Scag SWZU User Manual

MODEL SWZU

OPERATOR’S MANUAL

THIS MANUAL CONTAINS THE OPERATING INSTRUCTIONS AND SAFETY INFORMATION FOR YOUR SCAG MOWER. READING THIS MANUAL CAN PROVIDE YOU WITH ASSISTANCE IN MAINTENANCE AND ADJUSTMENT PROCEDURES TO KEEP YOUR MOWER PERFORMING TO MAXIMUM EFFICIENCY. THE SPECIFIC MODELS THA T THIS BOOK COVERS ARE CONTAINED ON THE INSIDE COVER. BEFORE OPERA TING YOUR MACHINE, PLEASE READ ALL THE INFORMATION ENCLOSED.

P ART NO. 03132

PRINTED 7/03

PRINTED IN USA

WARNING:

FAILURE TO FOLLOW SAFE OPERATING PRACTICES

MAY RESULT IN SERIOUS INJURY.

* Keep all shields in place, especially the grass discharge chute. * Before performing any maintenance or service, stop the machine and remove the spark plug wire and ignition key. * If a mechanism becomes clogged, stop the engine before cleaning. * Keep hands, feet and clothing away from power-driven parts. * Read this manual completely as well as other manuals that came with your mower. * Keep others off the tractor (only one person at a time)

REMEMBER - YOUR MOWER IS ONLY AS SAFE AS THE OPERATOR!

Hazard control and accident pre vention are dependent upon the awareness, concern, prudence, and proper training of the personnel involved in the operation, transport, maintenance, and storage of the equipment.

This manual covers the operating instructions

and illustrated parts list for:

SWZU36A-15KA with a serial number of 9090001 to 9099999 SWZU48A-17KA with a serial number of 9110001 to 9119999 SWZU48A-18HN with a serial number of 9630001 to 9639999 SWZU52A-17KA with a serial number of 9120001 to 9129999 SWZU52A-18HN with a serial number of 9130001 to 9139999 SWZU52A-18KH with a serial number of 9140001 to 9149999 SWZU-21KAE with a serial number of 9190001 to 9199999 SWMU-52A with a serial number of 9200001 to 9209999 SWMU-61A with a serial number of 9210001 to 9219999

Always use the entire serial number listed on the serial number tag when referring to this product.

TABLE OF CONTENTS

SUBJECT PAGE

Introduction.................................................................................................. 1

Direction Reference..................................................................................... 1

Servicing the Engine and Drive T rain Components ..................................... 1

Symbols....................................................................................................... 2-3

General Safety Instructions.......................................................................... 4

Signal Words ............................................................................................... 4

Before Operating ......................................................................................... 4

Operation Considerations............................................................................ 6

Maintenance and Storage ........................................................................... 7

Initial Run-In Procedures ............................................................................. 7

Mower Operation ......................................................................................... 8

Cutter Deck Belt Adjustments...................................................................... 9

Cutter Deck Adjustments ............................................................................. 9-10

Cutter Blades............................................................................................... 10

Custom-Cut Baffle Adjustment..................................................................... 10-11

Neutral Adjustment ...................................................................................... 11

Steering Control Rod Adjustment ................................................................ 12

Tracking Adjustment .................................................................................... 12

Parking Brake .............................................................................................. 13

Lubrication and Maintenance Chart ............................................................ 14

Checking Hydraulic Oil Level ...................................................................... 15

Changing Hydraulic Oil ............................................................................... 15

WE SUPPORT OPE

TECHNICIAN

CERTIFICATION

TABLE OF CONTENTS

(CONTINUED)

SUBJECT PAGE

Changing Hydraulic Oil Filter Element ........................................................ 15

Engine Oil Maintenance .............................................................................. 16

Engine Air Cleaner Maintenance ................................................................. 16

Checking Electrolyte Level and Cleaning Battery ....................................... 16

Charging the Battery.................................................................................... 17

Jump Starting .............................................................................................. 17

Troubleshooting Cutting Conditions ............................................................ 18-20

Technical Specifications .............................................................................. 21-22

Illustrated Parts List

Notes ....................................................................................................................... 23

SWMU-36"A Cutter Deck ............................................................................ 24-25

SWMU-48"A, 52"A, & 61"A Cutter Decks .................................................... 26-27

Cutter Deck Frame 36" ................................................................................ 28-29

Cutter Deck Frame 48" & 52" Small Frame.................................................. 30-31

Cutter Deck F rame 52" & 61" Large Frame.................................................. 32-33

Engine Deck................................................................................................ 34-35

Drive And Brake Components ..................................................................... 36-37

Handle Assembly - Small Frame (16")......................................................... 38-39

Handle Assembly - Large Frame (SWZU-21KAE)....................................... 40-41

Hydraulic Assembly ..................................................................................... 42-43

Hydraulic Pump Assembly .......................................................................... 44-45

Engine Deck Wire Harness (Manual Start) .................................................. 46

Handle Wire Harness (Manual Start) ........................................................... 46

Engine Deck Wire Harness - Kawasaki (Electric Start) ............................... 47

Handle Wire Harness - Kawasaki (Electric Start) ........................................ 47

Wire Harness Adaptor - Honda.................................................................... 48

Wire Harness Adaptor - Kawasaki (15HP & 17HP)..................................... 48

Replacement Decals ................................................................................... 49-50

Warranty Statement ......................................................................... Inside Back Co ver

INTRODUCTION

GENERAL INFORMATION

Your mower was built to the highest standards in the industry . However, the prolonged life and maximum efficiency of your mower depends on you following the operating, maintenance and adjustment instructions in this manual.

