Super Surfer Series II GSKH1848S, GSKH2352S, GSKH2561S GSKW1948S, GSKW2352S, GSKA1948S OPERATOR S MANUAL REV. 04/11/2007

Transcription

1 Super Surfer Series II GSKH1848S, GSKH2352S, GSKH2561S GSKW1948S, GSKW2352S, GSKA1948S OPERATOR S MANUAL REV. 04/11/2007 North Amerian Version

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3 Introdution Using Your Operator s Manual This manual is an important part of your mahine and should remain with the mahine when you sell it. Use the safety and operating information in the mahine operator s manual to operate and servie the mahine safely and orretly. An engine manufaturer s owner s manual has been provided with your mahine. This will provide maintenane and troubleshooting information for the engine installed in your mahine. Speifiations and design are subjet to hange without notie. WARNING: The Engine Exhaust from this produt ontains hemials known to the State of California to ause aner, birth defets or other reprodutive harm. California Proposition 65 Warning Speial Messages Your manual ontains speial messages to bring attention to potential safety onerns, mahine damage as well as helpful operating and serviing information. Please read all the information arefully to avoid injury and mahine damage. CAUTION: Avoid injury! This symbol and text highlight potential hazards or death to the operator or bystanders that may our if the hazards or proedures are ignored. IMPORTANT: Avoid Damage! This text is used to tell the operator of ations or onditions that might result in damage to the mahine. NOTE: General information is given throughout the manual that may help the operator in the operation or servie of the mahine. All information, illustrations and speifiations in this manual are based on the latest information at the time of publiation. The right is reserved to make hanges at any time without notie. COPYRIGHT 2007 Auburn Consolidated Industries, In. All rights reserved Previous Editions COPYRIGHT 2002 Produt Identifiation Reord Identifiation Numbers Super Surfer GSKH18-48S Serial Number ( ) GSKH23-52S Serial Number ( ) GSKH25-61S Serial Number ( ) GSKW1948S Serial Number ( ) GSKW2352S Serial Number ( ) GSKA1948S Serial Number ( ) If you need to ontat an Authorized Servie Center for information on serviing, always provide the produt model and serial numbers. You will need to loate the model and serial numbers for the mahine and for the engine of your mahine and reord the information in the spaes provided. DATE OF PURCHASE: DEALER NAME: DEALER PHONE: PRODUCT IDENTIFICATION NUMBER: Model Number Serial Number

4 SAFETY LABELS ENGINE MODEL, SPECIFICATION, AND SERIAL NUMBER: Model Number Speifiation Serial Number Safety Labels Safety Labels Understanding The Mahine Safety Labels MX20097 WARNING (A) Hot Surfae. WARNING (B) To avoid injury from rotating belts, keep all shields and guards in plae. Safety-Alert Symbol The mahine safety labels shown in this setion are plaed in important areas on your mahine to draw attention to potential safety hazards. On your mahine 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 neessary in speial safety messages that are identified with the word, CAUTION, and the safety-alert symbol. DANGER (C) To avoid injury from rotating blades, stay lear of dek edge. DANGER (D) To avoid injury from rotating blades and thrown objets, stay lear of dek edge and keep others away. Do not mow without disharge hute or entire grass ather in plae. DANGER (E) Do not mow without disharge hute or entire grass ather in plae. MX20138 DANGER (F) To avoid injury to hildren, stop mower when hildren are near. Do not mow in reverse. Look behind when baking. Never arry riders, espeially hildren. CAUTION: (G) Before operating read operators manual and safety instrutions. Safety Labels - 2

