Great Dane C5 Chariot GCBV2348S, C5 Chariot GCKA1948S, C5 Chariot GCBR2652S, C5 Chariot GCKH2361S, C5 Chariot GCKA1952S, C5 Chariot GCBR2661S, C5 Chariot GCKH2352S, C5 Chariot GCKH2348S, C5 Chariot GCBV2361S User Manual

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Chariot

GCBR2652S, GCBR2661S, GCKA1948S, GCKA1952S, GCBV2348S, GCBV2361S, GCKH2348S,GCKH2352S, GCKH2361S

TCU20866

C5

OPERATOR’S MANUAL

200964 06/17/2007

INTRODUCTION

WARNING: The Engine Exhaust from this product contains chemicals known to the State of California to cause cancer,

birth defects or other reproductive harm.

California Proposition 65 Warning

All information, illustrations and specifications in this manual are based on the latest information at the time of publication. The right is reserved to make changes at any time without notice.

COPYRIGHT© 2007

Auburn Consolidated Industries Inc. All rights reserved COPYRIGHT© 2006

Introduction

Using Your Operator’s Manual

This manual is an important part of your machine and should remain with the machine when you sell it.

Use the safety and operating information in the machine operator’s manual to operate and service the machine safely and correctly.

An engine manufacturer’s owner’s manual has been provided with your machine. This will provide maintenance and troubleshooting information for the engine installed in your machine.

Specifications and design are subject to change without notice.

Special Messages

Your manual contains special messages to bring attention to potential safety concerns, machine damage as well as helpful operating and servicing information. Please read all the information carefully to avoid injury and machine damage.

CAUTION: Avoid injury! This symbol and text highlight potential hazards or death to the operator or bystanders that may occur if the hazards or procedures are ignored.

IMPORTANT: Avoid damage! This text is used to tell the operator of actions or conditions that might result in damage to the machine.

NOTE: General information is given throughout the manual that may help the operator in the operation or service of the machine.

Product Identification

Record Identification Numbers

Chariot

 

GCBR2652S

S/N 637910001

GCBR2661S

S/N 638910001

GCBV2348S

S/N 638510001

GCBV2361S

S/N 639610001

GCKA1948S

S/N 638710001

GCKA1952S

S/N 638810001

GCKH2348S

S/N 641010001

GCKH2352S

S/N 641110001

GCKH2361S

S/N 641210001

If you need to contact an Authorized Service Center for information on servicing, always provide the product model and serial numbers.

You will need to locate the model and serial numbers for the machine and for the engine of your machine and record the information in the spaces provided.

DATE OF PURCHASE:

_________________________________________

DEALER NAME:

_________________________________________

DEALER PHONE:

_________________________________________

Introduction - 1

SAFETY LABELS

MODEL NUMBER (POWER UNIT) (A):

__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __

SERIAL NUMBER (POWER UNIT) (A):

__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __

ENGINE MODEL NUMBER(B):

__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __

ENGINE SERIAL NUMBER (B):

__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __

ENGINE SPECIFICATION NUMBER (B):

__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __

MOWER DECK MODEL NUMBER (C):

__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __

MOWER DECK SERIAL NUMBER (C):

__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __

__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __

ROPS SERIAL NUMBER (D):

Safety Labels

Understanding The Machine Safety Labels

The machine safety labels shown in this section are placed in important areas on your machine to draw attention to potential safety hazards.

On your machine safety labels, the words DANGER, WARNING, and CAUTION are used with this safety-alert symbol. DANGER identifies the most serious hazards.

The operator’s manual also explains any potential safety hazards whenever necessary in special safety messages that are identified with the word, CAUTION, and the safety-alert symbol.

DANGER

To avoid injury from rotating blades, stay clear of deck edge.

Safety Labels - 2

SAFETY LABELS

DANGER

DANGER

 

 

 

 

 

 

Do not mow without discharge chute or entire grass catcher in place.

DANGER

To avoid injury from rotating blades and thrown objects, stay clear of deck edge and keep others away. Do not mow without discharge chute or entire grass catcher in place.

Cigarettes, flames or sparks could cause battery to explode. Always shield eyes and face from battery. Do not charge or use booster cables or adjust post connections without proper instruction and training.

Contains sulfuric acid. Avoid contact with the skin, eyes or clothing. In event of accident, flush with water and call a physician immediately. Keep out of reach of children.

WARNING

To avoid injury from tipover, drive across slopes, not up and down. If machine stops going uphill, stop blades and back down slowly.

Safety Labels - 3

SAFETY LABELS

WARNING

To avoid injury from rotating belts, keep all shields and guards in place.

WARNING

Hot surface

CAUTION

Read operator’s manual

Keep shields in place

Never carry riders

Keep people a safe distance away

Maintain all safety devices

Before leaving machine:

Stop engine

Set park brake

Remove key

WARNING

AVOID CRUSHING

Keep Rollover Protective Structure fully extended

Do not jump if machine tips

Use seat belt

When Structure must be down

DO NOT use seat belt

Drive with extra care

WARNING

Seat belts are not to be mounted in this hole, because seat will not meet SAE J386 test requirements. Failure to comply with warning could cause

serious injury or death.

• Operator training required

Safety Labels - 4

SAFETY

Emission Control System Certification Label

NOTE: Tampering with emission controls and components by unauthorized personnel may result in severe fines or penalties. Emission controls and components can only be adjusted by EPA and/or CARB authorized service centers. Contact your Great Dane Equipment Retailer concerning emission controls and component questions.

The presence of an emissions label signifies that the engine has been certified with the United States Environmental Protection Agency (EPA) and/or California Air Resources Board (CARB).

The emissions warranty applies only to those engines marketed by Great Dane that have been certified by the EPA and/or CARB; and used in the United States and Canada in off-road mobile equipment.

Emission Compliance Period

If your engine has the emission compliance category listed on the emission control system certification or air index label, this indicates the number of operating hours for which the engine has been certified to meet EPA and/or CARB emission requirements. The following table provides the engine compliance period in hours associated with the category found on the certification label.

Agency

Category

Hours

 

 

 

 

 

 

EPA

C

250

 

 

 

EPA

B

500

 

 

 

EPA

A

1000

 

 

 

CARB

Moderate

125

 

 

 

CARB

Intermediate

250

 

 

 

CARB

Extended

500

 

 

 

Certification

Your product has been tested and evaluated by the manufacturer and conforms with American National Standard B-71.4, “Safety Specifications” for commercial turf care equipment.

Canadian Electromagnetic Compatibility (EMC) Compliance

This spark ignition system complies with Canadian ICES-002.

Safety

Operator Training Required

Read the operator’s manual and other training material. If the operator or mechanic cannot read English, it is the owner’s responsibility to explain this material to them. This publication is available in other languages.

Become familiar with the safe operation of the equipment, operator controls, and safety signs.

All operators and mechanics should be trained. The owner of the machine is responsible for training the users.

