability is needed. The
tractor unit consists of either an 18 hp Kohler, 22 hp
Kohler, 25 hp Kohler, or 22 hp water cooled
Kawasaki, two cylinder engine, and a power take-off
(PTO) shaft. The engine has a pressurized oil lubrication system with spin-on type filter, fused electronic ignition, electric start and a 5 gallon fuel tank.
Two hydrostatic pumps and two wheel motors are
used for propelling and steering. The pumps are belt
driven by the engine output shaft. One lever for each
drive controls both speed and direction. This independent control of each drive wheel coupled with
continuously variable speed selection gives the Zero
Turn mower exceptional maneuverability.
The mower deck is driven by a power take-off
(PTO) shaft from the engine. An electrically controlled clutch is used to engage/disengage the PTO.
The mower attachment is available in three sizes;
48”, 54”, and 60” cut. The mower has three uplift
blades, driven by the input gearbox through a single
V-belt controlled by a spring loaded tensioner.
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CONTROLS
SAFETY INTERLOCK SYSTEM
Your Bush Hog Zero Turn is equipped with a Safety
Interlock System that is designed to help prevent
possible serious injuries. Understanding and maintaining this system is vital, for safe operation.
To Start Engine:
1. Blades (PTO) must be disengaged.
2. Control levers in neutral (swung out).
3. Parking brake on.
4. Operator in seat.
The Engine Will Kill If:
1. The operator leaves the seat with:
a. The control levers out of neutral (swung in).
b. The blades are engaged.
c. The parking brake is off.
d. All of the above.
2. The park brake is on before the control levers
are in neutral (swung out).
DO NOT OPERATE MOWER IF SAFETY SWITCHES ARE NOT OPERATING PROPERLY.
CONTROL LOCATIONS
① Ignition Key - On right hand control console.
② Engine Throttle - On right hand control console.
③ Two Steering/Speed Control Levers - In front of
seat at side. (Not shown below)
④ PTO Clutch Switch - On right hand control
console.
⑤ Parking Brake Lever - On left hand control con-
sole. (Not shown below)
⑥ Blade Height Adjust Lever - Right side of deck. (Not
shown below)
⑦ Choke - On right hand control console.
⑧ Hydrostatic Pump Bypass Valve - Right sides of
pumps. (Not shown below)
⑨
Light Switch - On right hand control console.
➉ Hour Meter - On right hand control console.
11
Warning Light - On right hand control console.
WARNING
DO NOT OPERATE MACHINE UNLESS
INTERLOCK SYSTEM FUNCTIONS PROPERLY. FAILURE TO HEED THIS WARNING
MAY RESULT IN SERIOUS INJURY, DEATH
OR EQUIPMENT DAMAGE.
TRACTOR SPECIFICATIONS
Width - All Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49”
Height - Kohler Models (Top of seat back) . . . . . . . . . 46”
Kawasaki (Top of seat back) . . . . . . . . . . . . . 46”
All Models with ROPS . . . . . . . . . . . . . . . . . . 72”
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . Approx. 5 gallons
Hydrostatic Fluid Reservoir . . . . . . . . . Approx. 3 gallons
Hydrostatic Pumps- All Models . . (2) Hydro-Gear pumps
Engine - Zero Turn 18 18 h.p. Kohler Command
Zero Turn 22 22 h.p. Kohler Command
Zero Turn 25 25 h.p. Kohler Command
Zero Turn 22W 22 h.p. Water Cooled Kawasaki
Tires - All Models - Front . . . . . . . . . . . . . . . . 410/350 x 4
Drive . . . . . . . . . Turf 20 - 10.00 x 10
Bar 21 - 11.00 x 10
Knobby 20 - 11.00 x 10
Rear (Single Wheel) . . . 13 - 6.50 x 6
(Dual Wheels) . . . . 13 - 6.50 x 6
①
② ④
⑦
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➉
DECK SPECIFICATIONS
ITEM D 48-1 D54-1 D 60-1
Cutting width 48” 54” 60”
Cutting Heigh ------------------ 1.00” to 5.00”------------Blades 17” 19” 21”
Overall width
including chute 63-1/2” 66-1/2” 73-1/2”
Material thickness - skirt -------------7 GA.---------------
Reinforcement plate ------------------7 GA.--------------Spindle bearings ----------------------25 mm--------------
- deck -----------10 GA.--------------
⑨
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SECTION II
OPERATION
GENERAL SAFETY
Only qualified people familiar with this operator’s
manual should operate this machine. Operator
should wear hard hat, safety glasses, and safety
shoes. Avoid loose fitting clothing or jewelry. The
operator should read, understand and practice all
safety messages shown on the caution, warning and
danger decals affixed to the machine to avoid serious injury or death. Before beginning operation, clear
work area of any objects that may be picked up and
thrown by mower. Check for ditches, stumps, holes
or other obstacles that could upset power unit or
damage mower. Always push steering levers apart,
set parking brake, disengage PTO, turn off engine,
and allow blades to come to a complete stop before
leaving operator’s seat. Do not operate without all
shields in place and in good condition.
PRE-OPERATION CHECKLIST
1. Make sure fuel tank is full. Use regular unleaded
gasoline. (See engine owner’s manual for more
details)
WARNING
AVOID SERIOUS INJURY OR DEATH:
GASOLINE IS EXTREMELY FLAMMABLE AND
EXPLOSIVE UNDER CERTAIN CONDITIONS.
● REFUEL IN A WELL VENTILATED AREA WITH
ENGINE STOPPED.
● DO NOT SMOKE OR ALLOW FLAMES OR
SPARKS IN THE REFUELING AREA OR
WHERE GASOLINE IS BEING STORED.
● DO NOT OVERFILL FUEL TANK. AFTER
REFUELING, MAKE CERTAIN THE TANK CAP
IS CLOSED PROPERLY AND SECURELY.
● BE CAREFUL NOT TO SPILL FUEL WHEN
REFUELING. FUEL VAPOR OR SPILLED FUEL
MAY IGNITE. IF ANY FUEL IS SPILLED, MAKE
SURE THE AREA IS DRY BEFORE STARTING
THE ENGINE.
● KEEP OUT OF REACH OF CHILDREN
2. Make sure dirt and foreign matter are kept out of
fuel tank. Use a clean funnel and fuel can.
3. Do not mix oil with gasoline.
4. Do not use white, high test or premium gasoline.
Do not use de-icers, carburetor cleaners or other
such additives.
5. Check the crankcase oil level. Make sure the
engine is off. The mower should be parked on a
level area. Do not overfill. (See your engine manual for more detailed instructions.)