If additional information or service is needed, contact your Scag Power Equipment Dealer.

We encourage you to contact your dealer for repairs. All Scag dealers are informed of the latest methods to service this equipment and provide prompt and efficient service in the field or at their service shop. They carry a full line of Scag service parts.

USE OF OTHER THAN ORIGINAL SCAG REPLACEMENT PARTS WILL VOID THE WARRANTY.

For pictorial clarity , some illustrations and figures in this manual may show shields, guards or plates open or removed. Under no circumstances should your mower be operated without these devices in place.

Use only Scag approved attachments and accessories.

Scag Approved Attachments: GC-F4 GC-4D Scag Approved Accessories: Mulch Plate Mulch Master Cup Holder Hour Meter Turbo Baffle Blade Buddy Using unapproved attachments, (especially "stand-up" riding attachments) may be hazardous.

DIRECTION REFERENCE

The “Right” and “Left”, “Front” and “Rear” of the machine are referenced from the operator’s right and left when seated in the normal operating position and facing the forward travel direction.

SERVICING THE ENGINE AND DRIVE TRAIN COMPONENTS

All information is based upon product information available at the time of approval for printing. Scag Power Equipment reserves the right to make changes at any time without notice and without incurring any obligation.

WARNING

FALLING HAZARD

USE ONLY SCAG APPROVED

RIDING ATTACHMENTS

SEE OPERATOR'S MANUAL

481109

The detailed servicing and repair of the engine and hydraulic pumps are not covered in this manual; only routine maintenance and general service instructions are provided. For service of these components during the limited warranty period, it is important to contact your Scag dealer or find a local authorized servicing agent of the component manufacturer. Any unauthorized work done on these components during the warranty period may void your warranty .

ISO Symbols

CE Mark

SYMBOL DESCRIPTION

Parking Brake

On/Start

SYMBOL DESCRIPTION

TransmissionChoke

Spinning Blade

48071S

Spring T ension on Idler

Off/Stop

Oil

WARNING

Falling Hazard

FALLING HAZARD

USE ONLY SCAG APPROVED

RIDING ATTACHMENTS

SEE OPERATOR'S MANUAL

481109

SYMBOL DESCRIPTION SYMBOL DESCRIPTION

481039S

Fast

Continuously V ariable - Linear

Pinch Point

Slow

Cutting Element - Basic Symbol

Cutting Element - Engage

Hourmeter/Elapsed Operating Hours

Thrown Object Hazard

Keep Bystanders Away

Cutting Element - Disengage

Read Operator's Manual

SAFETY INFORMATION

GENERAL SAFETY INFORMATION

Your mower is only as safe as the operator. Carelessness or operator error may result in serious bodily injury or death. Hazard control and accident prevention are dependent upon the awareness, concern, prudence, and proper training of the personnel involved in the operation, transport, maintenance and storage of the equipment. and thoroughly familiar with all of the controls before operating the mower.

READ THIS OPERATOR’S MANUAL BEFORE ATTEMPTING TO START YOUR MOWER.

Make sure every operator is properly trained

The signal word “DANGER” denotes that an extremely hazardous situation exists on or near the machine that could result in high probability of death or irreparable injury if proper precautions are not taken.

WARNING:

The signal word “WARNING” denotes that a hazard exists on or near the machine that can result in injury or death if proper precautions are not taken.

A replacement manual is available from your authorized Scag Service Dealer or by contacting Scag Power Equipment, Service Department at P.O. Box 152, Mayville, WI 53050 or contact us via the Internet at www.scag.com. Use the contact form to make your request. Please indicate the complete model and serial number of your Scag product when requesting replacement manuals.

SIGNAL WORDS

This symbol means “Attention! Become Alert! Your Safety is Involved!" The symbol is used with the

following signal words to attract your attention to safety messages found on the decals on the machine and throughout this manual. The message that follows the symbol contains important information about safety . T o avoid injury and possible death, carefully read the message! Be sure to fully understand the causes of possible injury or death.

CAUTION:

The signal word “CAUTION” is a reminder of safety practices on or near the machine that could result in personal injury if proper precautions are not taken.

Your safety and the safety of others depends significantly upon your knowledge and understanding of all correct operating practices and procedures of this machine.

BEFORE OPERATION CONSIDERATIONS

1. NEVER allow children to operate this machine.

Do not allow adults to operate this machine without proper instructions.

2. DO NOT mow when children and/or others are

present.

3. Clear the area to be mowed of objects that could be picked up and thrown by the cutter blades.

Signal Word:

The signal word is a distinctive word found on the safety decals on the machine and throughout this manual that alerts the viewer to the existence and relative degree of the hazard.

4. DO NOT wear loose fitting clothing that could get tangled in moving parts. Do not operate the machine wearing shorts; always wear adequate protective clothing including long pants. W earing safety glasses, safety shoes and a helmet is advisable and is required by some local ordinances and insurance regulations.

WARNINGWARNING

DO NOT OPERATE WITHOUT DISCHARGE CHUTE, MULCHING KIT, OR ENTIRE GRASS CATCHER INSTALLED

BEFORE OPERATION CONSIDERATIONS

(CONT'D)

5. Operator hearing protection is recommended, particularly for continuous operation of the mower. W ear suitable hearing protection. Prolonged exposure to loud noise can cause hearing impairment or hearing loss.

6. Keep the machine and attachments in good operating condition. Keep all shields and safety devices in place. If a shield, safety device or decal is defective or damaged, repair or replace it before operating the machine.

