Great Dane Super Surfer Series II GSKH2352S, Super Surfer Series II GSKH1848S, Super Surfer Series II GSKW1948S, Super Surfer Series II GSKH2561S, Super Surfer Series II GSKW2352S User Manual

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Super Surfer Series II

GSKH1848S, GSKH2352S, GSKH2561S GSKW1948S, GSKW2352S, GSKA1948S

OPERATOR’S MANUAL

200036 REV. 04/11/2007

North American Version

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 Previous Editions COPYRIGHT© 2002

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.

c

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

Super Surfer

GSKH18-48S Serial Number (636510001-)

GSKH23-52S Serial Number (636610001-)

GSKH25-61S Serial Number (636710001-)

GSKW1948S Serial Number (636410001-)

GSKW2352S Serial Number (637010001-)

GSKA1948S Serial Number (6373010001-)

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:

_________________________________________

PRODUCT IDENTIFICATION NUMBER: Model Number

_________________________________________

Serial Number

_________________________________________

SAFETY LABELS

ENGINE MODEL, SPECIFICATION, AND SERIAL NUMBER: Model Number

_________________________________________

Specification

_________________________________________

Serial Number

_________________________________________

Safety Labels

Understanding The Machine Safety Labels

Safety-Alert Symbol

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.

Safety Labels

MX20097

WARNING (A)

Hot Surface.

WARNING (B)

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

DANGER (C)

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

DANGER (D)

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.

DANGER (E)

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

MX20138

DANGER (F)

To avoid injury to children, stop mower when children are near. Do not mow in reverse. Look behind when backing. Never carry riders, especially children.

CAUTION: (G)

Before operating read operators manual and safety instructions.

Safety Labels - 2

SAFETY

CAUTION: HELP AVOID INJURY (H)

Operator training required

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

CAUTION (I)

Be safe! To avoid a fire hazard remove all leaves, grass and debris from engine, hydro pumps and motors, pulleys, belts, hoses, engine deck and cutter deck.

DANGER/POISON (J)

Shield Eyes: Explosive gases can cause blindness or injury.

NO

Sparks

Flames

Smoking

Sulfuric acid can cause blindness or severe burns.

Flush eyes immediately with water. Get medical help fast.

Keep out of reach of children.

Do not tip.

Do not open battery.

WARNING (K)

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

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.

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.

Safety - 3

SAFETY

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.

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

Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job.

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

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.

Parking Safely

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

2.Disengage mower blades.

3.Lock the park brake.

4.Stop the engine.

5.Remove the key.

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

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

8.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.

Safety - 4

SAFETY

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.

Protect Children

MX18014

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. Never mow on inclines exceeding 15°.

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.

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. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. Information may be obtained in the United States and Canada only by calling 1-800- 822-8262.

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.

Safety - 5

SAFETY

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.

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.

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.

Safety - 6

OPERATING

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

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

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

Remove grass and debris from machine and mower deck.

Remove grass and debris from operator station foot plate, pump drive belt compartment, hydraulic pump and pump mounting plate.

Test park brake.

Test safety systems.

Check battery.

Check for oil leaks.

Check engine oil and hydraulic oil levels.

Check all belts for damage or cracking.

Check engine air filter.

Check mower level.

Adjust cutting height if necessary.

Check wheel bolt torque. Tighten if necessary.

Check tire air pressure. Check tires for damage or cracking. Check and adjust speed control linkages and lock.

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.

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

MX20138

Picture Note:

A-Speed Control Bar Lock

B-Speed Control Bar

C-Left Motion Control Lever

D-Right Motion Control Lever

E-Hydrostatic Oil Reservoir Cap and Dipstick

F-Ignition Key Switch

G-Fuel Tank Cap

H-PTO Switch

I-Optional Light Switch Location

J-Hourmeter

Operating - 7

OPERATING

K-Choke

L-Throttle Lever

M-Park Brake Lever

Mower Deck Controls

A-Mower Deck Lift Levers

B-Height-of-Cut (HOC) Pin

Miscellaneous Controls

A-Free-Wheeling Valves

Mounting and Dismounting Machine Safely

MX20095

1.Step on operator’s platform (A) at the rear of machine to mount the machine.