Never let children or untrained people operate or service the equipment. Local regulations may restrict the age of the operator.

The owner/user can prevent and is responsible for accidents or injuries occurring to themselves, other people, or property.

Operate the machine in an open, unobstructed area under the direction of an experienced operator.

Preparation

Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job. Only use accessories and attachments approved by the manufacturer.

Wear appropriate clothing including hard hat, safety glasses and hearing protection. Long hair, loose clothing or jewelry may get tangled in moving parts.

Inspect the area where the equipment is to be used and remove all objects such as rocks, toys and wire which can be thrown by the machine.

Use extra care when handling gasoline and other fuels. They are flammable and vapors are explosive.

a.Use only an approved container.

b.Never remove gas cap or add fuel when engine is running. Do not smoke.

c.Never refuel or drain the machine indoors.

• Check that the operator’s presence controls, safety switches and shields are attached and functioning properly. Do not operate unless they are functioning properly.

Operating Safely

Never run an engine in an enclosed area where dangerous carbon monoxide fumes can collect.

Only operate in good light, keeping away from holes and hidden hazards.

Be sure all drives are in neutral and parking brake is engaged before starting engine. Only start engine from the operator’s position. Use seat belts if provided.

Slow down and use extra care on hillsides. Be sure to travel in the recommended direction on hillsides. For this machine, drive across hillsides, not up and down. Turf conditions can affect the machine’s stability. Use caution while operating near drop-offs.

Slow down and use caution when making turns and when changing directions on slopes.

Never raise deck with the blades running.

Never operate with the PTO shield, or other guards, not securely in place. Be sure all interlocks are attached, adjusted properly, and functioning properly.

Never operate with the discharge deflector raised, removed or altered, unless using a grasscatcher. Do not operate mower without discharge chute or entire grasscatcher in place.

Do not change the engine governor setting or overspeed the engine. Operating the engine at excessive speed can increase the hazard of personal injury.

Stop on level ground, lower implements, disengage drives, engage parking brake, and shut off engine before leaving the operator’s position for any reason including emptying the grasscatchers or unclogging the chute.

Stop equipment and inspect blades after striking objects or if an abnormal vibration occurs. Make necessary repairs before resuming operations.

Keep hands and feet away from the cutting units.

Look behind and down before backing up to be sure of a clear path.

Never carry passengers and keep pets and bystanders away.

Slow down and use caution when making turns and crossing roads and sidewalks. Stop blades if not mowing. Watch for traffic when operating near or crossing roadways.

Safety - 5

SAFETY

Be aware of the mower discharge direction and do not point it at anyone.

Do not operate the machine while under the influence of alcohol or drugs.

Use care when loading or unloading the machine into or off of a trailer or truck.

Use care when approaching blind corners, shrubs, trees, or other objects that may obscure vision.

Inspect machine before you operate. Be sure hardware is tight. Repair or replace damaged, badly worn, or missing parts. Be sure guards and shields are in good condition and fastened in place. Make any necessary adjustments before you operate.

Before using, always visually inspect to see that the blades, blade bolts and the mower assembly are not worn and damaged. Replace worn and damaged blades and bolts in sets to preserve balance.

Keep safety labels visible when installing accessories and attachments.

Do not wear radio or music headphones. Safe service and operation require your full attention.

When machine is left unattended, stored, or parked, lower the mower deck unless a positive mechanical lock is used.

Using a Spark Arrestor

The engine in this machine is not equipped with a spark arrestor muffler. It is a violation of California Public Resource Code Section 4442 to use or operate this engine on or near any forest-covered, brush-covered or grass-covered land unless the exhaust system is equipped with a spark arrestor meeting any applicable local or state laws. Other states or federal areas may have similar laws.

A spark arrestor for your machine may be available from your authorized dealer. An installed spark arrestor must be maintained in good working order by the operator.

Checking Mowing Area

Parking Safely

1.Stop machine on a level surface, not on a slope.

2.Move motion control levers out to the neutral lock position.

3.Disengage mower blades.

4.Lower attachments to the ground.

5.Lock the park brake.

6.Stop the engine.

7.Remove the key.

8.Wait for engine and all moving parts to stop before you leave the operator’s seat.

9.Close fuel shut-off valve, if your machine is equipped.

10.Disconnect the negative battery cable or remove the spark plug wire (for gasoline engines) before servicing the machine.

Rotating Blades are Dangerous

HELP PREVENT SERIOUS OR FATAL ACCIDENTS:

• Rotating blades can cut off arms and legs, and throw objects. Failure to observe safety instructions could result in serious injury or death.

• Keep hands, feet and clothing away from mower deck when engine is running.

• Be alert at all times, drive forward carefully. People, especially children can move quickly into the mowing area before you know it.

• Do not mow in reverse.

• Shut off blades when you are not mowing.

• Park machine safely before leaving the operator station for any reason including emptying the catchers or unplugging the chute.

Clear mowing area of objects that might be thrown. Keep people and pets out of mowing area.

Low-hanging branches and similar obstacles can injure the operator or interfere with mowing operation. Before mowing, identify potential obstacles such as low-hanging branches, and trim or remove those obstacles.

Study mowing area. Set up a safe mowing pattern. Do not mow where traction or stability is doubtful.

Test drive area with mower lowered but not running. Slow down when you travel over rough ground.

Safety - 6

SAFETY

Protect Children

Death or serious injury can occur when young children associate having fun with a lawn mowing machine simply because someone has given them a ride on a machine.

Children are attracted to lawn mowing machines and mowing activities. They don’t understand the dangers of rotating blades or the fact that the operator is unaware of their presence.

Children who have been given rides in the past may suddenly appear in the mowing area for another ride and be run over or backed over by the machine.

Tragic accidents with children can occur if the operator is not alert to the presence of children, especially when a child approaches a machine from behind. Before and while backing up, stop mower blades and look down and behind the machine carefully, especially for children.

Never carry children on a machine or attachment, even with the blades off. Do not tow children in a cart or trailer. They can fall off and be seriously injured or interfere with safe machine operation.

Never use the machine as a recreational vehicle or to entertain children.

Never allow children or an untrained person operate the machine. Instruct all operators not to give children a ride on the machine or in an attachment.

Keep children indoors, out of the mowing area, and in the watchful eye of a responsible adult, other than the operator, when a mower is being operated.

Stay alert to the presence of children. Never assume that children will remain where you last saw them. Turn the machine off if a child enters the work area.

Avoid Tipping

Slopes are a major factor related to loss-of-control and tip-over accidents, which can result in severe injury or death. Operation on all slopes requires extra caution.

If you feel uneasy on a hillside, do not mow it.

Mow across slopes, not up and down.

Watch for holes, ruts, bumps, rocks, or other hidden objects. Uneven terrain could overturn the machine. Tall grass can hide obstacles.

Choose a low ground speed so you will not have to stop or shift while on a slope.