WARNING:

This machine is equipped with an interlock system intended to protect the operator and others from injury. This is accomplished by preventing the engine from starting unless the deck drive is disengaged, the parking brake is on, and the speed adjustment lever is in the neutral position. The system shuts off the engine if the operator releases the operator presence levers with the deck drive engaged and/or the speed adjustment lever not in the neutral position, or the parking brake disengaged. Never operate equipment with the interlock system disconnected or malfunctioning.

8. Before attempting to start the engine, move the speed adjustment lever into the neutral position, move the blade engagement switch to the OFF position, apply the parking brake, and move the neutral latches to neutral.

9. The discharge chute must always be installed and in the down position on the side discharge cutter deck except when the Scag optional grass catcher or mulching plate are properly installed.

ROTATING BLADES

NEVER PUT Y OUR HANDS INT O THE DISCHARGE CHUTE FOR ANY REASON! Shut off the engine and remove the key and only then use a stick or similar object to remove material if clogging has occurred.

7. Gasoline is highly flammable, handle it carefully. Fill the fuel tank outdoors. Never indoors. Fill the fuel tank with clean, fresh gasoline, with a minimum octane rating of 87. Use a funnel or spout to prevent spillage.

A. Use an approved gasoline container. B. DO NOT add fuel to a running or hot engine.

Allow the engine to cool for several minutes before adding fuel.

C. Keep flammable objects (cigarettes, matches,

etc.), open flames and sparks away from the fuel tank and fuel container.

D. Fill the fuel tank outdoors and up to approxi-

mately 1" (25 mm) below the bottom of the filler neck.

E. Wipe up any spilled gasoline.

10. If the mower discharge ever plugs, shut off the engine, remove the ignition key, and wait for all movement to stop before removing the obstruction. Do not use your hand to dislodge the clogged discharge chute. Use a stick or other device to remove clogged material.

1 1. Check the blade mounting bolts at frequent intervals

for proper tightness.

12. Make sure all hydraulic fluid connections are tight and all hydraulic hoses and lines are in good condition before starting the machine.

OPERATION CONSIDERATIONS

1. Know the function of all controls and how to stop quickly.

2. Start the engine when the neutral latches are in the neutral lock position, the cutter blades are disengaged, the parking brake is on and the speed adjustment lever is in the neutral position.

3. Be sure the interlock switches are functioning correctly.

4. Using the machine demands attention. To prevent loss of control:

A. Mow only in daylight or when there is good

artificial light. B. Watch for holes or other hidden hazards. C. Do not drive close to a drop-off, ditch, creek

bank, or other hazard. D. Reduce speed when making sharp turns and

when turning on hillsides. E. Always be sure of your footing. Keep a firm

hold on the handles and walk---never run. F. Do not operate where conditions are slippery

WARNING:

DO NOT operate on steep slopes. T o check a slope, attempt to back up it (with the cutter deck down). If the machine can back up the slope without the wheels slipping, reduce speed and use extreme caution. ALWAYS FOLLOW OSHA APPROVED OPERA TION.

5. Disengage power to the cutter deck before backing up. Do not mow in reverse unless absolutely necessary and then only after observation of the entire area behind the mower.

7. Shut the engine off and wait until the blades come to a complete stop before removing the grass catcher container.

8. Never raise the cutter deck while the blades are rotating.

ROTATING BLADES

NEVER PUT Y OUR HANDS INT O THE DISCHARGE CHUTE FOR ANY REASON!

9. DO NOT operate without the side discharge chute installed and in the down position.

10. DO NOT direct the discharge of material toward bystanders or allow anyone near the machine while in operation.

11. If the cutting blades should strike a solid object or the equipment should start to vibrate abnormally, stop the engine, disconnect the spark plug wire, and check immediately for the cause. Vibration is generally a warning of trouble. Check the machine for damaged or defective parts. Repair any damage before starting the engine or operating the cutter deck. Be sure the blades are in good condition and the blade bolts are tight.

12. Take all possible precautions when leaving the machine unattended, such as disengaging the mower, setting the parking brake, stopping the engine, and removing the key .

13. DO NOT touch the engine or the muffler while the engine is running or immediately after stopping. These areas may be hot enough to cause a burn.

6. Disengage power to the cutter deck before crossing roads, walks or gravel drives.

14. DO NOT run the engine inside a building or a

confined area without proper ventilation. Exhaust fumes are hazardous and could cause death.

MAINTENANCE AND STORAGE

1. Allow only trained personnel to service the machine.

2. Never make adjustments to the machine with the

engine running unless specifically instructed to do so. If the engine is running, keep hands, feet, and clothing away from moving parts.

3. Remove the key from the ignition switch and

disconnect the wire from the spark plug(s) to prevent accidental starting of the engine when servicing, adjusting or storing the machine.

4. If the mower must be tipped to perform maintenance

or adjustment, remove the battery, drain the gasoline from the fuel tank and the oil from the crankcase.

5. Be sure the machine is in safe operating condition by

keeping nuts, bolts, and screws tight. Check the blade mounting bolts and nuts frequently to be sure they are tightened.

6. Do not change the engine governor settings or

overspeed the engine. See the engine operator's manual for information on engine settings.

7. To reduce fire hazard, keep the engine free of grass,

leaves, excessive grease, oil and dirt.

8. The engine must be shut off before checking the oil

or adding oil to the crankcase.

12. Batteries release explosive gases when being charged or discharged. Keep batteries away from any source of sparks and/or flame.