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

MX20093

3. Step off operator’s platform to dismount machine.

4. Keep operator’s platform and suspension springs clean and free of debris.

Raising and Lowering Thigh Pad

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

MX20094

MX20096

2. Raise and lower thigh pad (A) as required.

Adjusting Mower Deck Cutting Height

The mower deck height adjustment consists of seven different cutting heights. The cutting heights range from 38-114 mm (1-1/2-4-1/2 in.) in 13 mm (1/2 in.) increments.

c

CAUTION: Avoid injury! Before adjusting cutting height, stop engine and lock the park brake.

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

2.Disengage PTO.

Operating - 8

OPERATING

3. Stop engine and lock park brake.

NOTE: Discharge chute raised for clarity.

 

 

 

 

 

 

MX20099

4.Remove retaining ring (A) from HOC pin (B).

5.Push down on deck lift lever (C).

6.Remove HOC pin.

7.Place HOC pin in desired height hole (D).

8.Release deck lift lever (C).

9.Install retaining ring (A) in HOC pin (B).

10.Repeat procedure for opposite side.

Leveling Mower Deck

c

CAUTION: Avoid injury! Rotating blades are dangerous. Before adjusting or servicing mower:

Disconnect spark plug wire(s) or battery negative (-) cable to prevent engine from starting accidently.

Always wear gloves when handling mower blades or working near blades.

NOTE: Mower deck anti-scalp wheels should not contact the ground.

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

2.Inflate tires to the correct pressure.

3.Inspect mower blades for:

Blade sharpness.

Blade damage.

Bent blades.

Checking Level (Side-to-Side)

NOTE: Mower deck anti-scalp wheels should not contact the ground.

1. Adjust mower deck to 76 mm (3 in.) cutting height position.

MX20139

2. Position right mower blade (A) (discharge side) perpendicular to direction of travel.

NOTE: Use a short ruler or a leveling gauge to check the mower blade level.

3.Measure distance (B) from outside blade tip to the ground.

4.Position left mower blade perpendicular to direction of travel.

5.Measure from outside blade tip to the ground.

The difference between both measurements should be no greater than 3 mm (1/8 in.).

6.If side-to-side level is not within the tolerance, an adjustment is necessary.

Adjusting Level (Side-to-Side)

NOTE: When adjusting U-bolts, maintain a minimum clearance of 3 mm (1/8 in.) between mower deck and stop pads.

MX20099

Adjust four U-bolts (C) (two on each side of deck) until deck is within 3 mm (1/8 in.) of level from side-to-side.

Operating - 9

OPERATING

MX20100

a.Loosen jam nuts (D) and adjust nuts (E) on each U-bolt until side-to side level is reached.

b.Tighten jam nuts (D).

Checking Level (Front-to-Rear)

1. Set height-of-cut (HOC) to the 76 mm (3 in.) cutting height position.

NOTE: The height of the rear blade tip should be between 3-6 mm (1/ 8-1/4 in.) higher than the front blade tip.

MX20122

2.Position right mower blade (F) (discharge side) parallel to the direction of travel.

3.Measure distance (G) from front blade tip to the ground.

4.Turn blade 180° and measure from rear blade tip to the ground.

5.If the front-to-rear level is not within the tolerance, an adjustment is necessary.

Adjusting Level (Front-to-Rear)

c

IMPORTANT: Avoid damage: Adjust the left and right deck lift assist rods equally.

NOTE: Adjust side-to-side mower level before adjusting front-to-rear level.

Adjust both sides of the mower deck equally. All lift chains must remain taut.

MX20099

1.Loosen jam nut (H) on both deck lift assist rods.

2.Adjust front-to-rear mower level:

Turn nut (I) on both sides clockwise to raise front of mower deck, or counterclockwise to lower front of mower deck.

3.Verify that the adjustment on right and left sides is equal.

4.Tighten jam nuts (H).

5.Check front-to-rear mower level.

Checking and Adjusting Cutting Height

c

CAUTION: Avoid injury! Rotating blades are dangerous. Before adjusting or servicing mower:

•Disconnect spark plug wire(s) or battery negative (-) cable to prevent engine from starting accidentally.

•Always wear gloves when handling mower blades or working near blades.

Checking Overall Cutting Height

1.Inflate tires to correct pressure.

2.Lower mower deck to the 76 mm (3 in.) cutting height.

3.Position right mower blade (discharge side) parallel to the direction of travel.

4.Measure from the front of the blade tip to the ground.

5.If blade tip height is not within 73-79 mm (2-7/8-3-1/8 in.), an adjustment is needed.