6. Check the hydrostatic transmission oil level. (See
“Maintenance” section of this manual.)
7. Check battery fluid level.
8. Inspect V-belts
9. Check tire pressure: Deck tires - 11”, 22 psi,
Tire Sealant Filled; Drive tires - 20”, Turf Tire 22 psi, Bar Tire - 22 psi, Knobby Tire (ATV Type)
- 5 psi; Rear tires - 13”, 18 psi.
10. Make sure underside of mower deck is free of
grass.
11.Make sure mower blades are sharp and secured
tightly.
12. Clean the air intake screen on the engine if
necessary.
13. Perform any other maintenance as it becomes
necessary. (See “Maintenance” section)
14.Check low oil pressure warning buzzer for operation. (It should “sound-off” whenever ignition key
is in the “on” position, but engine is not running.)
15. Check parking brake operation by disengaging
hydrostatic pumps (freewheeling position), and
placing the brake lever in the “on” position.
Attempt to rock tractor by hand. Both drive wheels
should be locked. When the brake handle is in the
“off” position, both drive wheels should turn freely.
If there is a problem in either position, refer to
adjustment procedure in the maintenance section.
WARNING
ENGINE EXHAUST GASES CONTAIN
POISONOUS CARBON MONOXIDE.
● NEVER RUN ENGINE IN A CLOSED BUILDING
OR CONFINED AREA.
● AVOID INHALING EXHAUST GASES.
OPERATION
1. MOVE CONTROL LEVERS TO neutral “OUT”
position by pushing each one straight sideways.
2. SET PARKING BRAKE. Pull rearward to set.
3. DISENGAGE MOWER BLADE CLUTCH by
moving clutch switch to “OFF” (down) position.
4. SET ENGINE CHOKE CONTROL for cold starts
to full position.
5. SET ENGINE THROTTLE TO 1/2 throttle.
6. TURN IGNITION KEY to “START” position and
release to “RUN” as soon as engine starts.
NOTE: Prolonged cranking will damage starter
motor and shorten the battery life.
7. ADJUST ENGINE THROTTLE AND CHOKE for
desired engine smoothness and speed. NOTE:
When mowing, always run engine at full throttle.
8. RELEASE PARKING BRAKE. Push brake lever
forward to release.
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CAUTION
If the operator is inexperienced with the zero
turning radius lever steering/speed control,
he/she should follow these recommendations:
Disengage the mower blades. Go very slowly
until thoroughly familiar with the machine. Keep
away from fences, buildings, and other obstructions. While becoming familiar with the machine,
move the Control Levers smoothly and slowly.
Practice until operation is smooth and efficient.
9. TO DRIVE: Adjust seat forward or backward for
operator comfort. Move the Control Levers to the
“IN” position. Move Control Levers forward to
move forward. Move levers slowly forward to
increase speed. To reverse direction, move the Control
Lever on the side to which you want to turn slightly rearward of the other Control Lever. To turn on
a zero radius axis, go slowly and pull one Control
Lever back and push the other Control Lever forward, depending on which direction you wish to
turn.
CUTTING
HEIGHT
ADJUSTMENT
DECALS
12.ENGAGE MOWER BLADES by pulling
up on the PTO clutch switch. The engine will not
start if the PTO switch is engaged. If the engine
is running while the PTO clutch is engaged and
the operator leaves the seat, the engine will stop.
WARNING
AVOID SERIOUS INJURY OR DEATH:
DO NOT MOVE STEERING LEVERS FROM FORWARD TO REVERSE OR REVERSE TO FORWARD POSITION RAPIDLY. A SUDDEN
CHANGE IN DIRECTION MAY CAUSE LOSS OF
CONTROL AND/OR DAMAGE TO EQUIPMENT.
FOR SMOOTH, SAFE OPERATION, MOVE THE
CONTROL LEVERS IN A GENTLE, SLOW
MOTION, ESPECIALLY ON GRADES.
10. BRAKING: To brake mower, gently move
Control Levers in the direction opposite to travel.
If the parking brake is engaged with the Control
Levers in the “IN” position the engine will stop.
11. CUTTING HEIGHT ADJUSTMENT: Cutting
height is changed by moving the deck adjusting
lever forward to lower the cut and rearward to
raise the cut.
There are two ranges of travel allowing the
mower deck to be adjusted from 1” - 3-1/2”, refered to as the low range, and 2” - 5”, refered to
as the high range.
To obtain the low range deck heights, adjust the
short adjusting assembly to 9-5/8”. This length
gives cutting heights from 1” - 3-1/2” in 1/2”
increments.
To obtain the high range deck heights, adjust
the short adjusting assembly to 10-1/4”. This
length gives cutting heights from 2” - 5” in 1/2”
increments.
CAUTION
AVOID HILLS AND SLOPES. USE EXTREME
CAUTION WHEN MOWING UP OR DOWN
SLOPES. NEVER MOW ACROSS THE FACE OF
A SLOPE. IF A SLOPE MUST BE ASCENDED,
DRIVE UP THE SLOPE; BACK DOWN WHEN
DESCENDING.
13.TO STOP:
A. Slow engine speed with throttle to slowest
position
B. Disengage the mower blade clutch by mov-
ing the PTO clutch switch to the “OFF” position.
.
C. Move Control Levers to neutral position and
then to the “OUT” position.
D. Set the parking brake.
E. Turn ignition key to “OFF” position.
F. Remove the key and wait for all movement
and all sound to cease before dismounting.
WARNING
AVOID SERIOUS INJURIES TO OTHERS:
ALWAYS REMOVE THE KEY FROM THE IGNITION SWITCH WHENEVER THE MOWER IS
UNATTENDED TO PREVENT CHILDREN OR
UNAUTHORIZED PERSONS FROM STARTING
THE ENGINE.
14. PUMP BYPASS-TO MOVE THE TRACTOR
WITHOUT POWER: The pump bypass valves
are located on the right sides of each pump.
Access to the valve controls is from the underside of the tractor. Turn the control counterclockwise two complete turns to release the
pump for free wheeling; turn them clockwise for
operation.
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Page 13
Pump as seen
from above. Use
a rod through
the hex head, or
a 5/8” wrench to
open or close
the valve.
NOTE: To move the tractor without power, the
pumps must be unlocked and in the free
wheel position. Failure to do so could possibly
damage the hydraulic motors. Never pull at more
than 2 MPH.
MOWING RECOMMENDATIONS
slide the bar from its stored position.
2. Fold steering levers outward and raise the foot
deck into vertical position and lock into place;
move the levers to the in position.
3. Push the height control handle all the way forward past lowest cutting height position.
Remove deck locking pins.