13. Make sure all hydraulic fluid connections are tight and all hydraulic hoses and lines are in good condition before starting the machine.

14. Hydraulic fluid is under high pressure. Keep body and hands away from pinholes or nozzles that eject hydraulic fluid under high pressure. If you need service on your hydraulic system, please see your authorized Scag dealer . Hydraulic fluid under high pressure may have sufficient force to penetrate skin and cause serious injury . If hydraulic fluid is injected into the skin, it must be surgically removed within a few hours by a doctor or gangrene may result.

INITIAL RUN-IN PROCEDURES (FIRST DAY OF USE OR APPROXIMATELY 10 HOURS)

1. Check the steering control rods and the speed control for neutral adjustment. (See Adjust ments, page 11-12)

2. Check the tires for proper pressure.

Caster Wheels 25 psi. Drive Wheels 12 psi.

3. Check for loose hardware. Tighten as needed.

9. Allow the engine to cool before storing the mower in any enclosure such as a garage or storage shed. Make sure the fuel tank is empty if the machine is to be stored in excess of 30 days. Do not store the mower near any open flame or where gasoline fumes may be ignited by a spark.

10. Always store gasoline in a safety-approved, red container.

11. Be careful when servicing the battery as it contains acid, which is corrosive and could cause burns to skin and clothing.

4. Check the safety switches for proper adjustment:

* On electric start machines the engine should

crank and start if the machine is in neutral, the PTO engagement switch is OFF and the parking brake is ON.

5. Apply lubricant to all the grease fittings. Lubricant was applied at the factory. This is just a precautionary check to make sure that all the fittings have been lubricated.

MOWER OPERATION

1. Read and understand the safety instructions before attempting to operate this machine.

2. Before starting the engine:

* Check the oil level in the engine and the

hydraulic reservoir.

* Fill the fuel tank with clean, fresh, lead-free

gasoline.

* Open the fuel valve on the bottom of the fuel

tank.

-NOTE-

Use gasoline with an octane rating no less than

87.

* The speed adjustment lever must be in

NEUTRAL.

* The blade clutch switch must be in the OFF

position.

* The neutral latches must be in the neutral lock

position. * The key switch must be on. * The parking brake must be on.

3. Start the engine:

* Choke as required. If the engine is cold, pull the

choke knob out. When the engine starts, slowly push the choke in. If the engine stalls, repeat the above operation. When the engine is warm, choking may not be necessary.

* Cold starting. In the spring and fall when the

morning temperatures are cool it may be difficult to start the machine due to the parastatic load from the hydraulic drive. To relieve this load, pull out and up on the de-clutch chain located on the right side of the machine behind the tire. This will allow you to start the engine easily. When the engine is warmed up, slowly release the declutch chain to engage the hydraulic system.

4. Engage the cutter blades by pulling the blade clutch switch into the ON position. Push the switch to the OFF position to disengage the cutter blades.

PULL UP TO ENGAGE

PUSH DOWN TO DISENGAGE

390S0138

-NOTE-

When PTO is engaged or (possibly) disengaged, a squealing sound from the underside of the machine is normal. It is caused by the electric clutch plates meshing as the mower comes up to speed. For best equipment life, engage the clutch with the engine at 3/4 throttle, not under full load.

WARNING:

If you are not familiar with the operation of the hydrostatic drive and zero turn feature, practice turning and maneuvering with the hand controls before engaging the blades.

5. Release the parking brake. Move the speed adjustment lever to the desired mowing speed.

-NOTE-

Top speed is suggested only for transport!

6. While squeezing the steering brake levers with both hands, release both neutral latches.

7. When the steering brake levers are released, the

machine will travel straight. To make a right turn, squeeze the RH lever. To turn left, squeeze the LH lever.

8. TO STOP, squeeze both levers, lock the neutral latches, and move the speed adjustment lever to neutral.

9. To move the machine in reverse, squeeze up on both steering control levers.

10. To "freewheel" or move the machine around

Remove Hair Pins

SWU99DHA

without the engine running, turn the dump valve levers located at the back of the pumps to the "freewheel" positions (see Figure 1). To operate the machine, the dump valve levers must be returned to the closed positions.

Dump Valve Levers

(normal position)

SGB112

Figure 1. Dump Valves

PITCH is the angle of the blades (comparing front to rear). A 1/4" downward pitch (front of deck down) is recommended for best cutting performance.

HEIGHT is the nominal distance the blade is off of the ground. This measurement is made with the blades pointed side to side and distance is measured between cutting tip and ground.

Changes to the cutting height can be achieved by repositioning the cutter deck. There are eight available positions from 1" to 4-1/2" (See Figure 2).

WARNING:

Do not adjust the cutting height with the mower blades rotating. Shut off the engine and remove the ignition key. Bodily injury could occur from the rotating blades.

1. Shut off the engine and remove the ignition key .

CUTTER DECK BELT ADJUSTMENTS

-NOTE-

All the belts on the SWZU are spring loaded and do not require adjustment. Check the belts for excessive wear or damage daily for the first week. After the first week, check the belts monthly.

1. Remove the belt covers.

2. Inspect the belts for wear, cracking, or glazing. Contact your Scag dealer if any unusual wear is noted.

3. Replace the belt covers.

CUTTER DECK ADJUSTMENTS

Due to the many cutting conditions that exist, it is difficult to suggest a cutter deck setting that will work for every lawn. There are two adjustments that can be made on these decks, pitch and height.

2. While holding up on the deck support handle, remove the two hairpins from the adjusting pins on one side of the cutter deck (See Figure 2).