Operating - 10

OPERATING

Adjusting Overall Cutting Height

NOTE: When adjusting U-bolts, maintain a minimum clearance of 3 mm (1/8 in.) between mower deck and stop pads.

Adjust both sides of the mower deck equally. All lift chains must remain taut.

MX20099

1. Adjust four U-bolts (A) (two on each side of deck) until blade tip height is within 73-79 mm (2-7/8-3-1/8 in.) of the 76 mm (3 in.) setting.

Adjusting Mower Deck Anti-Scalp Wheels

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.

1.Inflate tires to correct pressure.

2.Adjust mower deck to desired cutting height.

MX15658

3.Adjust anti-scalp wheel (A) to one of three positions (D).

Remove screw (E), nut (C) and washer (B).

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

4.Install wheel with attaching hardware.

5.Adjust all wheels to the same height.

Testing Safety Systems

c

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.

cIf 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.Stand on operator’s platform with motion control levers in the neutral position.

2.Lock park brake.

3.Pull PTO switch up to engage.

4.Turn key switch to the start position.

Result: The engine must not crank.

Testing Park Brake Switch

1.Push PTO switch down to disengage.

2.Unlock park brake.

3.Turn key switch to the start position.

Result: The engine must not crank.

Testing Neutral Switch (Start)

1.Lock park brake.

2.Push PTO switch down to disengage.

3.Push one motion control lever forward.

4.Turn key switch to the start position.

Result: The engine must not crank.

Testing Neutral Switch (Run)

1.Lock park brake.

2.Push PTO switch down to disengage.

3.Start engine.

4.Push one motion control lever forward.

5.Repeat procedure using the other lever.

6.Repeat procedure pushing each motion control lever rearward.

Result: The engine must stop when either lever is moved from neutral position.

Operating - 11

OPERATING

Testing Operator Presence Switch

NOTE: Ensure OPC switch bracket is depressed when standing on operator’s station.

1.Stand on operator’s platform with motion control levers in the NEUTRAL position.

2.Start engine.

3.Unlock park brake.

4.Step completely off operator’s platform.

Result: The engine must stop.

NOTE: Ensure OPC switch bracket is depressed when standing on operator’s station.

5. Stand on operator’s platform with motion control levers in the NEUTRAL position and start engine.

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CAUTION: Avoid injury! Thrown objects can be dangerous. Before operating the attachment:

Clear area of bystanders, especially children.

Pick up objects which may be thrown by the attachment.

6.Pull PTO switch up to engage.

7.Step completely off operator’s platform.

Result: The engine must stop.

Testing the Park Brake

MIF

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

2.Repeat procedure with machine facing uphill.

Result: Park brake must hold the machine stationary. (Machine should move no more that 61cm (24 in.) in one hour.) If machine moves more than that, brakes need to be adjusted. See your authorized dealer or refer to Adjusting Park Brake in the SERVICE STEERING AND BRAKES section.

Using Park Brake

Locking Park Brake

MX20102

Raise park brake lever (A) to lock park brake. Unlocking Park Brake:

Lower park brake lever (A) to unlock park brake.

Using the PTO

Engage PTO:

1.Stand on operator’s platform with motion control levers in the neutral position.

2.Start engine.

3.Release park brake.

4.Move throttle lever to the 1/2 to 3/4 fast position.

MX12854

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

6.Move throttle lever forward to the fast position for mowing.

Disengage PTO:

1.Push PTO knob (A) down.

2.Set park brake.

Operating - 12

OPERATING

Using the Throttle

Neutral Position

 

 

 

 

 

 

MX12847

Push throttle lever (A) forward to the fast position (B) when mowing.

Move throttle lever (A) to the half fast position (C) when starting and warming the engine.

Pull throttle lever (A) backward to the slow position (D) to idle engine. Do not run engine at slow idle any longer than necessary for cooldown after mowing.

Using the Hourmeter

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

MX20091

Hourmeter (A) shows number of hours the machine has been operated.

Use hourmeter and SERVICE INTERVAL section to determine when machine needs service.

Using the Motion Control Levers

The functions of the motion control levers are:

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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.

Steering.

Acceleration.

Deceleration.

MX20091

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

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

Operator can exit the mower with the engine running when the park brake is locked and the PTO switch is disengaged.

Forward and Reverse Motion:

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CAUTION: Avoid injury! Children or bystanders may be injured by runover and rotating blades. Before traveling forward or rearward:

Carefully check the area around the machine.

Disengage the mower before backing up.