4. Depresss the deck weight transfer arms with the
lift bar and unlatch the lift chains.
5. Insert the deck lift bar into the lift tube, locking in
place with the pin,and lift the front of the deck
rotating it past 90 degrees.
6. Install pins in the locking holes to secure deck in
the folded position.
1. Keep mower blades sharp.
2. Make sure deck and discharge chute are clean.
WARNING
TO AVOID SERIOUS INJURY FROM
BLADE CONTACT, POWER MUST BE
OFF TO CLEAN DISCHARGE CHUTE
DANGER
KEEP HANDS AND FEET AWAY FROM
UNDERNEATH MOWER TO AVOID SERIOUS
INJURY OR DEATH.
WARNING
ROTARY MOWERS CAN DISCHARGE
OBJECTS AT HIGH SPEEDS. TO AVOID
SERIOUS INJURIES OR DEATH:
● OPERATE ONLY WITH SIDE BANDS IN
GOOD REPAIR AND CHUTE OR GRASS
CATCHER ATTACHMENT INSTALLED.
● KEEP CHILDREN, PETS, AND
BYSTANDERS AWAY FROM THE WORK
AREA.
● DO NOT OPERATE MOWER IN THE VICIN-
ITY OF OTHER PERSONS.
● DISCHARGE AWAY FROM BULIDINGS,
7. Remove the deck lift bar.
LOWERING & REATT ACHING THE DECK
1. Remove the pins from the locking holes used to
secure the folded deck.
2. Insert the deck lift bar into the lift tube, locking in
place with the pin, and rotate the deck back to
the horizontal position.
3. Move the deck handle assembly past the lowest cut-
ting position to assist in re-installing the deck locking
pins.
4. Depress the weight transfer arms with the lift bar
and latch the lift chains.
5. Insert the deck lift bar back in the stored position
and pin in place.
6. Lower the foot deck and re-adjust the deck handle
to the desired cutting height.
Mower Deck Tilted Up
MOWER DECK TILT-UP PROCEDURE
CAUTION
STOP ENGINE, SET PARKING BRAKE,
REMOVE IGNITION KEY AND SPARK
PLUG WIRES FOR SAFETY. WEAR
PROTECTIVE GLOVES AND USE CARE
WHEN LIFTING TO PREVENT THE
DECK FROM ACCIDENTALLY FALLING.
REFER TO PHOTOGRAPHS ON FOLLOWING
PAGE FOR DETAILED VIEWS
1. Remove the pin holding the deck lift bar and
WARNING
THE POWER UNIT IS VERY UNSTABLE WITHOUT
AN ATTACHMENT (MOWER, ETC.). OPERATION
WITHOUT AN ATTACHMENT CAN CAUSE SERIOUS INJURY OR DEATH DUE TO POWER UNIT
OVERTURNING.
11
Page 14
DECK TILT PROCEDURE (48 “ DECK SHOWN)
Deck Lift Bar Installed For Rotating Deck
Pin Holding Lift Bar In Stored Location
Deck Pinned Into Raised Position
Lift Bar Being Removed From Stored Location
Lift Chains, Weight Transfer Arms, And Pins
Depressing Weight Transfer Arm To Release Chain
12
Page 15
SECTION III
MAINTENANCE
CAUTION
BEFORE PERFORMING ANY MAINTENANCE, TURN OFF ENGINE, REMOVE KEY AND DISCONNECT SPARK
PLUGS. USE EXTREME CARE WHEN WORKING ON MACHINERY. DO NOT WEAR WATCH OR JEWELRY. DO
NOT WEAR LOOSE FITTING CLOTHES, AND OBSERVE ALL COMMON SAFETY PRACTICES WITH TOOLS.
BEFORE PERFORMING ANY SERVICING, MAINTENANCE OR REPAIR ON THE ENGINE, REFER TO THE
RESPECTIVE ENGINE MANUFACTURERS OPERATOR’S MANUAL FOR SPECIFIC INFORMATION
CONCERNING YOUR PARTICULAR BRAND OF ENGINE.
MAINTENANCE SCHEDULE
SERVICE WHEN
Check crankcase oil level_______________________________________________________before each use
Check air intake screen__________________________________________________________after each use
Clean grass from under deck _____________________________________________________after each use
Check tire pressure ____________________________________________________________every 10 hours
Sharpen mower blades _________________________________________________________every 10 hours
Clean air filter element __________________________________________________________every 25 hours
Check 20W50 motor oil
in hydrostatic system ___________________________________________________________every 10 hours
IMPORTANT:
Check drive belts ______________________________________________________________every 50 hours
(20 hr breakin)
Grease driveline ______________________________________________________________every 50 hours
Grease deck pivot tube (2 fittings) _________________________________________________every 50 hours
Grease blade spindles __________________________________________________________every 50 hours
Change engine every 50 hours
crankcase oil ________________________________________________________________(5 hrs breakin)
Change engine oil filter_________________________________________________________every 100 hours
Change hydrostatic oil filter (See your Bush Hog Dealer)
Important: Substitution of an improper filter will cause every 250 hours
hydrostatic failure which will not be covered under warranty _____________________(50 hrs breakin)
Change oil in deck gearbox (Mobil SHC 630 Synthetic Motor Oil)
(Never mix brands or types of oil! EP 80W90 Gear Oil may be substituted
after gearbox has been completely drained of original oil.)___________________annually or 500 hours
Grease top bearing in deck gearbox with 1-2 shots ___________________________________every 50 hours
Replace air
filter element ____________________________________________________________annually or 500 hours
Check spark plugs________________________________________________________annually or 100 hours
Service battery___________________________________________________________annually or 500 hours
Perform these maintenance procedures more frequently under extremely dusty, dirty conditions.
Replace decals when illegible. Write parts dept. for free replacement.
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Page 16
1. ENGINE:
For complete maintenance and operating information for your engine, please refer to your
engine operating and maintenance instructions
furnished by the engine manufacturer and included in your Zero Turn mower information packet.
Air intake screen must be kept clean. If
NOTE
plugged, engine may be seriously damaged by over heating.
2. BATTERY:
WARNING
● THE BATTERY CONTAINS SULFURIC ACID.
● BATTERIES PRODUCE EXPLOSIVE GASES.
● KEEP OUT OF REACH OF CHILDREN.
AVOID SERIOUS INJURY OR DEATH:
AVOID CONTACT WITH SKIN, EYES OR CLOTHING.
EYES - FLUSH WITH WATER AND GET PROMPT MEDICAL ATTENTION.