5 SAFETY CAUTION: HELP AVOID INJURY (H) Operator training required Read operator s manual Keep shields in plae Never arry riders Keep people a safe distane away Maintain all safety devies Before leaving mahine: 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 dek and utter dek. DANGER/POISON (J) Shield Eyes: Explosive gases an ause blindness or injury. NO Sparks Flames Smoking Sulfuri aid an ause blindness or severe burns. Flush eyes immediately with water. Get medial help fast. Keep out of reah of hildren. Do not tip. Do not open battery. WARNING (K) To avoid injury from tipover, drive aross slopes, not up and down. If mahine stops going uphill, stop blades and bak down slowly. Emission Control System Certifiation Label NOTE: Tampering with emission ontrols and omponents by unauthorized personnel may result in severe fines or penalties. Emission ontrols and omponents an only be adjusted by EPA and/or CARB authorized servie enters. Contat your Great Dane Equipment Retailer onerning emission ontrols and omponent questions. The presene of an emissions label signifies that the engine has been ertified with the United States Environmental Protetion Ageny (EPA) and/or California Air Resoures Board (CARB). The emissions warranty applies only to those engines marketed by Great Dane that have been ertified by the EPA and/or CARB; and used in the United States and Canada in off-road mobile equipment. Emission Compliane Period If your engine has the emission ompliane ategory listed on the emission ontrol system ertifiation or air index label, this indiates the number of operating hours for whih the engine has been ertified to meet EPA and/or CARB emission requirements. The following table provides the engine ompliane period in hours assoiated with the ategory found on the ertifiation label. Ageny Category Hours EPA C 250 EPA B 500 EPA A 1000 CARB Moderate 125 CARB Intermediate 250 CARB Extended 500 Certifiation Your produt has been tested and evaluated by the manufaturer and onforms with Amerian National Standard B-71.4, Safety Speifiations for ommerial turf are equipment. Safety Operator Training Required Read the operator s manual and other training material. If the operator or mehani annot read English, it is the owner s responsibility to explain this material to them. This publiation is available in other languages. Beome familiar with the safe operation of the equipment, operator ontrols, and safety signs. All operators and mehanis should be trained. The owner of the mahine is responsible for training the users. Never let hildren or untrained people operate or servie the equipment. Loal regulations may restrit the age of the operator. The owner/user an prevent and is responsible for aidents or injuries ourring to themselves, other people, or property. Operate the mahine in an open, unobstruted area under the diretion of an experiened operator. Preparation Evaluate the terrain to determine what aessories and attahments are needed to properly and safely perform the job. Only use aessories and attahments approved by the manufaturer. Wear appropriate lothing inluding hard hat, safety glasses and hearing protetion. Long hair, loose lothing or jewelry may get tangled in moving parts. Inspet the area where the equipment is to be used and remove all objets suh as roks, toys and wire whih an be thrown by the mahine. Use extra are when handling gasoline and other fuels. They are flammable and vapors are explosive. a. Use only an approved ontainer. b. Never remove gas ap or add fuel when engine is running. Do not smoke.. Never refuel or drain the mahine indoors. Chek that the operator s presene ontrols, safety swithes and shields are attahed and funtioning properly. Do not operate unless they are funtioning properly. Operating Safely Never run an engine in an enlosed area where dangerous arbon monoxide fumes an ollet. Safety - 3

6 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 are on hillsides. Be sure to travel in the reommended diretion on hillsides. For this mahine, drive aross hillsides, not up and down. Turf onditions an affet the mahine s stability. Use aution while operating near drop-offs. Slow down and use aution when making turns and when hanging diretions on slopes. Never raise dek with the blades running. Never operate with the PTO shield, or other guards, not seurely in plae. Be sure all interloks are attahed, adjusted properly, and funtioning properly. Never operate with the disharge defletor raised, removed or altered, unless using a grassather. Do not operate mower without disharge hute or entire grassather in plae. Do not hange the engine governor setting or overspeed the engine. Operating the engine at exessive speed an inrease 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 inluding emptying the grassathers or unlogging the hute. Stop equipment and inspet blades after striking objets or if an abnormal vibration ours. Make neessary repairs before resuming operations. Keep hands and feet away from the utting units. Look behind and down before baking up to be sure of a lear path. Never arry passengers and keep pets and bystanders away. Slow down and use aution when making turns and rossing roads and sidewalks. Stop blades if not mowing. Wath for traffi when operating near or rossing roadways. Be aware of the mower disharge diretion and do not point it at anyone. Do not operate the mahine while under the influene of alohol or drugs. Use are when loading or unloading the mahine into or off of a trailer or truk. Use are when approahing blind orners, shrubs, trees, or other objets that may obsure vision. Inspet mahine before you operate. Be sure hardware is tight. Repair or replae damaged, badly worn, or missing parts. Be sure guards and shields are in good ondition and fastened in plae. Make any neessary adjustments before you operate. Before using, always visually inspet to see that the blades, blade bolts and the mower assembly are not worn and damaged. Replae worn and damaged blades and bolts in sets to preserve balane. Keep safety labels visible when installing aessories and attahments. Do not wear radio or musi headphones. Safe servie and operation require your full attention. When mahine is left unattended, stored, or parked, lower the mower dek unless a positive mehanial lok is used. Using a Spark Arrestor The engine in this mahine is not equipped with a spark arrestor muffler. It is a violation of California Publi Resoure Code Setion 4442 to use or operate this engine on or near any forest-overed, brush-overed or grass-overed land unless the exhaust system is equipped with a spark arrestor meeting any appliable loal or state laws. Other states or federal areas may have similar laws. A spark arrestor for your mahine may be available from your authorized dealer. An installed spark arrestor must be maintained in good working order by the operator. Cheking Mowing Area Evaluate the terrain to determine what aessories and attahments are needed to properly and safely perform the job. Clear mowing area of objets 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 tration 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 mahine on a level surfae, not on a slope. 2. Disengage mower blades. 3. Lok 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 mahine is equipped. 8. Disonnet the negative battery able or remove the spark plug wire (for gasoline engines) before serviing the mahine. Rotating Blades are Dangerous HELP PREVENT SERIOUS OR FATAL ACCIDENTS: Rotating blades an ut off arms and legs, and throw objets. Failure to observe safety instrutions ould result in serious injury or death. Keep hands, feet and lothing away from mower dek when engine is running. Be alert at all times, drive forward arefully. People, espeially hildren an move quikly into the mowing area before you know it. Safety - 4