Do not mow or operate machine on wet grass. Tires may lose traction. Tires may lose traction on slopes even though the brakes are functioning properly.

Avoid starting, stopping or turning on a slope. If the tires lose traction, disengage the blades and proceed slowly, straight down the slope.

Keep all movement on slopes slow and gradual. Do not make sudden changes in speed or direction, which could cause the machine to roll over.

Use extra care while operating machine with grasscatchers or other attachments, they can affect stability of the machine. Do not use on steep slopes.

Do not mow near drop-offs, ditches, embankments, or bodies of water. The machine could suddenly roll over if a wheel goes over the edge or the edge caves in.

Follow the manufacturer’s recommendations for wheel weights or counterweights for added stability when operating on slopes or using front or rear mounted attachments. Remove weights when not required.

Drive machine very slowly and avoid quick stops when attachment is removed.

Transport machine with decks lowered to improve stability.

Use Seat Belt Properly

Use a seat belt when operating with the folding Roll-Over Protective Structure (ROPS) in the upright position to minimize chance of injury from an accident, such as an overturn.

Do not use a seat belt when operating with the folding ROPS in the folded position. Return the folding ROPS to the upright position as soon as possible.

Never modify, disassemble or attempt to repair the seat belt.

Replace entire seat belt if mounting hardware, buckle, belt, or retractor show signs of damage.

Inspect seat belt and mounting hardware at least once a year. Look for signs of loose hardware or belt damage, such as cuts, fraying, extreme or unusual wear, discoloration, or abrasion. Replace only with replacement parts approved by your Great Dane.

Layers of heavy clothing can interfere with proper positioning of the seat belt and can reduce the effectiveness of the seat belt.

Keep ROPS Installed Properly

Make certain all parts of the ROPS are installed correctly if the ROPS structure is loosened or removed for any reason. All ROPS hardware should be tightened to the proper torque per manufacturer’s recommendations.

Any alteration of the ROPS must be approved by the manufacturer. The protection provided by the ROPS will be impaired if the ROPS is subjected to structural damage, is involved in an overturn incident, or is in any way altered by welding, bending, drilling, or cutting.

Never attempt to repair a damaged or altered ROPS. It must be replaced to maintain the manufacturer’s certification of the structure.

Safety - 7

SAFETY

Keep Riders Off

Only allow the operator on the machine. Keep riders off.

Riders on the machine or attachment may be struck by foreign objects or thrown off the machine causing serious injury.

Riders obstruct the operator’s view resulting in the machine being operated in an unsafe manner.

Avoid High Pressure Fluids

Hydraulic hoses and lines can fail due to physical damage, kinks, age, and exposure. Check hoses and lines regularly. Replace damaged hoses and lines.

Hydraulic fluid connections can loosen due to physical damage and vibration. Check connections regularly. Tighten loose connections.

Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source.

Driving Safely on Public Roads

Avoid personal injury or death resulting from a collision with another vehicle on public roads:

Use safety lights and devices. Slow moving machines when driven on public roads are hard to see, especially at night.

Whenever driving on public roads, use flashing warning lights and turn

signals according to local regulations. Extra flashing warning lights may need to be installed.

Checking Wheel Hardware

A serious accident could occur causing serious injury if wheel hardware is not tight.

Check wheel hardware tightness often during the first 100 hours of operation.

Wheel hardware must be tightened to specified torque using the proper procedure anytime it is loosened.

Wear Appropriate Clothing

Always wear safety goggles, or safety glasses with side shields, and a hard hat when operating the machine.

Wear close fitting clothing and safety equipment appropriate for the job.

While mowing, always wear substantial footwear and long trousers. Do not operate the equipment when barefoot or wearing open sandals.

Wear a suitable protective device such as earplugs. Loud noise can cause impairment or loss of hearing.

Maintenance and Storage

Never operate machine in a closed area where dangerous carbon monoxide fumes can collect.

Disengage drives, lower implement, lock parking brake, stop engine and remove key or disconnect spark plug (for gas engines). Wait for all movement to stop before adjusting, cleaning or repairing.

Clean grass and debris from cutting units, drives, mufflers, and engine to help prevent fires. Clean up oil or fuel spillage.

Let engine cool before storing and do not store near flame.

Safety - 8

SAFETY

Shut off fuel while storing or transporting. Do not store fuel near flames or drain indoors.

Park machine on level ground. Never allow untrained personnel to service machine. Understand service procedure before doing work.

Use jack stands or lock service latches to support components when required. Securely support any machine elements that must be raised for service work.

Before servicing machine or attachment, carefully release pressure from any components with stored energy, such as hydraulic components or springs.

Release hydraulic pressure by lowering attachment or cutting units to the ground or to a mechanical stop and move hydraulic control levers back and forth.

Disconnect battery or remove spark plug (for gas engines) before making any repairs. Disconnect the negative terminal first and the positive last. Reconnect positive first and negative last.

Use care when checking blades. Wrap the blades or wear gloves, and use caution when servicing them. Only replace blades. Never straighten or weld them.

Keep hands, feet, clothing, jewelry and long hair away from moving parts. If possible, do not make adjustments with the engine running.

Charge batteries in an open well ventilated area, away from spark and flames. Unplug charger before connecting or disconnecting from battery. Wear protective clothing and use insulated tools.

Keep all parts in good working condition and all hardware tightened. Replace all worn or damaged decals.

Check grasscatcher components and the discharge guard frequently and replace with manufacturer’s recommended parts, when necessary. Grasscatcher components are subject to wear, damage, and deterioration which could expose moving parts or allow objects to be thrown.

Keep all nuts and bolts tight, especially blade attachment bolts, to be sure the equipment is in safe working condition.

Check brake operation frequently. Adjust and service as required.

On multi-bladed machines, take care as rotating one blade can cause other blades to rotate.

Prevent Fires

Remove grass and debris from engine compartment and muffler area, before and after operating machine, especially after mowing or mulching in dry conditions.

Empty the grasscatcher completely before storing.

Always shut off fuel when storing or transporting machine, if the machine has a fuel shutoff.

Do not store machine near an open flame or source of ignition, such as a water heater or furnace.

Check fuel lines, tank, cap, and fittings frequently for cracks or leaks. Replace if necessary.

Tire Safety

Explosive separation of a tire and rim parts can cause serious injury or death:

Do not attempt to mount a tire without the proper equipment and experience to perform the job.

Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion. Welding can structurally weaken or deform the wheel.

When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly.

Check tires for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.

Handling Fuel Safely

To avoid personal injury or property damage, use extreme care in handling fuel. Fuel is extremely flammable and fuel vapors are explosive:

Extinguish all cigarettes, cigars, pipes, and other sources of ignition.

Use only an approved fuel container. Use only non-metal, portable fuel containers approved by the Underwriter’s Laboratory (U.L.) or the American Society for Testing & Materials (ASTM). If using a funnel, make sure it is plastic and has no screen or filter.