3. Lift or lower the deck to the desired cutting height and reinstall the hairpins. A deck height decal is located on the deck mounting frame as an aid in adjusting the deck to the desired height.

4. Repeat the above process on the opposite side of the cutter deck.

Figure 2. Cutting Height Adjustment

CUTTER DECK PITCH ADJUSTMENTS

The cutter deck pitch adjustment has been set at the factory and normally will not need to be changed. However, if the pitch needs to be adjusted due to service work performed on the deck, follow the procedure below (see Figure 3).

1. Shut off the engine and remove the key.

2. Support the cutter deck with four blocks (you will be removing the hair pins to make this adjustment).

3. Remove the front hair pins from the front deck support pins.

4. Loosen the jam nuts on the deck support pins.

5. Turn the deck support pins to lengthen or shorten the pins to reach the desired result.

6. Tighten the jam nut, replace the hair pin, and remove the blocks. Check that the desired deck pitch is achieved.

WARNING:

Always wear proper hand and eye protection when working with cutter blades.

-NOTE-

Dress the blade with a file. Using a wheel grinder may burn the blade. Check the balance of the blade. If blades are out of balance, vibration and premature wear of spindle assembly can occur. See your authorized Scag dealer for blade balancing or special tools, if you choose to balance your own blades.

Angle Blade Back

Do Not Cut In

X Must NOT Exceed

1/3 Blade Width

SGB033

REMOVE HAIR PIN

LOOSEN JAM NUT

SWU99PA

Figure 3. Deck Pitch Adjustment

CUTTER BLADES

Do not sharpen beyond 1/3 of the width of the blade. (See Figure 4)

Figure 4. Blade Sharpening

Custom-Cut Baffle Adjustment

The Custom-Cut Baffle is designed to deliver optimum airflow and superior cutting performance in any type of grass. The Custom-Cut Baffle can be raised or lowered to precisely tailor the deck's performance for the type of grass being cut. The baffle can be set in three (3) different positions for optimum performance.

A. 3" Position - baffle is installed using the top set of

holes on the front baffle welded inside the cutter deck. (See Figure 6, Page 11). The Advantage cutter deck will deliver the best quality-of-cut in very tall, wiry , tough to cut grass.

B. 3-1/2" Position (factory setting) - baffle is installed

using the middle set of holes on the front baffle welded inside the cutter deck. (See Figure 7, Page

11). For general purpose cutting, place the Custom Cut Baffle in the 3-1/2" position. This gives the best mix of cutting performance in all types of grass.

C. 4" Position - baffle is installed using the bottom set of

holes on the front baffle welded inside the cutter deck. (See Figure 8). Placing the baffle in the 4" setting will enhance fall cutting (leaf pickup) and reduce cutter deck "blowout".

T o Adjust the Custom-Cut Baffle height:

1. Remove the hardware securing the Custom-Cut Baffle

to the cutter deck (See Figure 5).

MIDDLE SET OF HOLES FOR 3-1/2" SETTING

CARRIAGE BOLT

2004 CCB - 3-1/2" Setting

ELASTIC STOP NUT

-NOTE-

Hardware location used in the illustrations are for reference only. Location of hardware may vary depending on the cutter deck size.

MOUNTING HARDWARE

2004 CCB

Figure 5. Custom-Cut Baffle

2. Move the Custom-Cut Baffle to desired position. (See

Figures 6 through 8 for position).

3. Reinstall the mounting hardware as shown. (See Figures

6 though 8). Torque hardware to 39ft.lbs.

TOP SET OF HOLES FOR 3" SETTING

CARRIAGE BOLT

Figure 7. 3-1/2" Custom-Cut Baffle Position

BOTTOM SET OF HOLES FOR 4" SETTING

CARRIAGE BOLT

2004 CCB - 4" Setting

ELASTIC STOP NUT

Figure 8. 4" Custom-Cut Baffle Position

NEUTRAL ADJUSTMENT

-NOTE-

Neutral has been set by your Scag dealer at the time of setup and normally does not need to be adjusted. If, however, you find that neutral has come out of adjustment, follow the procedure below.

1. Raise the drive wheels off the ground and block the caster wheels to prevent the machine from moving.

2004 CCB - 3" Setting

ELASTIC STOP NUT

Figure 6. 3" Custom-Cut Baffle Position

2. Make sure the speed control lever is in neutral, the steering control levers are in the neutral latch position, and the parking brake is on. Start the engine.

3. Release the parking brake and note if the tires are rotating.

4. Starting on the left side of the machine, using the adjustment wrench located on the left side of the machine, rotate the tracking adjustment nut counter clockwise just until the LH wheel starts to creep forward. Make a note of the position of the adjustment nut. (See Figure 9)

5. Turn the adjustment nut clockwise just until the wheel turns rearward. Make a note of the position of the adjustment nut. To adjust neutral, split the difference between the two noted positions of the adjustment nut. Repeat on the right side as needed.

TRACKING

ADJUSTMENT

SEE OPERATOR'S

FAST

SLOW

390s0198-1

Figure 10. Control Rod Adjustment

6. Place the wrench in the holder on the left side of the machine and turn the engine off.

Figure 9. Neutral Adjustment

STEERING CONTROL ROD ADJUSTMENT

-NOTE-

This adjustment is made to allow the steering control levers to be moved out of the neutral latch without engaging reverse.

Before making this adjustment be sure that the speed control bearing is just touching the speed control cam and that the bellcrank bearing is resting in the center groove of the neutral cam.