ANTIDOTE: INTERNAL - DRINK LARGE QUANTITIES
OF WATER OR MILK. FOLLOW WITH MILK OF MAGNESIA, BEATEN EGG OR VEGETABLE OIL. CALL A
PHYSICIAN IMMEDIATELY.
KEEP SPARKS, FLAMES AND SMOKING MATERIALS AWAY. VENTILATE WHEN CHARGING IN AN
ENCLOSED SPACE. WEAR EYE PROTECTION
WHEN WORKING NEAR BATTERIES.
When taking the battery out of the mower for ser
vicing, make sure to reconnect the cables to the
battery exactly as they were prior to removal.
Keep the battery clean. Remove the corrosion
around the battery terminals by applying a solution of one part baking soda to four parts water.
Coat all exposed terminal surfaces with a light
layer of grease or petroleum jell to prevent corrosion.
NOTE
At temperatures below 32 degrees F (0 deg
C) the full charge state must be maintained to
prevent cell electrolyte from freezing and
causing permanent battery damage.
3. TIRES:
Correct tire pressure is essential for efficient
operation of the mower. Check tire air pres-
sure periodically. Inflate tires to the pressure
listed:
TIRE PRESSURE
Front Tires
Drive Tires Rear Tires
11” Sealant Filled 20” 13” 18 psi
22 psi Turf Tire - 22 psi
Bar Tire - 22 psi
Knobby Tire (ATV Type) - 5 psi
4. MOWER BLADES:
Check sharpness of mower blades after every 10
hours of operation. To sharpen blades proceed as
follows:
CAUTION
STOP ENGINE, SET PARKING BRAKE,
REMOVE IGNITION KEY AND SPARK PLUGS
FOR SAFETY.
A. Tilt deck up into raised position and secure with
deck pins.
B. Remove bolt, cup washer, and blade from shaft.
C Blades should be discarded when worn exces-
sively. See sketch.
New Blade
25 Degrees
When Notch Starts
Discard Blade
Dangerous!
D. Sharpen blade with a hand file, electric grinder
or blade sharpener. Wear gloves and eye protection
when sharpening. Grind blade at original bevel.
E. Check balance of blade by positioning the blade
on a nail or blade balance pedestal. Grind the blade
on the end that is heavier until both sides balance.
F. Install blades with the concave side of the cup
washer against blade. Be sure blades are installed
with uplifts and cutting edges in the proper directions.
Tighten retaining bolt to 76 ft./lbs.
5. CHECKING DECK DRIVE GEARBOX FLUID LEVEL
A. Rotate deck into the upright position and
secure with deck pins.
B. Remove the hex head plug at the low end of
the gearbox housing. (Plug closest to the drive
shaft.) The fluid level should be level with the bottom
of the threaded hole.
6. CHANGING FLUID IN DECK DRIVE GEARBOX
(Annually or every 500 hours)
A. Rotate the deck into the upright position,
secure deck with pins and remove drain plug from
bottom edge of gearbox.
B. Lower deck to drain fluid.
C. When the fluid has drained from the gearbox,
raise deck back up and fill with Mobil SHC 630
synthetic motor oil (or EP 80W90). Fill to the bottom of the hole that the plug was removed from.
D. Reinstall drain plug.
Lug nuts should be checked regularly for tightness. Torque lug nuts to 50 ft./lbs. The center
hub nut should be torqued to 175 - 200 ft./lbs.
and cotter key installed.
Deck Drive Gearbox Drain/Fill/Check Plug
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7. GREASING TOP BEARING IN GEARBOX
Grease top bearing with grease gun (1-2 shots)
every 50 hours.
Grease Fitting For Top Bearing
TEST DRIVE OPERATIONS
Check air pressure in tires. Equal tire pressure is
critical for proper drive operation.
1. Raise drive wheels off ground. Safely block
the frame in this position.
2. Put control levers in neutral lock position
(control levers swung outward).
3. Start engine.
Wheels should not rotate. If one or both drive wheels
are turning, perform procedures under “Neutral
Adjustments” for side(s) that wheel turns.
NEUTRAL ADJUSTMENT - DRIVE
1. Raise the drive wheels of the Zero Turn off of the
ground. Safely block the frame in this position so it is
secure.
2. Check to be sure the self centering dampener is
in synchronized with the control levers. (Pull back on
control levers and let go; they should return to the
neutral location.) This is adjusted by locking the control lever in the neutral position (swung out) and
loosening the retainer nut on the self centering
dampener located on either side of the seat frame.
Allow the self centering dampener to locate the position in the slot and retighten the nut.
3. With the operator in the seat, start the engine,
leaving the control levers in the neutral position.
Release the parking brake. Check drive wheels for
any rotation.
4. Stop engine and engage parking brake. If the
drive wheels creeped (rotated) in the neutral position
this should be adjusted out. This adjustment is performed at the adjustable pump link on each corresponding pump. Make the adjustment by either
lengthening or shortening the distance of the adjusting links. If the wheel rotates in the forward direction,
shorten the rod. If the wheel rotates in the reverse
direction, lengthen the rod. Retighten the jam nut.
Start the engine and recheckthe adjustment.
5. If wheel still creeps, repeat procedure in step 4.
6. After final adjustment is made (make sure that
the jam nut is tight on pump link), take unit for a test
drive.
DRIVE ADJUSTMENTS
Slotted Hole With
Retaining Nut On Back Side
Pump LInk Adjustments
Pump Arm
Self Centering Dampener
Control Lever
Mounting Plate
LEVELING THE DECK
CAUTION
STOP ENGINE, SET PARKING BRAKE, REMOVE
IGNITION KEY AND SPARK PLUG WIRES
FOR SAFETY
1. Set all tire pressures to correct specifications.
2. Place machine on a level slab of concrete.
3. Lower the deck to ground level.
4. (SIDE TO SIDE) Wear heavy gloves and position the blades by hand so all the blades are pointed
in the same direction from “SIDE TO SIDE”.
Measure from the blade tip (beveled edge) to the
ground on all three blades. If there is more than
3/16” difference from one side to the other, the deck
should be leveled.
Steering and motion controls should be uniform in all
forward and reverse speeds. Levers should automatically return to neutral when released.
CAUTION
STOP THE ENGINE BEFORE MAKING
ADJUSTMENTS.
5. Correct the difference by shortening or lengthening the side adjusting links. To raise the deck, shorten the length of the adjusting link. To lower the
deck, lengthen the adjusting link.
6. (FRONT TO REAR) Wear heavy gloves and position the blades by hand so all the blades are pointed
in the same direction from “FRONT TO REAR”.
15
Page 18
Measure from the blade tip (beveled edge) to the
ground on all three blades. If there is more than 3/8”
difference from front to rear, then the deck should
be adjusted.