Safety - 9

OPERATING

Never remove the fuel tank cap or add fuel with the engine running. Allow engine to cool before refueling.

Never add fuel to or drain fuel from the machine indoors. Move machine outdoors and provide adequate ventilation.

Clean up spilled fuel immediately. If fuel is spilled on clothing, change clothing immediately. If fuel is spilled near machine, do not attempt to start the engine but move the machine away from the area of spillage. Avoid creating any source of ignition until fuel vapors have dissipated.

Never store the machine or fuel container where there is an open flame, spark, or pilot light such as on a water heater or other appliance.

Prevent fire and explosion caused by static electric discharge. Static electric discharge can ignite fuel vapors in an ungrounded fuel container.

Never fill containers inside a vehicle or on a truck or trailer bed with a plastic liner. Always place containers on the ground away from your vehicle before fueling.

Remove fuel-powered equipment from the truck or trailer and refuel it on the ground. If this is not possible, then refuel such equipment with a portable container, rather than from a fuel dispenser nozzle.

Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until the fueling is complete. Do not use a nozzle lockopen device.

Never overfill fuel tank. Replace fuel tank cap and tighten securely.

Replace all fuel container caps securely after use.

For gasoline engines, do not use gas with methanol. Methanol is harmful to your health and to the environment.

Handling Waste Product and Chemicals

Waste products, such as, used oil, fuel, coolant, brake fluid, and batteries, can harm the environment and people:

Do not use beverage containers for waste fluids - someone may drink from them.

See your local Recycling Center or authorized dealer to learn how to recycle or get rid of waste products.

A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques. The seller of the chemical products used with your machine is responsible for providing the MSDS for that product.

Operating

Daily Operating Checklist

oMake sure all necessary guards and shields are safely and securely attached. Check for loose, missing, or damaged parts.

oRemove mower deck belt shields. Clean grass and debris from belt area.

oRemove grass and debris from machine and mower deck. oTest park brake.

oTest safety systems.

oInspect battery terminals and hold-downs. oInspect for oil leaks.

oCheck engine and hydraulic oil levels. oInspect all belts for damage or cracking. oInspect engine air filter.

oInspect mower level.

oAdjust cutting height if necessary.

oInspect wheel bolt torque. Tighten if necessary.

oCheck tire air pressure. Check tires for damage or cracking. oInspect front caster spindles/wheels.

Avoid Damage to Plastic and Painted Surfaces

Do not wipe plastic parts unless rinsed first.

Insect repellent spray may damage plastic and painted surfaces. Do not spray insect repellent near machine.

Operating - 10

OPERATING

Be careful not to spill fuel on machine. Fuel may damage surface. Wipe up spilled fuel immediately.

Prolonged exposure to sunlight will damage the hood surface.

Operator Station Controls

A- Motion Control Levers

B- Park Brake Lever

C- Seat Adjustment Lever

D- Hourmeter

E- Ignition Key Switch

F- PTO Knob

G- Choke (Carbureted Engines Only)

H- Throttle Lever

I- Mower Deck Lift/Lower Lever

J- Height-of-Cut (HOC) Adjustment Pin

K- Mower Deck Transport Position Lock Lever

Miscellaneous Controls

A- Hydraulic Pump Free-Wheel Valves

Mounting and Dismounting Machine Safely

Do not step on the mower deck when mounting and dismounting the machine. Mount the machine from the front using the foot plate (A). Park machine safely (See Parking Safely in the SAFETY section) before dismounting.

Keep the foot plate clean.

Raising and Lowering Operator Seat

CAUTION: Avoid injury! The seat is heavy and can cause injury if it falls. When performing any service function under the operator seat, make sure the seat is tilted forward and rests against the hinge stops.

Raising the Seat:

1.Park machine safely. (See Parking Safely in the SAFETY section.)

2.Slide seat to full rear position.

3.Remove two locknuts (A) and capscrews securing the flanges at the rear of the seat frame (B) to the machine.

4.Lift seat frame and tilt forward until it rests against the hinge stops.

Lowering the Seat:

1.Stand on the side of the machine.

2.Slowly lower seat frame. Secure with cap screws and locknuts, removed earlier.

3.Adjust seat as necessary for operator comfort.

Operating - 11

OPERATING

Adjusting Seat

Front-to-Back Adjustment

1.Park machine safely. (See Parking Safely in the SAFETY section.)

2.Sit on the operator seat.

CAUTION: Avoid injury! Never adjust seat while machine is moving. Stop machine before adjusting seat to prevent loss of machine control.

3.To adjust the seat front to back, push and hold the seat adjustment lever

(A) away from the seat.

4.Slide forward or backward to desired position.

5.Release lever.

Seat Height Adjustment

1.Sit on the operator seat.

2.To lower the seat, turn knob (B) counterclockwise.

3.To raise the seat, turn knob (B) clockwise.

Using Seat Belt

CAUTION: Avoid injury! Always wear seat belt when operating machine with non-folding Roll-Over Protective Structure (ROPS) or folding ROPS in upright position. Do not jump from machine if machine tips.

•If folding ROPS must be folded to operate in a low clearance area, do not use seat belt. Raise ROPS and use seat belt as soon as conditions permit.

1.Sit in seat.

2.Pull belts across your lap and insert seat belt buckle (A) into latch (B) until it locks.

3.To release seat belt, press red button (C) until buckle comes out of latch.

Raising and Lowering ROPS

Raising ROPS

1.Park machine safely. (See Parking Safely in the SAFETY section.)

2.Remove spring pin (A) from drilled pin (B) on left and right side of ROPS. 3.Remove drilled pin from left and right side of ROPS.

Operating - 12

OPERATING

4.Push ROPS into upright position.

5.Install drilled pin (B) into holes on left and right side of ROPS, and secure in place with spring pins (A).

6.Check the ROPS bolt torque if the ROPS is loose.

Lowering ROPS

CAUTION: Avoid injury! Use roll-over protection system (ROPS) in lowered position only when low clearance operation is necessary.

•Do not use seat belt when ROPS is in lowered position.

•Do not operate machine on slope with ROPS in folded position.

•Raise ROPS and fasten seat belt as soon as conditions permit.

1.Park machine safely. (See Parking Safely in the SAFETY section). 2.Remove spring pin (A) from drilled pin (B) on left and right side of ROPS. 3.Remove drilled pin from left and right side of ROPS.

4.Pull ROPS rearward to lower.

5.Install drilled pins and spring pins back into hole in ROPS to secure in place.

Adjusting Mower Deck Cutting Height

CAUTION: Avoid injury! Rotating blades are dangerous and can cut fingers and toes. Stop engine, lock the park brake, and wait for blade to stop rotating before adjusting cutting height.

Cutting height can be adjusted from approximately 25-125 mm (1-5 in.). Each hole adjusts the height-of-cut (HOC) in approximately 12 mm (1/2 in.) increments.