3. Reinstall the speed control spring onto the swivel. Install the hair pin onto the swivel. (See Figure 10)

TRACKING ADJUSTMENT

-NOTE-

Before proceeding with this adjustment, be sure that the tire pressures are correct. (see page 7) and that the neutral adjustment and the steering control rod adjustment have been completed.

1. With the machine on a flat level surface, start the engine and place the speed adjustment lever into the speed that will most often be used.

2. Squeeze the steering control levers and release the neutral latch. Slowly release the steering control levers, allowing the machine to move forward.

WARNING:

BEFORE ATTEMPTING TO MAKE ANY TRACKING ADJUSTMENTS:

1. Remove the speed control spring. Remove the steering control rod swivel hair pin. Check the location of the swivel in the slotted hole in the bell crank.

2. Turn the swivel joint on the steering control rods until the swivel joint is centered in the slot in the bellcrank.

1. Move the speed adjustment lever to the neutral position.

2. Place the blade engagement switch in the OFF position.

3. Apply the parking brake.

4. Move the steering control levers into the neutral position.

3. If the machine pulls to one side. Stop the mower by placing the steering control levers in the neutral position. Using the adjustment wrench located on the left side of the machine, turn the tracking adjustment nut on the slower side counter clockwise until the machine tracks straight. (See Figure 11)

4. Bring the steering control levers back to the neutral lock position and check to see that the machine does not creep forward on the adjusted wheel.

5. If the machine creeps in neutral you have moved out of the neutral band and will have to turn the tracking adjustment nut clockwise until the machine does not creep.

PARKING BRAKE

1. Adjust the parking brake so that when the brake hand lever is against the stop on the handle bar, the brake levers on the brake shaft weldment are against the stops on the engine deck.

CAUTION:

Adjust the brake only enough to hold the machine. Excessive force may cause damage to the machine or brake components.

6. Repeat steps 1 and 2. If the machine continues to pull to one side, stop the mower by placing the steering control levers in the neutral position. Turn the tracking adjustment nut on the faster side clockwise until the machine tracks straight.

7. If tracking cannot be achieved, contact your Scag servicing dealer.

Figure 11. Tracking Adjustment

2. Adjust the brake actuator rod on either side of the machine to obtain proper brake adjustment.

LUBRICATION & MAINTENANCE

BREAK-IN

+ Grease spindle until grease comes out the relief valve

8 HOURS (DAILY)

Compatible Greases: Lidok EP #2 (found at industrial shops)

Ronex MP (Exxon service stations)

40 HOURS (WEEKLY)

100 HOURS (BIWEEKLY)

Shell Alvania (Shell service stations) Mobilux #2 (Mobil service stations) Super Lub M EP #2 (Conoco service stations)

500 HRS OR ANNUALLY

PROCEDURE

X X

X Check engine oil Do not over fill X Remove debris from under belt cover More often if needed X Sharpen cutter blades More often if needed X Grease spindle bearings + US Lithium MP White Grease 2125 X Clean air filter More often if needed

X Check belt tension Adjust as needed

X Check tire pressure Add or adjust as required

X Check battery level Adjust as needed

X Replace air filter More often if needed X Grease caster wheel bearings Chassis grease X Grease caster wheel pivot shafts Chassis grease X Grease idler pulley bracket on cutter deck Chassis grease X Change hydrostatic oil filter Clean area before removing the filter X Change engine oil and filter See engine manufacturer information X Grease idler arm pivots Chassis grease X Grease brake hand lever Chassis grease X Grease brake actuator levers Chassis grease

Check all hardware for proper tightness Change engine oil and filter at 5 hours

X Check all hardware for proper tightness X Adjust air gap on electric clutch Contact your Scag dealer for information about X Drain hydraulic system and replace oil making this adjustment.

COMMENTS

HYDRAULIC SYSTEM

Hydraulic Oil Drain Cap

2003SWZ-Oil Drain

Filter Head

Hydraulic Oil Filter

Checking Hydraulic Oil Level

The hydraulic oil level should be checked after the first 10 hours of operation. Thereafter, check the oil after every 200 hours of machine operation or monthly , whichever occurs first.

-IMPORTANT-

If the oil level is consistently low , check for leaks and correct immediately .

1. Wipe dirt and contaminants from around the reservoir cap. Remove the cap from the hydraulic oil reservoir.

2. Visually check the level of hydraulic oil. Hydraulic oil must be at least 2" inches from top of the filler neck. If the level cannot be determined visually, use a clean tape measure to check the level. If the fluid is low, add 20W50 motor oil. DO NOT overfill; (overfilling the oil reservoir may cause oil seepage around the cap area).

2. Place a suitable container under the hydraulic oil drain. Remove the fill cap from the reservoir. Remove the drain cap from the T-Fitting located on the hydraulic system filter head. (See Figure 12). Allow the fluid to drain into the container and properly discard it.

Figure 12 Hydraulic Oil Drain Cap

3. Reinstall the drain cap onto the T-Fitting and be sure it is tight.

3. Clean the fill cap and install it onto the reservoir.

Changing Hydraulic Oil

The hydraulic oil should be changed after every 500 hours or annually , whichever occurs first. The oil should also be changed if the color of the fluid has become black or milky . A black color and/or a rancid odor usually indicates possible overheating of the oil, and a milky color usually indicates water in the hydraulic oil.

-NOTE-

The hydraulic oil should be changed if you notice the presence of water or a rancid odor to the hydraulic oil.