1.Move throttle lever to the fast position.

2.Unlock park brake.

3.Push motion control levers forward to begin forward motion. The further forward the control levers are moved, the faster the machine will travel.

Forward speed range: 0–14.8 km/h (0–9.2 mph)

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

•Reverse speed range: 0–6.4 km/h (0–4 mph)

5. 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.

Operating - 13

OPERATING

Forward:

MX12788

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

Reverse:

MX12789

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

Gentle Left Turn:

MX12790

• Push right motion control lever further forward than the left motion control lever.

Gentle Right Turn:

MX12791

• Push left motion control lever further forward than the right motion control lever.

Sharp Left Turn:

MX12792

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

Sharp Right Turn:

MX12793

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

Operating - 14

OPERATING

Starting Engine

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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.Stand on operator’s platform.

2.Lock park brake.

MX20091

3.Put motion control levers (A) in the NEUTRAL position.

4.Push PTO switch knob (B) down to disengage PTO.

5.Move throttle lever (C) to set engine speed at the 1/2 to 3/4 fast position.

6.Position choke knob (D):

Cold engine: Pull knob up to the CHOKE position.

Warm/Hot engine: If necessary, pull knob up to the CHOKE position.

7.Turn key switch (E) to the START position.

8.Release key to the RUN position when engine starts.

9.With engine started:

Push choke knob to the OFF position.

Move throttle lever to the FAST position.

Unlock park brake.

Engaging Mower

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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.

MX20091

3.Move throttle lever (A) to the 1/2 to 3/4 fast position.

4.Unlock park brake.

NOTE: In cold weather or with a new machine, allow engine to reach operating temperature before engaging PTO to prevent engine from stalling.

5.Pull PTO knob (B) up to engage mower deck.

6.Move throttle lever to the fast position (C).

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

7. Push motion control levers (D) forward slowly. Mow at a safe travel speed.

Stopping the Engine

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IMPORTANT: Avoid damage! To help prevent engine backfiring, throttle lever should be set at the half-speed position prior to stopping the engine.

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

1.Lock park brake.

2.Reduce engine speed to half-throttle.

3.Turn key switch to STOP position (C).

4.Remove key.

Operating - 15

OPERATING

Using Pump Free-Wheel Valves

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CAUTION: Avoid injury! With the free-wheeling valve open, the machine will have unrestricted motion.

The machine may free-wheel out of control if the freewheeling valve is opened with the machine on an incline.

Park the machine on a level surface before opening the free-wheeling valve.

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

Move machine by hand only.

Do not use another vehicle to move machine.

Do not tow machine.

NOTE: The pump free-wheel valves must be turned fully clockwise (closed) during normal machine operation.

When the machine needs to be moved without starting the engine, use the pump free-wheel valves:

1. Lock park brake.

NOTE: The pumps (A) are located in the back of the machine, behind the rear shield (B).

MX20094

2.Turn both pump free-wheel valves (C) counterclockwise approximately one full turn (open position).

3.Unlock park brake.

4.Push machine to desired location. Due to hydraulic system drag, machine will move slowly.

5.Turn pump free-wheel valves (C) on both pumps one full turn clockwise (closed position). Tighten valves to 11 N•m (100 lb-in.).

6.Lock park brake.

Transporting Machine on a Trailer

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

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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.

1.Raise mower deck to the transport position.

2.Drive machine onto a trailer.

3.Stop engine and lock 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 downward 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:

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 speeds for:

Slopes.

Trimming.

Close quarters.

Tall grass.

Use faster travel speeds for:

• Normal mowing on level ground.

Dismounting to Inspect Mower

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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.Disengage PTO.

3.Move motion control levers to the neutral position.

4.Lock park brake.

5.Stop engine and remove key. Wait for mower blades to stop turning before leaving operator’s position.

Operating - 16

SERVICE INTERVALS

Service Intervals

Servicing Your Machine

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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.

Servicing Engine

See engine manufacturer’s owner’s manual provided with your machine for engine service information.

Break-In (After First 10 Hours)

Check air pressure in tires.

Check wheel bolt torque.

Check and adjust park brake.

Change engine oil and filter.

Check mower deck drive belt tension.

Check hydraulic pump drive belt.

Check transmission neutral adjustment.

Every 40 Hours

Check air pressure in tires.

Check wheel bolt torque.

Check and adjust park brake.

Change engine oil and filter.

Check foam and paper air cleaner elements.

Clean engine shrouds as needed.