The deck can also be raised and locked in a transport position, to provide maximum ground clearance when moving the machine from one area to another.

1.Park machine safely. (See Parking Safely in the SAFETY section.)

2.Move the mower deck lift lever (A) to the transport position (D).

3.Position the HOC adjustment pin (C) in the proper hole for the desired height-of-cut.

4.Pull back and hold the mower deck lift lever (A) and release the transport position lock lever (B).

5.Allow the mower deck lift lever (A) to rest against the HOC adjustment pin (C).

Adjusting Mower Deck Anti-Scalp Wheels

1.Park machine safely. (See Parking Safely in the SAFETY section.)

CAUTION: Avoid injury! Fingers and loose clothing can get caught in rotating parts. Do not operate machine without all mower deck belt shields installed.

NOTE: The flattest cut can be achieved by having all anti-scalp wheels adjusted off the ground. Check anti-scalp wheel adjustments each time the mower deck cutting height is changed.

It is recommended that all anti-scalp wheels be kept off the ground to minimize scuffing.

2.Inflate tires to correct pressure.

3.Adjust mower deck to desired cutting height.

Operating - 13

OPERATING

NOTE: The rear anti-scalp wheels are located under the rear of the mower deck.

4.Adjust anti-scalp wheel (A) to one of two positions (B).

Remove screw (C), nut and washer.

Adjust wheel up or down so it is approximately 6-13 mm (1/4-1/2 in.) above mowing surface.

5.Install wheel with attaching hardware. 6.Adjust all wheels to same height.

Testing Safety Systems

CAUTION: Avoid injury! Engine exhaust fumes contain carbon monoxide and can cause serious illness or death.

Move the machine to an outside area before running the engine.Do not run an engine in an enclosed area without adequate ventilation.•

•Connect a pipe extension to the engine exhaust pipe to direct the exhaust fumes out of the area.

•Allow fresh outside air into the work area to clear the exhaust fumes out.

The safety systems installed on your machine should be checked before each machine use. Be sure you have read the machine operator manual and are completely familiar with the operation of the machine before performing these safety system checks.

Use the following checkout procedures to check for normal operation of machine.

If there is a malfunction during one of these procedures, do not operate machine. See your authorized dealer for service.

Perform these tests in a clear open area. Keep bystanders away.

Testing Safety Systems

CAUTION: Avoid injury! Engine exhaust fumes contain carbon monoxide and can cause serious illness or death.

Move the machine to an outside area before running the engine.Do not run an engine in an enclosed area without adequate ventilation.•

•Connect a pipe extension to the engine exhaust pipe to direct the exhaust fumes out of the area.

•Allow fresh outside air into the work area to clear the exhaust fumes out.

The safety systems installed on your machine should be checked before each machine use. Be sure you have read the machine operator manual and are completely familiar with the operation of the machine before performing these safety system checks.

Use the following checkout procedures to check for normal operation of machine.

If there is a malfunction during one of these procedures, do not operate machine. See your authorized dealer for service.

Perform these tests in a clear open area. Keep bystanders away.

Testing PTO Switch

1.Sit on the operator seat with the motion control levers in the neutral detent position (standard levers) or neutral lock position (optional “over the lap” levers).

2.Lock the park brake.

3.Pull PTO knob up to engage.

4.Turn key switch to the start position.

Result: The engine must not crank.

Testing Park Brake Switch

1.Sit on the operator seat with the motion control levers in the neutral detent position (standard levers) or neutral lock position (optional “over the lap” levers).

2.Push PTO knob down to disengage.

3.Unlock the park brake.

4.Turn key switch to the start position.

Result: The engine must not crank.

Testing Neutral Start Switch

NOTE: Repeat this test three times, with the motion control levers in the following positions:

Right side motion control lever inward.

Left side motion control lever inward.

Both motion control levers inward.

1.Move motion control lever(s) out of the neutral detent position (standard levers) or neutral lock position (optional “over the lap” levers).

2.Lock the park brake.

3.Push PTO knob down to disengage.

4.Turn key switch to the start position.

Result: The engine must not crank.

Operating - 14

OPERATING

Testing Seat Switch

Procedure 1:

1.Sit on the operator seat with the motion control levers in the neutral detent position (standard levers) or neutral lock position (optional “over the lap” levers).

2.Unlock the park brake.

3.Push PTO knob down to disengage.

4.Turn key switch to the start position.

5.Raise slightly off the seat.

Result: The engine must stop.

Procedure 2:

1.Start engine.

2.Lock the park brake.

3.Pull PTO knob up to engage.

4.Raise slightly off the seat.

Result: The engine must stop.

Testing the Park Brake

1.Stop machine on a 17° slope (30% grade). Stop the engine and lock the park brake.

Result: Park brake must hold the machine stationary. (Machine should move no more that 61 cm (24 in.) in one hour.) If machine moves more than that, brakes need to be adjusted. See Adjusting Park Brake in the Service Steering & Brakes section.

Using the Park Brake

CAUTION: Avoid injury! Children or bystanders may attempt to move or operate an unattended machine.

Always lock the park brake and remove the key before leaving the machine unattended.

Locking Park Brake:

CAUTION: Avoid injury! If the engine should stop while operating on an incline, the mower can free wheel. If this should occur:•lock the park brake,

•start the engine,

•unlock the park brake,

•resume operation.

• Raise and pull rearward park brake lever (A) to lock the park brake.

Unlocking Park Brake:

• Lower park brake lever (A) forward to unlock the park brake.

Operating - 15

OPERATING

Using the Key Switch

NOTE: Machine will only start if the following conditions exist:

Park brake is locked.

PTO is disengaged.

Motion control levers are in the neutral detent position (standard levers) or neutral lock position (optional “over the lap” levers).

A

B

STOP

C

To turn ignition off, turn key to the STOP position (A).

To turn ignition on, turn key to the run position (B).

To start engine, turn key to the start position (C). Once engine begins to run, release key back to the run position.

Using the PTO

Engage PTO:

1.Move throttle lever (A) to the 1/2- to 3/4-throttle position. 2.Pull PTO knob (B) up to engage mower deck.

3.Move throttle lever (A) forward to the fast detent position (C) for mowing.

Disengage PTO:

• Push PTO knob (B) down.

Using the Throttle Lever

Push throttle lever (A) all the way forward to the full-throttle detent position (B) when mowing.

Move throttle lever (A) to the 1/2-throttle position (C) when starting and warming the engine.

Pull throttle lever (A) rearward to the slow position (D) to idle engine. Do not run engine at slow idle any longer than necessary.

Using the Hourmeter

NOTE: The machine is equipped with an electric start. The hourmeter will continue to run with the key switch left in the run position.

The hourmeter (A) shows the number of hours the machine has run.

The service interval chart gives necessary service intervals. Use the hourmeter and service interval chart in the Service Intervals section to determine when machine will need service.