1. Park the mower on a level surface and stop the engine.

-NOTE-

Before refilling the hydraulic oil reservoir the hydraulic oil filter should be changed as well. See instructions outlined below.

4. Fill the reservoir to 2" inches from the top of the filler neck with 20W50 motor oil.

5. Replace the reservoir fill cap. Start the engine and drive forward and backward for two minutes. Check the oil level in the reservoir. If necessary, add oil to the reservoir.

Changing Hydraulic Oil Filter Element

The hydraulic oil filter should be changed after every 500 hours of operation or annually , whichever occurs first.

1. Remove the oil filter element (Figure 12) and properly discard it. Fill the new filter with clean oil and install the filter. Hand tighten only .

BATTERY (ELECTRIC START UNITS ONLY)

2. Run the engine at idle speed with the speed control lever in neutral for five minutes.

3. Check the oil level in the hydraulic tank. It must be 2" inches from the top of the filler neck. If necessary, add SAE 20W50 motor oil.

Checking Engine Crankcase Oil Level

The engine oil level should be checked after every 8 hours of operation or daily as instructed in the Engine Operator’s Manual furnished with this mower .

Changing Engine Crankcase Oil

After the first 5 hours of operation, change the engine crankcase oil and replace the oil filter. Thereafter, change the engine crankcase oil after every 100 hours of operation or bi-weekly, whichever occurs first. Refer to the Engine Operator’s Manual furnished with this mower for instructions.

Checking Electrolyte Level and Cleaning Battery

This machine was equipped from the factory with a sealed battery. Maintenance is not required to maintain the electrolyte level. Dirt and fluid on the top of the battery can cause the battery to discharge. Corrosion of the battery terminals or loose connections will cause poor battery performance.

WARNING:

Lead-acid batteries produce flammable and explosive gases. To avoid per sonal injury when checking, testing or charging batteries, DO NOT use smoking materials near batteries. Keep arcs, sparks and flames away from batteries. Provide proper ventilation and wear safety glasses.

Changing Engine Oil Filter

After the first 5 hours of operation, replace the engine oil filter. Thereafter, replace the oil filter after every 200 hours of operation or every month, whichever occurs first. Refer to Engine Operator’s Manual for instructions.

Engine Air Cleaner

For any air cleaner, the operating environment dictates how often the air cleaner should be serviced. Refer to the Engine Operator’s Manual furnished with this mower for instructions.

-NOTE-

In extremely dusty conditions it may be necessary to service the air cleaner daily to prevent engine damage.

WARNING:

Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive harm. Wash hands after handling.

1. Loosen the two plastic wing nuts and then remove the battery cover.

2. Clean the cable ends and battery posts with steel wool. Use a solution of baking soda and water to clean the battery. Do not allow the solution to enter the battery cells.

3. Tighten the cable connections securely and apply a light coat of silicone dielectric grease to the terminal connections to prevent corrosion.

4. Install the battery cover.

WARNING:

Electric storage battery fluid contains sulfuric acid which is POISON and can cause SEVERE CHEMICAL BURNS. A void contact of fluid with eyes, skin, or clothing. Use proper protective gear when handling batteries. DO NO T tip any battery beyond 45° angle in any direction. If fluid contact does occur, follow fir st aid suggestions below.

BATTERY ELECTROLYTE FIRST AID

EXTERNAL CONT ACT - Flush with water .

EYES - Flush with water for at least 15 minutes and get medical attention immediately .

WARNING:

BA TTERIES PR ODUCE EXPLOSIVE GASES. Charge the battery in a well ventilated space so gases produced while charging can dissipate.

Charging rates between 3 and 50 amperes are satisfactory if excessive gassing or spewing of electrolyte does not occur or the battery does not feel excessively hot (over 125°F). If spewing or gassing occurs or the temperature exceeds 125°F, the charging rate must be reduced or temporarily stopped to permit cooling.

Jump Starting

INTERNAL - Drink large quantities of water. Follow with Milk Of Magnesia, beaten egg, or vegetable oil. Get medical attention immediately. In case of internal contact, DO NO T give fluids that would induce vomiting.

Charging the Battery

Refer to the battery charger’s manual for specific instructions.

Under normal conditions the engine’s alternator will have no problem keeping a charge on the battery. If the battery has been completely discharged for a long period of time, the alternator may not be able to recharge the battery, and a battery charger will be required.

DO NOT charge a frozen battery. It may explode and cause injury. Let the battery warm before attaching a charger.

1. The booster battery must be a 12 volt type. If a

vehicle is used for jump starting, it must have a negative ground system.

2. When connecting the jumper cables, connect the

positive cable to the positive battery post, then connect the negative cable to the negative battery post.

Whenever possible, remove the battery from the mower before charging.

TROUBLESHOOTING CUTTING CONDITIONS

CONDITION

CAUSE

CURE

Stringers - Occasional Low engine RPM Run engine at full 3600 RPM Blades of Uncut Grass Ground speed too fast Slow speed to adjust for conditions

Wet grass Cut grass after it has dried out Dull blades, incorrect sharpening Sharpen blades Deck plugged, grass accumulation Clean underside of deck

Width of Deck

SGB020

Belts slipping Adjust belt tensions

Streaking - Strips of Dull, worn blades Sharpen blades Uncut Grass in Cutting Path Incorrect blade sharpening Sharpen blades

Low engine RPM Run engine at full 3600 RPM Belt slipping Adjust belt tension Deck plugged, grass accumulation Clean underside of deck Ground speed too fast Slow speed to adjust for conditions Wet grass Cut grass after it has dried out