Lubricate front caster spindles and wheels.

Lubricate mower deck lift pivot tubes.

Lubricate mower deck idler pivot.

Lubricate mower deck push arms.

Check mower deck drive belt tension.

Lubricate hydraulic pump idler pivot.

Check hydraulic pump drive belt.

Check hydraulic fluid level.

If operating machine in extremely dusty or dirty conditions:

Clean behind engine shrouds and exposed fins.

Remove screws on blower fan screen and clean behind.

Every 100 Hours

Lubricate mower deck spindles.

Clean and gap spark plugs.

Check hydraulic pump drive belt.

Clean behind engine shrouds and exposed fins.

Remove screws on blower fan screen and clean behind.

Every 500 Hours

• Change hydraulic oil and filter.

Yearly

Change fuel filter.

Clean battery.

Change engine oil and filter at least once per season.

Change hydraulic oil and filter at least once per season.

Replace spark plugs.

Service Lubrication

Grease

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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.

Lubricating Front Caster Spindles and Wheels

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CAUTION: Avoid injury! Fingers or loose clothing can get caught in rotating parts. Stop engine and wait for all moving parts to stop before servicing.

MX15286

• Lubricate two spindle grease fittings (A) and two wheel grease fittings

(B).

Service Intervals - 17

SERVICE ENGINE

Lubricating Deck Lift Pivot Points

Lubricating Mower Deck Idler Pivot

 

 

 

 

 

 

MX20104

• Lubricate two front deck lift pivot grease fittings (A) and two rear deck lift pivot grease fittings (B).

Lubricating Pump Idler Pivot

MX15095

• Lubricate one pump idler pivot grease fitting (A).

Lubricating Mower Deck Spindles

MX15287

• Lubricate three mower deck spindle grease fittings (A).

MX20106

• Lubricate one deck idler pivot grease fitting (A).

Lubricating Mower Deck Push Arms

MX20107

• Lubricate two push arm grease fittings (A), one located on each side of the machine.

Service Engine

Avoid Fumes

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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 - 18

SERVICE ENGINE

Checking Engine Oil Level

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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.

3.Clean area around dipstick to prevent debris from falling into crankcase.

MX20155

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

NOTE: Allow dipstick cap to rest on threads of filler tube when checking oil level. Do not tighten dipstick cap when checking oil level.

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

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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.

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

NOTE: Refer to engine manufacturers operating manual for correct type and grade of oil.

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.

7.Install and tighten dipstick.

Changing Engine Oil and Filter

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CAUTION: Avoid injury! Touching hot surfaces can burn skin. The engine, components, and fluids will be hot if the engine has been running. Be cautious and wear protective clothing when servicing or working near a hot engine and components.

IMPORTANT: Avoid Damage! Change the oil more often if the machine is used in extreme conditions:

Extremely dusty conditions.

Frequent slow or low-speed operation.

Frequent short trips.

1.Clean area around dipstick cap and filter.

2.Start engine and run until it reaches normal operating temperature.

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

MX201858

4.Put oil drain pan under drain tube.

5.Remove plug (A).

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

7.After oil drains, install and securely tighten drain plug (A).

MX20149

8.Turn oil filter (B) counterclockwise to remove.

9.Apply a film of clean engine oil to gasket of new filter.

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IMPORTANT: Avoid Damage! Do not use wrench to tighten oil filter.

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

11.Raise thigh pad.

12.Remove dipstick cap.

NOTE: Refer to engine manufacturers operating manual for correct type and grade of oil.

13. Add approximately 1.7 L (1.75 qt) of oil.

Service Engine - 19

SERVICE ENGINE

14.Insert dipstick. Tighten cap.

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

16.Stop engine.

17.Check oil level:

• Remove dipstick cap. Wipe dipstick clean.

NOTE: Allow dipstick cap to rest on threads of filler tube when checking oil level. Do not tighten dipstick cap when checking oil level.

• Insert dipstick and allow cap to rest on threads of filler. Do not tighten cap.

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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.

• Remove dipstick. Add oil as needed to bring level to the full mark without overfilling.

18. Insert dipstick. Tighten cap.

Cleaning Engine Air Intake Screen and Fan

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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).

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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

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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.

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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.

Checking Spark Plug

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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.

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.

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.

Adjusting Carburetor

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

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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.

IMPORTANT: Avoid Damage! When installing a new fuel filter, the filter arrow must be pointed in the direction of the fuel flow.