See the service interval chart in the engine manufacturer’s owners manual supplied with your machine to determine when the engine will need service.

Operating - 16

OPERATING

Using the Choke

Engage Choke:

• Pull choke knob (A) out.

Disengage Choke:

• Push choke knob (A) in.

Using the Motion Control Levers

CAUTION: Avoid injury! Learn use of the motion control levers and practice at half throttle until becoming proficient and comfortable with the operation of the machine.

Do not move motion control levers from forward to reverse or reverse to forward position rapidly. Sudden direction changes could cause loss of control or damage the machine.

NOTE: Two types of control levers are available - standard “center steer” levers and optional “over the lap” levers. The operation of both styles of levers is the same except as noted.

The functions of the motion control levers are:

Dual function neutral position.

Steering.

Acceleration.

Braking.

Neutral Detent Position - Standard “Center Steer” Levers

NOTE: When the control levers are in the neutral detent position, the control lever rollers (A) located on each side of the control console will be seated in the notches in the console.

• Motion control levers must be in the neutral detent position, the PTO

switch disengaged and the park brake locked to start the engine.

Neutral Lock Position - Optional “Over the Lap” Levers

Picture Note: Motion control levers (A) shown in the neutral lock position.

Motion control levers must be in the neutral lock position, the PTO switch disengaged and the park brake locked to start the engine.

Forward and reverse movement of the motion control levers is prevented when levers are moved to the neutral lock position.

Operator can exit mower with the engine running when the PTO switch is disengaged, the motion control levers are in the neutral lock position and the park brake is locked.

Motion control levers must be in the neutral lock position to safely enter and exit the operator seat.

Neutral Position - Optional “Over the Lap” Levers

Picture Note: Motion control levers (A) shown in the neutral position.

• Machine speed, motion, and direction can be controlled when the engine is running, operator is on the seat and the park brake is unlocked.

Operating - 17

OPERATING

Forward and Reverse Motion:

CAUTION: Avoid injury! Children or bystanders can be injured or killed by moving machine and rotating blades. Before traveling forward or rearward:•

•Carefully check area around machine.

•Disengage mower before backing up.

1.Move throttle lever to the full-throttle position.

2.Unlock the park brake.

3.Optional “over the lap” levers: Move both motion control levers from the neutral lock position inward to the neutral position.

4.Push the control levers forward to begin forward motion.

The farther forward the control levers are moved, the faster the machine will travel.

Forward speed range: 0-14 km/h (0-9 mph).

5.Pull both control levers rearward at the same time to begin reverse motion.

• Reverse speed range: 0-6 km/h (0-4 mph).

6.To stop motion, move both motion control levers forward or rearward until the machine comes to a stop.

NOTE: The motion control linkages are adjustable. If adjustment is required, see Checking and Adjusting Motion Control Linkages in the Service Transmission section.

Forward:

• Push both motion control levers forward at the same time.

Reverse:

• Pull both control levers past center rearward at the same time.

Gentle Left Turn:

• Push right control lever farther forward than the left control lever.

Gentle Right Turn:

• Push left control lever farther forward than the right control lever.

Operating - 18

OPERATING

Sharp Left Turn:

• Push right control lever forward and pull left control lever rearward at the same time.

Sharp Right Turn:

4.Push PTO knob (A) down to disengage PTO. 5.Move throttle lever to set engine speed:

Cold engine: Set throttle lever at the 1/2- to 3/4-throttle position.

Warm/Hot engine: Set throttle lever to the 1/2-throttle position. 6.Position choke knob (D):

Cold engine: Pull knob up and hold in choke position.

Warm/Hot engine: If necessary, pull knob up and hold in choke position.

IMPORTANT: Avoid damage! Starter may be damaged if starter is operated for more than 20 seconds at a time:

• Wait two minutes before trying again if engine does not start.

• Push left control lever forward and pull right control lever rearward at the same time.

Starting the Engine

CAUTION: Avoid injury! Engine exhaust fumes contain carbon monoxide and can cause serious illness or death.

Move the machine to an outside area before running the engine.Do not run an engine in an enclosed area without adequate ventilation.

•Connect a pipe extension to the engine exhaust pipe to direct the exhaust fumes out of the area.

•Allow fresh outside air into the work area to clear the exhaust fumes out.

1.Sit on the operator seat.

2.Lock the park brake.

3.Move both motion control levers to the neutral detent position (standard levers) or neutral lock position (optional “over the lap” levers).

STOP

C

B

7.Turn key switch to start position (B).

If the engine does not start, wait 10 seconds.

Turn key to start position again for no more than 5 seconds.

Repeat the procedure if necessary.

IMPORTANT: Avoid damage! Unnecessary engine idling can cause engine overheating, carbon build-up, and poor performance.

8.Release key to run position (C) when engine starts. 9.With engine started:

Push choke knob to off position.

Move throttle lever to full-throttle position.

Unlock the park brake.

Operating - 19

OPERATING

Engaging Mower

CAUTION: Avoid injury! Clear mowing area of all bystanders when operating this machine.

Thrown objects could cause serious injury or death.

Keep hands and feet away from blades and discharge opening.

Do not mow in reverse unless absolutely necessary.

IMPORTANT: Avoid damage! To help prevent damage to PTO clutch:

• Do not engage PTO with throttle in the fast position.

1.Adjust mower deck to desired cutting height. 2.Start engine.

3.Move throttle lever to the 1/2 - 3/4 throttle position. 4.Unlock the park brake.

5.Move both motion control levers to the neutral position.

NOTE: In cold weather or with a new machine, it may be necessary to engage the choke at the same time as the PTO knob to prevent the engine from stalling.

6.Pull PTO knob (A) up to engage mower deck.

7.Move throttle lever to full-throttle position.

NOTE: The travel speed and turn rate will vary with the amount that the control levers are moved.

8.Push motion control levers forward slowly. Mow at a safe travel speed.

Stopping the Engine

IMPORTANT: Avoid damage! To help prevent engine backfiring, throttle lever should be set at the 1/4 throttle position and run for 30 seconds prior to stopping the engine.

Do not stop engine when mower is on a slope of more than 30° for an extended period of time. Oil may run through valve train into carburetor and muffler.

1.Move the motion control levers to the neutral detent position (standard levers) or neutral lock position (optional “over the lap” levers).

2.Lock the park brake.

3.Push PTO switch down to disengage.

4.Move throttle lever to 1/4-throttle position and run for 30 seconds, then

move throttle to slow position.

A

STOP

5.Turn key switch to STOP position (A).

CAUTION: Avoid injury! Children or bystanders may attempt to move or operate an unattended machine.

Always lock the park brake and remove the key before leaving the machine unattended.

6.Remove key.

Transporting Machine

CAUTION: Avoid injury! Use extra care when loading or unloading the machine into a trailer or truck.

Close fuel shut-off valve, if your machine is equipped.