7. Also, correct this difference by shortening or
lengthening both the left and right side adjusting
links as stated above.
Blade Tips
Discharge
Side
(Bottom View)
DECK BELT ADJUSTMENT
Belt adjustment should be checked every 50 hours
to get maximum life and cutting performance from
the mower. Belt tension is adjusted by increasing or
decreasing the length of the spring on the movable
idler. For proper belt tension on the 48”, 54” and 60”,
mowers, the spring length should be set at 2.88”.
To adjust the spring length, loosen or tighten the
1/2” hex nuts on the spring adjusting rod until the
correct spring length is reached.
DECK BELT REPLACEMENT
USE ONLY GENUINE BUSH HOG REPLACEMENT PARTS
A. Remove the deck lift bar.
B. Remove the deck shield assembly.
DECK SPINDLE BELT ROUTING
Spring Loaded Idler Assembly
(Initial spring length should be set at 2.88”)
Torsion Bar Lever Arm
With Turnbuckle
Right Side
Deck Adjusting Link
C. Relieve the spring tension by loosening the two
1/2” hex nuts on the spring adjustment rod.
D. Remove old belt.
E. Install new belt. Be sure that the belt is properly
positioned in all sheave grooves.
F. Adjust tension on the belt by adjusting the length
of the spring on the moveable idler. The correct
spring length is 2.88” for the 48”, 54”, and 60” decks.
G. Replace the deck shield assembly.
H. Replace the deck lift bar.
Idler Spring Tension Adjustment
16
Page 19
WARNING
TO AVOID SERIOUS BURN INJURIES:
● ALLOW ENGINE, OIL AND HYDRAULIC FLUIDS TO COOL BEFORE SERVICING TRANSMIS-
SION OR ENGINE SYSTEMS.
CAUTION
TO AVOID CLEANING SOLVENT FIRES:
● AVOID USING FLAMMABLE SOLVENTS.
● AVOID AREAS WITH IGNITION SOURCES
WHEN USING FLAMMABLE SOLVENTS.
HIGH PRESSURE HYDRAULIC FLUID LEAKS
CAN PENETRATE SKIN CAUSING SERIOUS
INJURY AND GANGRENE.
INJECTED FLUID MUST BE SURGICALLY
REMOVED WITHIN A FEW HOURS BY A DOCTOR
FAMILIAR WITH THIS TYPE OF INJURY.
TO AVOID SERIOUS INJURY FROM
● USE CARDBOARD AND NOT HANDS TO
SEARCH FOR LEAKS.
● RELIEVE HYDRAULIC PRESSURE BEFORE
WORKING ON SYSTEM.
● CHECK HYDRAULIC HOSES, LINES, AND
CONNECTIONS FOR TIGHTNESS AND GOOD
CONDITION BEFORE APPLYING SYSTEM
PRESSURE.
WARNING
PRESSURE LEAKS:
ZERO TURN 18 WITH OPTIONAL DUAL TAILWHEEL AND REAR WEIGHT KIT
17
Page 20
START-UP MAINTENANCE
Start the engine and idle at the lowest possible RPM.
HYDROSTATIC FLUID
Bush Hog recommends the use of 20W50 motor oil
in the hydrostatic reservoir.
START-UP PROCEDURE
WARNING
TO AVOID INJURY FROM EQUIPMENT GROUND
TRAVEL AND MOVEMENT DURING
START-UP PROCEDURE:
DO NOT START OR JOG ENGINE UNTIL:
● PUMP IS IN NEUTRAL POSITION
● DRIVE WHEELS ARE RAISED OFF THE
GROUND.
● EQUIPMENT IS SECURELY BLOCKED-UP TO
KEEP WHEELS FROM GROUND CONTACT.
● PTO AND OTHER WORK FUNCTIONS ARE
DISCONNECTED.
● BODY AND CLOTHING IS KEPT AWAY FROM
OTHER MOVING PARTS.
Prior to starting the pump, make certain all system
components (reservoir, fittings, etc.) are clean prior
to filling with fluid.
Fill the reservoir with recommended fluid which
should be filtered prior to entering the reservoir.
With the bypass valve closed, slowly move the displacement control in both the forward and reverse
directions. As air is purged from the unit, the oil level
in the reservoir will drop and bubbles may appear in
the fluid. Refill the reservoir as necessary.
Place the steering levers in the neutral position and
open the bypass valve. Slowly move the steering
levers in both the forward and reverse directions to
purge the air from the closed circuit.
Close the bypass valve and run the unit in both directions for several minutes until any remaining air is
purged from the unit. Refill the reservoir as necessary.
Stop the engine, check for and correct any fluid leaks,
and check the reservoir level. Add fluid if necessary.
The transmission is now ready for operation.
HYDROSTATIC MAINTENANCE
Check the reservoir daily for proper fluid level.
The pump and motor units normally do not require
regular fluid changes. The system filter should be
changed after the first 50 hours of break-in, then
every 250 hours thereafter. The fluid and filter should
be changed and the system cleaned if the fluid
becomes contaminated with foreign matter (water,
dirt, etc.).
Hydrostatic Reservoir
Filler Cap
Reservoir
Drain Plug
PARKING BRAKE ADJUSTMENT
Adjust the brake handle so that a 20 pound pull
applied 1” from the top of the handle is required to
lock handle in the up position.
TO TIGHTEN BRAKE: Turn knob on the top of handle in the clockwise direction.
ADJUSTING TRACTION SPRING TENSION
WARNING - Do not over extend springs. Over extension will cause loss of weight to rear of tractor. This
could cause operator to lose control of the machine,
particularly while going down a hill.
Tighten nut on the eye bolt until the threads are 1/2”
past the end of the nut. Tighten the locking nut
against the frame locking the eyebolt in place.