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

2.Allow engine to cool.

Service Engine - 20

SERVICE TRANSMISSION

MX20149

3.Slide hose clamps (A) away from fuel filter (B).

4.Place drain pan under hoses to catch any fuel that may be left in the hoses.

5.Disconnect hoses from fuel filter (B).

6.Install new fuel filter (B).

Make sure fuel filter (B) is installed with arrow pointing in direction of fuel flow.

7.Connect hoses to new fuel filter (B).

8.Install hose clamps (A).

9.Start engine and check for fuel leaks.

Service Transmission

Hydraulic Oil

Use only 5W-50 or 15W-50 all synthetic oil.

Checking Hydraulic Oil Level

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IMPORTANT: Avoid Damage! Check oil level in reservoir tank when oil is cold.

Do not overfill oil reservoir tank. Oil will expand during operation and could overflow.

1. Park machine safely. (Refer to Parking Safely in SAFETY section.)

MX20114

2.Clean area around reservoir dipstick cap (A).

3.Remove dipstick cap (A). Wipe dipstick clean.

NOTE: Do not tighten dipstick cap when checking oil level.

4.Insert dipstick into reservoir filler neck (B). Do not tighten cap.

5.Remove dipstick. Check oil level on dipstick. Oil level should be in crosshatch area between ADD and FULL marks.

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

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

6.Insert dipstick. Tighten cap.

Changing Hydraulic Oil and Filter

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CAUTION: Avoid injury! 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.

Use caution when filling and draining hydraulic oil. During periods of machine operation the hydraulic oil reservoir can get hot. Allow engine and oil reservoir to cool before servicing.

IMPORTANT: Avoid Damage! Contamination of hydraulic fluid could cause transmission damage or failure. Do not open oil reservoir cap unless absolutely necessary.

Severe or unusual conditions may require a more frequent service interval.

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

2.Allow engine and hydraulic oil reservoir to cool.

MX13362

3.Clean area around reservoir dipstick cap and oil filter.

4.Turn metal cap (A) on bottom of hydraulic reservoir counterclockwise to remove.

5.Allow hydraulic oil to drain into a drain pan with a capacity of at least 3.8L (1.0 gal).

6.Turn oil filter (B) counterclockwise to remove.

7.Apply a film of clean hydraulic oil to gasket of new filter.

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

9.Remove dipstick cap from hydraulic reservoir filler neck.

Service Transmission - 21

SERVICE TRANSMISSION

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IMPORTANT: Avoid Damage! Do not add oil beyond FULL mark. Oil capacity after draining may be less than dry fill capacity. Check oil level before filling completely.

NOTE: Dry fill capacity for hydraulic system is 3.1L (3.3 qt).

10.Fill oil reservoir with approximately 1.9L (2 qt) of oil.

11.Insert dipstick. Tighten cap.

12.Start engine.

13.Move throttle lever to 1/2 to 2/3 position.

14.Unlock park brake.

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CAUTION: Avoid injury! Help prevent serious bodily injury. Remain alert to other people and the surroundings when operating the machine.

15.Cycle motion control levers forward and rearward several times. Check for leaks around filter.

16.Stop engine. Check oil level. Add oil as necessary to bring oil level to FULL mark on dipstick.

Cleaning Hydraulic Oil Pump Cooling Fins

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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! To ensure proper cooling, keep the cooling fins clean at all times. Operating the machine with obstructed cooling fins could cause damage due to overheating.

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

MX20126

2.Remove four cap screws (A).

3.Remove rear shield (B) to access hydraulic pumps (C).

4.Clean hydraulic oil cooling fins on each hydraulic pump with a rag, brush or compressed air.

5.Clean area around hydraulic pumps and frame.

Checking and Replacing Pump Traction Drive Belt

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CAUTION: Avoid injury! Fingers or loose clothing can get caught in rotating parts. Stop engine and wait for all moving parts to stop before servicing.

NOTE: The traction drive belt will not require a tension adjustment. Belt is self-adjusted using a spring tensioner.

Checking Traction Drive Belt:

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

MX20126

2.Remove four cap screws (A).

3.Remove rear shield (B).

MX20111

4. Inspect belt (C) through frame openings (D) for excessive wear, damage or stretching.

Removing Traction Drive Belt:

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

2.Remove mower deck drive belt. (See Replacing Mower Deck Drive Belt in the SERVICE MOWER section.)

Service Transmission - 22

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