IMPORTANT: Avoid damage! Transmission damage may occur if the machine is moved or towed incorrectly:

Move unit by hand only.

Do not use another vehicle to move unit.

Do not tow unit.

Use a heavy-duty trailer to transport your machine. Trailer must have signs and lights required by law.

1.Raise the mower deck lift lever to the transport position.

2.Drive machine on trailer.

3.Stop engine and lock the park brake.

4.Remove key.

5.Fasten machine to trailer with heavy-duty straps, chains or cables. Both front and rear straps must be directed down and outward from machine.

Mowing Tips

Mow grass with throttle lever in the full fast position.

Cut grass when it is dry.

Keep mower deck and discharge chute clean.

Mow with sharp blades.

Properly level mower deck for a smooth cut.

Mow grass high and often.

Use a travel speed that fits the conditions:

Operating - 20

SERVICE INTERVALS

Mow tall or wet grass twice. Cut grass at half desired height – then cut at desired height.

Travel slow when mowing tall, thick or wet grass.

Avoid damaging grass by slipping or skidding machine drive wheels. Practice smooth control lever movements.

When performing sharp turns, do not allow inside machine drive wheel to stop and twist on grass.

Mowing Travel Speeds

Use slow travel speed for:

Trimming.

Working in close quarters.

Mowing tall grass.

Use faster travel speeds for:

• Normal mowing on level ground.

Dismounting to Inspect Mower

CAUTION: Avoid injury! Help prevent serious injury. Keep hands and feet away from blades and the discharge opening.

Do not step on either side of the mower deck when mounting and dismounting the machine. Mount and dismount the machine using the front foot plate.

1.Park machine on a hard, level surface.

2.Push PTO knob down to disengage mower.

3.Move motion control levers to the neutral detent position (standard levers) or neutral lock position (optional “over the lap” levers).

4.Lock the park brake.

5.Stop engine and remove key. Always wait for mower blades to stop turning before leaving operator seat.

Service Intervals

Servicing Your Machine

IMPORTANT: Avoid damage! Operating in extreme conditions may require more frequent service intervals:

Engine components may become dirty or plugged when operating in extreme heat, dust or other severe conditions.

Engine oil may lose efficiency if vehicle is operated constantly at slow or low engine speeds or with frequent short trips.

Please use the following timetables to perform routine maintenance on your machine.

Break-In (After First 8 Hours of Operation)

NOTE: The following initial break-in items must be performed and verified to validate the warranty (dealer service invoice accepted).

Change engine oil and filter.

Check drive belt tension.

Check mower deck drive belt tension.

Check transmission neutral adjustment.

Check wheel nut torque.

Check and adjust (as needed) park brake.

Remove debris from the underside of the mower deck.

Every 25 Hours or Weekly (Whichever Comes First)

Grease mower deck thrust arms (two places).

Grease mower deck thrust arms (two places).

Grease traction drive belt tension arm.

Grease mower deck drive belt tension arm.

Grease HOC shafts (four places).

Lubricate front caster wheel spindles.

Remove debris from the underside of the mower deck.

Every 50 Hours or Weekly (Whichever Comes First)

Change engine oil and filter. See the engine manufacturer’s owner’s manual provided with your machine for the complete procedure.

Grease caster wheel spindle bearings (two places).

Grease mower deck thrust arms (two places).

Remove debris from the underside of the mower deck.

Check drive belt tension.

Check tire pressure.

Clean engine air filter.

Check wheel nut torque.

Every 160 Hours or Monthly (Whichever Comes First)

Grease mower spindle bearings (three places).

Check transmission oil level.

Check transmission oil level.

Lubricate mower deck idler pulley pivots (three places).

Lubricate seat platform hinges (two places)

Lubricate pump control arms (five places).

Lubricate control lever pivot shafts (two places).

Lubricate throttle cable.

Lubricate choke control cable.

Annually

Inspect all spindle bearings (6). Replace as needed.

Inspect all mower deck idler pulleys (3). Replace as needed.

Remove and inspect caster wheel roller bearings; clean and pack with grease. Replace as needed.

Remove and inspect caster pivot bearings; clean and pack with grease. Replace as needed.

Inspect drive belts. Replace as needed. Run-in and adjust tension.

Change hydraulic oil and filter (annually or 500 hours whichever comes first).

Check all bolts and nuts; tighten as needed.

Remove battery. Clean battery and holder.

Replace spark plugs.

Service Intervals - 21

SERVICE LUBRICATION

Service Lubrication

Grease

IMPORTANT: Avoid damage! The recommended grease is effective within an average air temperature range of -29 to 135 degrees C (-20 to 275 degrees F).

If operating outside that temperature range, contact your servicing dealer for a special-use grease.

Use a general all-purpose grease with an NLGI grade No.2 rating.

Wet or high speed conditions may require use of a special-use grease. Contact your Servicing dealer for information.

Spray Lubricant

Use a general-purpose petroleum-based spray lubricant.

Lubrication Points

CAUTION: Avoid injury! Rotating parts can catch fingers, loose clothing, or long hair. Wait for engine and all moving parts to stop before leaving operator’s station to adjust or service machine.

1.Park machine safely. (See Parking Safely in the SAFETY section.)

2.Grease caster wheel spindle bearings (B).

3.Grease HOC shafts (C) (two points on each side of the machine).

4.Grease mower deck thrust arms (D), located at the rear of the mower deck.

5.Apply grease to three spindle bearings.

Service Lubrication - 22

SERVICE ENGINE

6.Grease traction drive belt tension arm pivot (G).

7.Grease mower deck drive belt tension arm (H).

NOTE: Use spray lubricant to lubricate the following items:

8.Lubricate mower deck idler pulleys (K-M).

9.Lubricate hydraulic pump control arms (N). 10.Lubricate control lever pivot shaft (O). 11.Lubricate seat platform hinges (P). 12.Lubricate throttle control cable (Q). 13.Lubricate choke control cable (R).

Service Engine

Engine Warranty Maintenance Statement

Maintenance, repair, or replacement of the emission control devices and systems on this engine, which are being done at the customer’s expense, may be performed by any non-road engine repair establishment or individual. Warranty repairs must be performed by an authorized servicing dealer.

Avoid Fumes

CAUTION: Avoid injury! Engine exhaust fumes contain carbon monoxide and can cause serious illness or death.

Move the machine to an outside area before running the engine.Do not run an engine in an enclosed area without adequate ventilation.•

•Connect a pipe extension to the engine exhaust pipe to direct the exhaust fumes out of the area.

•Allow fresh outside air into the work area to clear the exhaust fumes out.

Engine Oil

Use oil viscosity based on the expected air temperature range during the period between oil changes.

Use oil that meets the following specification:

• See the engine manufacturer’s owner’s manual provided with your machine for the correct specifications.