18
Page 21
TROUBLESHOOTING CHECK LIST
1. ENGINE IDLES POORLY:
Carburetor maladjustment_________________________________________________readjust carburetor
Improper spark plug gap _______________________________________________check and re-gap plug
2. ENGINE BACKFIRES:
Carburetor maladjustment_________________________________________________readjust carburetor
3. ENGINE RUNS BUT POWER UNIT WON’T MOVE FORWARD
Drive belt loose or broken________________________________________________re-tension or replace
Pump shift arm disconnected _____________________________________________________reconnect
Hydrostatic reservoir oil low _________________________________________________________add oil
Pump bypass valve open________________________________________________put in closed position
Hydrostatic oil filter plugged_____________________________________________________replace filter
Bad pump or motor __________________________________________________________consult dealer
4. POWER UNIT LOSES POWER OR HYDROSTAT SYSTEM OVERHEATS
Hydrostatic oil reservoir too low ______________________________________________________add oil
Pump or motor damaged _____________________________________________________consult dealer
Hydrostatic oil reservoir blowing oil out cap _________________________overfilled or water contaminated
5. ENGINE STALLS WHEN BLADES ARE ENGAGED
Operator not on seat____________________________________________________________sit on seat
Faulty interlock system _______________________________________________________consult dealer
Bad blade spindle bearing_____________________________________________________consult dealer
Deck drive belt not properly routed ___________________________________________________reroute
Blades blocked by foreign material ___________________________________________clean under deck
•See engine manual for engine adjustments
ENGINE ELECTRICAL TROUBLE SHOOTING
1. ENGINE WILL NOT TURN OVER:
Dead battery
Bad ground connection
Bad terminal connection at battery
Wiring harness plugs are not attached properly at
the key switch or the PTO switch
Bad parking brake switch
Bad safety interlock module
Bad PTO switch
2. ENGINE WILL TURN OVER,
BUT WILL NOT START:
A. If there is spark at the plug:
No fuel
Bad fuel solenoid in engine
Bad electric fuel pump (Kawasaki only)
B. If there is no spark at the plug:
Make sure safety interlock system is sequenced:
PTO switch is off
Control levers in neutral position
Parking brake is on
Operator in seat
Check safety interlock switches:
Seat switch
Neutral switch
Bad ignition module on engine
19
Page 22
SECTION IV
ASSEMBLY
POWER UNIT ASSEMBLY
Mounting Drive Tires
Remove tractor from crating. Lay out hardware in
bolt bag.
Mount the drive tires with the five 1/2” lug nuts provided. Bush Hog offers three styles of drive tires; Turf
Tire, Knobby Tire, and a Bar Tire. When installing
the bar tire please notice the direction of the cleats on
the tires. Install the bar tires as pictured on page 18.
Torque the lug nuts to 50 ft./lbs.
Mounting the Single Rear Tailwheel
A. Remove the rear engine cover by loosening
the three knobs.
B. Remove the tailwheel assembly from the box
and assemble the wheel and fork assembly with the
1” clamp collar. Tighten collar with a socket head
bolt.
Mounting the Dual Rear Tailwheel
A. Remove the rear engine cover by loosening
the three knobs.
B. Remove the tailwheel assembly from the box
and assemble the wheel and fork assembly with the
1” clamp collar. Tighten collar with a socket head
bolt.
C. Attach the caster mount weldment to the
power unit frame with (4) 1/2” x 1-1/2” capscrews
and locknuts.
D. Install the spacer tube in the tailwheel assembly and align with the hole in the caster mount weldment. Secure with the 5/8” x 6-1/2” capscrew, flatwasher and locknut.
E. Reinstall the rear cover and tighten the three
knobs.
Page 23
Mounting the Control Levers
Attach the bracket angles to the control arms with
the 5/16” x 1” capscrews and flange locknuts. Install
each lever (grip inward) to the outside of each mount
angle with 5/16” x 1” capscrews, flatwashers and
flange locknuts. Adjust the levers so they are in line
with each other. Refer to picture below.
Control Lever
Control Arm
Bracket Angle
Battery
Attach the positive lead to the battery.
F. Position the lift arm weldment such that the ushaped cuffs extend between the ears on the pivot
tube and fasten with two 3/8” x 3” carriage bolts and
two locknuts. The carriage bolts should be positioned such that the bolts are installed from the bottom and the nut is tightened on the top.
54” OR 60” DECK TORSION BAR
A. Attach the deck bracket with 3/8 x 1” capscrews, as shown below. Fasten the turnbuckle
between the deck bracket and the torsion bar lever.
With the deck in the fully raised, position, turn the
turnbuckle so as to extend its length. The more it is
extended, the more the torsion bar will be preloaded
and the easier the deck will be to raise. The maximum center to center length of the turnbuckle should
never exceed 6 inches.
Bar Tire Turnbuckle
Additional wire tie straps are shipped to secure
wiring hardness as needed.
Items to Check:
Check oil level in the engine (see engine manual)
Check fluid level in the hydrostatic oil reservoir.
Check tightness of all fasteners, including bolts,
lug nuts, and setscrews.
Check tire pressure.
BASIC DECK ASSEMBLY
(Refer To Exploded Drawing On Next Page)
A. Remove the deck from the crating. Layout
hardware in the bolt bag.
B. Align the grass discharge shield with mounting
holes on the right side of the deck. Attach with
either two or three 3/8” x 1” capscrews and 3/8” locknuts. Tighten these fasteners tight and back off 1/8
turn to allow the shield to float.
C. Attach the deck lift handle assembly to the
deck adjusting height plate with a 1/2” x 1-1/4” capscrew and locknut. Tighten fastener tight and back
off 1/8 turn to allow pivoting.
D. Attach the clevis end of the short rod assembly to the deck mount with clevis spring pin. Align
the flattened end of the short rod assembly with the
mounting ears on the lift handle assembly. Install
the 3/8” x 1-1/8” linkage pin and one 1/8” cotter pin.
E. Install the last link of the four link chain to the
rear hanging brackets located on the back of the
deck. Secure with two 3/8” x 1” capscrews and locknuts.
Torsion Bar Lever Arm Deck Bracket Pivot Tube
BASIC DECK MOUNTING
A. With the foot plate raised, attach the PTO
driveline to the lower spline shaft of the power unit.
Move the mower deck to the front of the power unit.
Install the 3/16” x 1” key into the shaft of the gearbox. Extend the driveline attaching the smooth yoke
to the shaft of the gearbox. Position end of yoke
approximately 1/4” from deck. Torque the two
setscrews to 31 ft./lbs.
B. Move the deck closer to the power unit being
careful not to over extend the power shaft. Align the
lower hole of the lift arm weldment with the slotted
hole in the power unit frame and pin with the two
1/2” x 2-1/4” clevis pin, flatwashers, and 1/8” x 1-1/2”
cotter pins.
C. Rotate the deck lift handle past the lowest
possible position and install the two deck locking
pins and cotter pin in the deck hanger brackets.
D. Rotate the deck lift handle back toward the
tractor and locate in the highest cutting position.
21
Page 24
E. Use lift bar to apply pressure to the weight
transfer arms and attach the upper link of the four
link chain over the end of the arm, positioning in the
cut out slot.
F. Rotate the deck lift handle forward to achieve
a lower cutting height or rearward to achieve a higher cutting height and pin in the desired setting.
G. If the mower deck is not level refer back to
Maintenance Section for instructions.