Width of Deck

SGB018

Bent blades Replace blades

Streaking - Strips of Not enough overlapping Increase the overlap of each Uncut Grass Between between rows pass Cutting Paths

Width

Deck

SGB019

Width

Deck

TROUBLESHOOTING CUTTING CONDITIONS

CONDITION

CAUSE

CURE

Uneven Cut on Flat Lift worn off of blade Replace blade Ground - Wavy High-Low Blade upside down Mount with cutting edge toward Appearance, ground Scalloped Cut, or Rough Contour Deck plugged, grass accumulation Clean underside of deck

Too much blade angle (deck pitch) Adjust pitch and level Deck mounted improperly See your authorized SCAG dealer Bent spindle area See your authorized SCAG dealer Dull blade Sharpen blade

Width of Deck

SGB020

Uneven Cut on Uneven ground May need to reduce ground speed, Uneven Ground - raise cutting height, and/or change Wavy Appearance, direction of cut High-Low Scalloped Cut, or Rough Contour

Width of Deck

SGB021

Sloping Ridge Across Tire pressures not equal Check and adjust tire pressure Width of Cutting Path

Wheels uneven Check and adjust tire pressure Deck mounted incorrectly See your authorized SCAG dealer

Width of Deck

SGB023

TROUBLESHOOTING CUTTING CONDITIONS

CONDITION

CAUSE

CURE

Scalping - Blades Low tire pressures Check and adjust pressures Hitting Dirt or Cutting Very Close to Ground speed too fast Slow speed to adjust for conditions the Ground

Cutting too low May need to reduce ground speed,

raise cutting height, change direction of cut, and/or change pitch and level

Rough terrain May need to reduce ground speed,

raise cutting height, and/or change direction of cut

Ground speed too fast Slow speed to adjust for conditions

Width of Deck

SGB022

Wet grass Cut grass after it has dried out

Step Cut Blades not mounted evenly Adjust pitch and level Ridge in Center of Cutting Path Bent blade Replace blade

Internal spindle failure See your authorized SCAG dealer Mounting of spindle incorrect See your authorized SCAG dealer

Width of Deck

SGB024

Slope Cut - Sloping Bent spindle mounting area See your authorized SCAG dealer Ridges Across Width of Cutting Path Internal spindle failure See your authorized SCAG dealer

Bent deck housing See your authorized SCAG dealer

Width of Deck

SGB025

TECHNICAL SPECIFICATIONS

ENGINES

General Type: Heavy duty industrial/commercial Brand: Kohler, Kawasaki, Honda Models: Kohler CV493T, Kawasaki FH451V (15HP), FH500V (17HP)

FH641V (21HP), Honda GXV610QAF (18HP) Horsepower: Kohler 18HP; Kaw. 15HP; Kaw. 17HP; Kaw. 21HP; Honda 18HP Type: 4 cycle gas, vertical shaft engines Displacement: Kohler: 18HP = 490cc

Kawasaki: 15HP = 494cc, 17HP = 494cc, 21HP = 675cc.

Honda: 18HP=615cc Cylinders: Varied - see manufacturer's specifications Gove rno r: Mechanical type governor with variable speed control. Settings:

Kawasaki 15HP= 3600 rpm (

(+75 rpm), 17HP & 21HP= 3600 rpm (+75 rpm), idle set at

1550 rpm (+75 rpm), Kohler 18HP= 3600 rpm (+50 rpm), idle set

at 1500 rpm (+75 rpm), Honda 18HP=3600 rpm (+150 rpm),

idle set at 1700 rpm (+ 150 rpm). Exhaust Group: Single & dual exhaust canister muffler Fuel Pump Group: Varied - See manufacturer's specifications Oil Pump Group: Varied - See manufacturer's specifications Valve Group: Varied - See manufacturer's specifications Starter/Electrical: Electronic Ignition with recoil starter or 12 volt battery with

alternator, solid state ignition with key start Charging System: Varied - See manufacturer's specifications

+75 rpm), idle set at 1200 rpm

ENGINE DECK

Thickness: 7 gauge steel Fuel Tank: 5 gallon (19.0 litres) seamless polyethylene Drive Wheels/Tires: SWZU36A - 16x6.50-8 four-ply pneumatic tubeless

SWZU 48A & 52A - 18 x 8.50-8 four-ply pneumatic tubeless Brakes: Dynamic braking through hydro drive system Axles: 1" tapered Handle Bars: 1-1/4" diameter

DRIVE SYSTEM

Type: Hydro drive with two variable displacement pumps and two

cast-iron high torque motors Hydro Pumps: Two Hydro-Gear Model BDP 10L pumps with dump valves for

movement without running the engine Drive Wheel Motors: Two 12 cu. inch cast-iron high torque motors Hydro Fluid Cooling Group: 4qt. capacity nylon cooling reservoir, uses, SAE 20W50 fluid and

10 micron filter Steering / Travel Control:: Independent handle controls for each wheel, squeeze to move

from forward to neutral to reverse, neutral lock lever, speed

range controlled with single lever (patented design), in-field

tracking adjustment with no tools necessary Parking Brakes: 7.5" drum, band brake, one on each wheel Dump Valves: Allows for movement without engine running Axles: 1" tapered motor shafts Wire Harness: 14 gauge wire Safety Group: Handle actuated operator presence system (patented design),

blade / clutch and transmission interlock to engine kill Forward Speed Range: 0 to 7.4 mph Reverse Speed Range: 0 to 3.0 mph

Date of Issue: July, 2003 Specifications Subject to Change Without Notice

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