Service Engine - 23

SERVICE ENGINE

Checking Engine Oil Level

CAUTION: Avoid injury! Touching hot surfaces can burn skin. The engine, components, and fluids will be hot if the engine has been running. Allow the engine to cool before servicing or working near the engine and components.

IMPORTANT: Avoid damage! Failure to check the oil level regularly could lead to serious engine problems if oil level is low:

Check oil level before operating.

Keep oil level between the FULL and the ADD marks.

Check oil level when engine is stopped, level, and is cooled so oil has had time to drain into the sump.

NOTE: Check oil twice a day if you run engine over 4 hours in a day. Make sure engine is cool when checking engine oil level.

1.Park machine safely. (See Parking Safely in the SAFETY section.)

2.Allow engine to cool.

IMPORTANT: Avoid damage! Dirt and debris in oil may cause damage to the engine. Clean area around opening before removing plug or dipstick.

3.Remove dipstick (A). Wipe with a clean cloth.

4.Install dipstick and allow the cap to rest on the end of the tube. Do not tighten the cap.

IMPORTANT: Avoid damage! To prevent extensive engine wear or damage, always maintain the proper engine oil level. Never operate the engine with the oil level below the add mark or over the full mark.

5.Remove dipstick and check oil level on dipstick. Oil must be between the ADD and FULL marks.

If oil is low, add oil to bring oil level no higher than the FULL mark on dipstick.

If oil level is above the FULL mark, drain to proper level.

6.Install and tighten dipstick.

Changing Engine Oil and Filter

IMPORTANT: Avoid damage! Change the oil more often if the vehicle is used in extreme conditions:

Extremely dusty conditions.

Frequent slow or low-speed operation.

Frequent short trips.

1.Run engine to warm oil.

2.Park machine safely. (See Parking Safely in the SAFETY section).

3.Put container under drain tube.

4.Open drain valve (A) using a 10 mm socket, 1 ft extension, swivel and 3/ 8 in. drive ratchet.

5.Allow oil to drain into an oil drain pan.

6.After oil drains, close drain valve.

7.Remove oil filter using an appropriate filter wrench. Turn filter counterclockwise to remove.

8.Apply a film of clean engine oil on gasket of new filter.

9.Install filter. Turn filter clockwise until gasket makes contact with mounting surface. Tighten 1/2 to 3/4 turn after gasket contact.

10.Clean area around the dipstick.

11.Unscrew and remove dipstick.

IMPORTANT: Avoid damage! To prevent extensive engine wear or damage, always maintain the proper engine oil level. Never operate the engine with the oil level below the add mark or over the full mark.

12.Add approximately 1.4 L (1.5 qt) of oil.

13.Install and tighten dipstick.

14.Start engine and run at slow throttle for approximately two minutes. Check for leaks around filter and drain valve.

15.Stop engine.

16.Check oil level:

Remove dipstick. Wipe with a clean cloth.

Install dipstick and allow the cap to rest on the end of the tube. Do not tighten the cap.

Remove dipstick and check oil level on dipstick. Oil level should be between the ADD and FULL marks. Add oil if needed.

17.Install and tighten dipstick.

MODEL

Oil Capacity With Filter (Dry)

 

 

 

 

Kawasaki Engines

1.8 L (1.9 qt)

 

 

Kohler Engines

2.0 L (2.1 qt)

 

 

Service Engine - 24

SERVICE ENGINE

Cleaning Engine Air Intake Screen and Fan

CAUTION: Avoid injury! Compressed air can cause debris to fly a long distance.•

•Clear work area of bystanders.

•Wear eye protection when using compressed air for cleaning purposes.

•Reduce compressed air pressure to 210 kPa (30 psi).

IMPORTANT: Avoid damage! An obstructed air intake screen can cause engine damage due to overheating. Keep air intake screen and other external surfaces of the engine, including cooling fins, clean at all times to allow adequate air intake.

Keep air intake screens and engine cooling fins clear of debris to ensure proper cooling. See the engine manufacturer’s owner’s manual provided with your machine for the complete procedure.

Checking and Cleaning Air Filter Elements

CAUTION: Avoid injury! Touching hot surfaces can burn skin. The engine, components, and fluids will be hot if the engine has been running. Allow the engine to cool before servicing or working near the engine and components.

IMPORTANT: Avoid damage! Dirt and debris can enter the engine through a damaged filter element:

Do not wash paper element.

Do not attempt to clean paper element by tapping against another object.

Do not use pressurized air to clean element.

Replace element only if it is very dirty, damaged or the seal is cracked.

NOTE: It may be necessary to check the air filter more frequently if operating machine in dusty conditions.

Check and clean air filter elements at the intervals recommended in the Service Intervals section. See the engine manufacturer’s owner’s manual provided with your machine for the complete procedure.

Cleaning Engine Oil Cooler - Kohler Engines

Keep engine oil cooler fins clear of debris to ensure proper cooling. See the engine manufacturer’s owner’s manual provided with your machine for the complete procedure.

Checking Spark Plug

CAUTION: Avoid injury! Touching hot surfaces can burn skin. The engine, components, and fluids will be hot if the engine has been running. Allow the engine to cool before servicing or working near the engine and components.

IMPORTANT: Avoid damage! Do not clean spark plugs with abrasives.

Check spark plugs at the intervals recommended in the Service Intervals section. See the engine manufacturer’s owner’s manual provided with

your machine for the complete procedure.

Adjusting Carburetor

NOTE: Carburetor is calibrated by the engine manufacturer and is not adjustable.

If engine is operated at altitudes above 1829 m (6,000 ft), some carburetors may require a special high altitude main jet. See your authorized dealer.

If engine is hard to start or runs rough, check the TROUBLESHOOTING section of this manual.

Possible engine surging will occur at high throttle with transmission in “N” neutral and mower engagement lever disengaged. This is a normal condition due to the emission control system.

After performing the checks in the troubleshooting section and your engine is still not performing correctly, contact your authorized dealer.

Replacing Fuel Filter

CAUTION: Avoid injury! Fuel vapors are explosive and flammable:•Do not smoke while handling fuel.

•Keep fuel away from flames or sparks.

•Shut off engine before servicing.

•Cool engine before servicing.

•Work in a well-ventilated area.

•Clean up spilled fuel immediately.

1.Park machine safely. (See Parking Safely in the SAFETY section.)

2.Allow engine to cool.

3.Place a drain pan under hoses to catch any fuel that may be left in hoses.

Picture Note: Kawasaki engine shown.

4.Locate fuel hose (A) coming from fuel tank, disconnect it from the inlet side of fuel filter (B) and drain gasoline into a properly marked container.

5.Remove fuel filter from fuel hose (C) going to engine. Discard filter.

IMPORTANT: Avoid damage! When installing a new fuel filter, the filter arrow must be pointing in the direction of fuel flow. Make sure clamps are installed properly.

6.Connect a new fuel filter to hoses. Make sure fuel filter is installed with arrow pointing in direction of fuel flow.

Service Engine - 25

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