OPTIONAL -
REAR WEIGHT KIT MOUNTING
The optional rear weight kit is shipped with three
weights totaling 104 pounds. These weights can be
assembled on the single tailwheel assembly or the
dual tailwheel assembly. This kit includes fasteners
and spacers to accommodate attaching to both
assemblies.
To mount to the single tailwheel:
1. Remove the rear shield.
2. Position one 1/4” spacer on each leg of the
formed channel of the single tailwheel frame.
3. Stack the three rear weights, aligning the four
holes and spacers and install the four 5/16” x
4-1/4” capscrews, flatwashers, lockwashers and
hex nuts.
4. Install the rear shield with two of the three knobs.
The rear knob must be left off.
To mount to the dual tailwheel:
1. Remove the rear shield.
2. Position two 1-1/16” spacers toward the rear and
two 1-1/2” spacer toward the engine. Spacers
should be positioned over the four holes.
3. Stack the three rear weights, aligning the four
holes and spacers and install the four 5/16” x 51/2” capscrews, flatwashers, lockwashers and
hex nuts.
4. Install the rear shield with two of the three knobs.
The rear knob must be left off.
Page 25
KOHLER WIRING HARNESS
PARK BRAKE SWITCH
23
OIL HEAT SENDER
KOHLER ONLY
HEAD LIGHT
BLACK
HEAD LIGHT
WARNING LIGHTS
ORANGE/BLACK 18 GA
GRAY/BLACK
ENGINE CONNECTOR
RED 14 GA
ON
RED/WHITE
STARTER RELAY
TO GROUND
OFF
RED/
GREEN
BLACK
BATTERY
WHITE 18 GA
YELLOW 18 GA
TO
BLUE/WHITE
OIL
RED/BLACK STP. 18 GA
TEMP
WHITE 18 GA
RED 18 GA
5 AMP
10 AMP
15 AMP
20 AMP
RED
12 GA
VIOLET/WHITE
BLACK 18 GA
METER
HOUR
BROWN 18 GA
SEAT SWITCH
VIOLET
GREEN
GREEN 18 GA
PINK
RED 12 GA
KEY SWITCH
BLUE 14 GA
BLUE 14 GA
YELLOW 18 GA
BLACK
18 GA
BLUE 14 GA
BLACK 14 GA
PTO SWITCH
YELLOW 18 GA
A B C D E F
LEVER NEUTRAL
SWITCHES
ORANGE
BLUE/ 14 GA
BLUE 14 GA
BROWN 18 GA
ELECTRIC CLUTCH
Page 26
KAWASAKI WIRING HARNESS
24
BLACK
18 GA.
RED/WHITE
HEAD
LIGHT
HEAD
LIGHT
PINK
18 GA.
ON OFF
BLUE/WHITE
18 GA.
GRAY/BLACK
18 GA.
WARNING
LIGHTS
GREEN
END OF
HARNESS
RED/GREEN
BLACK
WHITE
18 GA.
YELLOW
OIL
10 AMP
TEMP
ALARM
20 AMP
POS
NEG.
BLUE 14 GA.
15 AMP
BLACK 16 GA.
BLACK
18 GA.
RED 12 GA.
GREEN/RED
16 GA.
VIOLET
18 GA.
BLACK
18 GA.
SEAT SWITCH
PINK
18 GA.
IGNITION
SWITCH
RED
14 GA.
BLUE 14 GA.
FUEL PUMP
PARK
BRAKE
SWITCH
PTO SWITCH
ENGINE
CONNECTOR
BROWN
GREEN
LEVER
NEUTRAL
SWITCH
ORANGE
BROWN 18 GA.
BLACK/ORANGE
PURPLE
STARTER
SOLENOID
VIOLET/WHITE
BLACK 18 GA.
RED 12 GA.
HOUR
METER
BLACK 14 GA.
ELECTRIC
BLUE 14 GA.
STARTER
CLUTCH
Page 27
SAFETY DECALS
To promote safe operation, Bush Hog supplies safety decals on all products manufactured. Because damage
can occur to safety decals either through shipment, use or reconditioning, Bush Hog will, upon request, provide
safety decals for any of our products in the field at no charge. Contact your authorized Bush Hog dealer for
more information.
WARNING
TO AVOID SERIOUS
INJURY:
● OPERA TE CONTR OLS SMOO THLY
AND SLOWLY , ESPECIALLY ON
SLOPES.
● MOVE VER Y SLO WLY WHEN
A TTACHMENT IS REMOVED.
● DO NOT OPERA TE ON STEEP SLOPES;
SEE OPERA TOR’S MANU AL FOR
DET AILS.
● AL W AYS LOOK BEHIND MACHINE
BEFORE BA CKING.
DANGER
KEEP AWAY!
SHIELD MISSING FROM THIS AREA
TO AVOID SERIOUS INJURY OR DEATH,
DO NOT OPERATE WITHOUT THIS AND
ALL OTHER SHIELDS IN PLACE AND IN
GOOD CONDITION.
DANGER
50012616
823324
● DO NOT MO W WHERE MACHINE
COULD SLIP OR TIP.
● BA CK DOWN SLOPES. GO FOR W ARD
UP SLOPES. 823319
94136
★ENTANGLEMENT WITH ROTATING DRIVE
PARTS CAN CAUSE INJURY OR DEATH.
★KEEP ALL DRIVE SHIELDS & GUARDS IN
PLACE & IN GOOD CONDITION.
★ALLOW NO RIDERS.
DANGER
KEEP AWAY - ROTATING BLADES
SERIOUS INJURY OR DEATH CAN RESULT FROM
THROWN OBJECTS OR BLADE CONTACT.
★ DO NOT STAND ON OR NEAR MACHINE WHEN IN OPERATION.
★ KEEP HANDS AND FEET AWAY FROM UNDERNEATH CUTTER TO AVOID
SERIOUS INJURY.
★ NEVER OPERATE WITHOUT DISCHARGE CHUTE OR GRASS CATCHER
ASSEMBLY IN PLACE. 823325
85020
25
KEEP AWAY!
80488
823322
WARNING
ROTATING DRIVE PARTS
BENEATH
★ ENTANGLEMENT WITH ROTATING DRIVE
PARTS CAN CAUSE INJURY OR DEATH.
★ DO NOT OPERATE WITHOUT THIS AND
ALL OTHER SHIELDS IN PLACE AND IN
GOOD CONDITION.
50012615
823323
Page 28
WARNING
WARNING
READ OPERATORS MANUAL
BEFORE OPERATING & FOLLOW ALL
PRECAUTIONS. (CONTACT DEALER FOR
MANUALS)
STOP ENGINE AND REMOVE KEY
BEFORE DISMOUNTING.
ALLOW NO CHILDREN OR
UNQUALIFIED PERSONS TO
OPERATE EQUIPMENT.
NO RIDERS. DO NOT OPERATE
MOWERS IN VICINITY OF OTHER
PERSONS
KEEP SHIELDS AND GUARDS IN
PLACE. KEEP CLEAR OF DRIVES
AND BELTS.
DECREASE SPEED WHEN TURNING.
TO AVOID SERIOUS
INJURY OR DEATH,
94135
TO AVOID SERIOUS INJURY OR DEATH
DO NOT OPERATE MOWER WITHOUT DISCHARGE SHIELD
OR DEFLECTOR IN PLACE AND GOOD REPAIR.
83056
★READ OPERATOR’S MANUAL BEFORE
OPERATING & FOLLOW ALL PRECAUTIONS.
(CONTACT DEALER FOR MANUALS)
★LOWER IMPLEMENT, STOP ENGINE AND
REMOVE KEY BEFORE DISMOUNTING.
★NO RIDERS. DO NOT OPERATE MOWER IN
VICINITY OF OTHER PERSONS.
★ALLOW NO CHILDREN OR UNQUALIFIED
PERSONS TO OPERATE EQUIPMENT.
★CLEAR MOWING AREA OF DEBRIS.
TO AVOID SERIOUS INJURY OR DEATH,
WARNING
★KEEP SHIELDS AND GUARDS IN PLACE.
KEEP CLEAR OF DRIVES AND BELTS.
★SECURELY SUPPORT MOWER &
REMOVE KEY BEFORE WORKING
UNDERNEATH.
★KNOW HOW TO STOP TRACTOR AND
EQUIPMENT QUICKLY IN AN
EMERGENCY.
★BE CAREFUL ON UNEVEN TERRAIN.
DECREASE SPEED WHEN TURNING.
26
94134
Page 29
Wrench
Size “A”
AMERICAN
Bolt Head Markings
SAE Grade 2
(No Dashes)
SAE Grade 5
(3 Dashes)
SAE Grade 8
(6 Dashes)
TORQUE SPECIFICATIONS
Proper toque for American fasteners used on Bush Hog equipment.
Recommended Torque in Foot Pounds (Newton Meters).*
BOLT DIAMETER
Bolt
Diameter “B”
WRENCH (IN.) “B” AND SAE SAE SAE
SIZE (IN.) “A” THREAD SIZE GRADE 2 GRADE 5 GRADE 8
7/16 1/4 - 2O UNC 6 (7) 8 (11) 12 (16)
7/16 1/4 - 28 UNF 6 (8) 10 (13) 14 (18)
1/2 5/16 - 18 UNC 11 (15) 17 (23) 25 (33)
1/2 5/16 - 24 UNF 13 (17) 19 (26) 27 (37)
9/16 3/8 - 16 UNC 20 (27) 31 (42) 44 (60)
9/16 3/8 - 24 UNF 23 (31) 35 (47) 49 (66)
5/8 7/16 - 14 UNC 32 (43) 49 (66) 70 (95)
5/8 7/16 - 20 UNF 36 (49) 55 (75) 78 (106)
3/4 1/2 - 13 UNC 49 (66) 76 (103) 106 (144)
3/4 1/2 - 20 UNF 55 (75) 85 (115) 120 (163)
7/8 9/16 - 12 UNC 70 (95) 109 (148) 153 (207)
7/8 9/16 - 18 UNF 79 (107) 122 (165) 172 (233)
15/16 5/8 - 11 UNC 97 (131) 150 (203) 212 (287)
15/16 5/8 - 18 UNF 110 (149) 170 (230) 240 (325)
1-1/8 3/4 - 10 UNC 144 (195) 266 (360) 376 (509)
1-1/8 3/4 - 16 UNF 192 (260) 297 (402) 420 (569)
1-5/16 7/8 - 9 UNC 166 (225) 430 (583) 606 (821)
1-5/16 7/8 - 14 UNF 184 (249) 474 (642) 668 (905)
1-1/2 1 - 8 UNC 250 (339) 644 (873) 909 (1232)
1-1/2 1 - 12 UNF 274 (371) 705 (955) 995 (1348)
1-1/2 1 - 14 UNF 280 (379) 721 (977) 1019 (1381)
1-11/16 1-1/8 - 7 UNC 354 (480) 795 (1077) 1288(1745)
1-11/16 1-1/8 - 12 UNF 397 (538) 890 (1206) 1444 (1957)
1-7/8 1-1/4 - 7 UNC 500 (678) 1120 (1518) 1817 (2462)
1-7/8 1-1/4 - 12 UNF 553 (749) 1241 (1682) 2013 (2728)
2-1/16 1-3/8 - 6 UNC 655 (887) 1470 (1992) 2382 (3228)
2-1/16 1-3/8 - 12 UNF 746 (1011) 1672 (2266) 2712 (3675)
2-1/4 1-1/2 - 6 UNC 870 (1179) 1950 (2642) 3161 (4283)
2-1/4 1-1/2 - 12 UNF 979 (1327) 2194 (2973) 3557 (4820)
Proper torque for metric fasteners used on Bush Hog equipment.
METRIC
Wrench
Size “A”
Numbers appearing on bolt heads
indicate ASTM class.
8.8
Bolt
Diameter “B”
*Use 75% of the specified torque value for plated
fasteners. Use 85% of the specificed torque
values for lubricated fasteners.
Recommended torque in foot pounds (newton Meters).*
WRENCH BOLT
SIZE DIA. ASTM ASTM ASTM ASTM
(mm) “A” (mm) “B” 4.6 8.8 9.8 10.9
8 5 1.8 (2.4) 5.1 (6.9) 6.5 (8.8)
10 6 3 (4) 8.7 (12) 11.1 (15)
13 8 7.3 (10) 21.1 (29) 27 (37)
16 10 14.5 (20) 42 (57) 53 (72)
18 12 25 (34) 74 (100) 73 (99) 93 (126)
21 14 40 (54) 118 (160) 116 (157) 148 (201)
24 16 62 (84) 167 (226) 181 (245) 230 (312)
30 20 122 (165) 325 (440) 449 (608)
33 22 443 (600) 611 (828)
36 24 211 (286) 563 (763) 778 (1054)
41 27 821 (1112) 1138 (1542)
46 30 418 (566) 1119 (1516) 1547 (2096)
27
Page 30
BUSH HOG
P.O. Box 1039 ● Selma, AL 36702-1039
Telephone (334) 872-6261
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