7 SAFETY Do not mow in reverse. Shut off blades when you are not mowing. Park mahine safely before leaving the operator station for any reason inluding emptying the athers or unplugging the hute. Protet Children MX18014 Death or serious injury an our when young hildren assoiate having fun with a lawn mowing mahine simply beause someone has given them a ride on a mahine. Children are attrated to lawn mowing mahines and mowing ativities. They don t understand the dangers of rotating blades or the fat that the operator is unaware of their presene. Children who have been given rides in the past may suddenly appear in the mowing area for another ride and be run over or baked over by the mahine. Tragi aidents with hildren an our if the operator is not alert to the presene of hildren, espeially when a hild approahes a mahine from behind. Before and while baking up, stop mower blades and look down and behind the mahine arefully, espeially for hildren. Never arry hildren on a mahine or attahment, even with the blades off. Do not tow hildren in a art or trailer. They an fall off and be seriously injured or interfere with safe mahine operation. Never use the mahine as a rereational vehile or to entertain hildren. Never allow hildren or an untrained person operate the mahine. Instrut all operators not to give hildren a ride on the mahine or in an attahment. Keep hildren indoors, out of the mowing area, and in the wathful eye of a responsible adult, other than the operator, when a mower is being operated. Stay alert to the presene of hildren. Never assume that hildren will remain where you last saw them. Turn the mahine off if a hild enters the work area. Avoid Tipping Slopes are a major fator related to loss-of-ontrol and tip-over aidents, whih an result in severe injury or death. Operation on all slopes requires extra aution. Never mow on inlines exeeding 15. Mow aross slopes, not up and down. Wath for holes, ruts, bumps, roks, or other hidden objets. Uneven terrain ould overturn the mahine. Tall grass an hide obstales. Choose a low ground speed so you will not have to stop or shift while on a slope. Do not mow or operate mahine on wet grass. Tires may lose tration. Tires may lose tration on slopes even though the brakes are funtioning properly. Avoid starting, stopping or turning on a slope. If the tires lose tration, disengage the blades and proeed slowly, straight down the slope. Keep all movement on slopes slow and gradual. Do not make sudden hanges in speed or diretion, whih ould ause the mahine to roll over. Use extra are while operating mahine with grassathers or other attahments, they an affet stability of the mahine. Do not use on steep slopes. Do not mow near drop-offs, dithes, embankments, or bodies of water. The mahine ould suddenly roll over if a wheel goes over the edge or the edge aves in. Follow the manufaturer s reommendations for wheel weights or ounterweights for added stability when operating on slopes or using front or rear mounted attahments. Remove weights when not required. Drive mahine very slowly and avoid quik stops when attahment is removed. Transport mahine with deks lowered to improve stability. Keep Riders Off Only allow the operator on the mahine. Keep riders off. Riders on the mahine or attahment may be struk by foreign objets or thrown off the mahine ausing serious injury. Riders obstrut the operator s view resulting in the mahine being operated in an unsafe manner. Avoid High Pressure Fluids Hydrauli hoses and lines an fail due to physial damage, kinks, age, and exposure. Chek hoses and lines regularly. Replae damaged hoses and lines. Hydrauli fluid onnetions an loosen due to physial damage and vibration. Chek onnetions regularly. Tighten loose onnetions. Esaping fluid under pressure an penetrate the skin ausing serious injury. Avoid the hazard by relieving pressure before disonneting hydrauli or other lines. Tighten all onnetions before applying pressure. Searh for leaks with a piee of ardboard. Protet hands and body from high pressure fluids. If an aident ours, see a dotor immediately. Any fluid injeted into the skin must be surgially removed within a few hours or gangrene may result. Dotors unfamiliar with this type of injury should referene a knowledgeable medial soure. Suh information is available from Deere & Company Medial Department in Moline, Illinois, U.S.A. Information may be obtained in the United States and Canada only by alling Cheking Wheel Hardware A serious aident ould our ausing serious injury if wheel hardware is not tight. Chek wheel hardware tightness often during the first 100 hours of operation. Wheel hardware must be tightened to speified torque using the proper proedure anytime it is loosened. Wear Appropriate Clothing Always wear safety goggles, or safety glasses with side shields, and a hard hat when operating the mahine. Safety - 5

8 SAFETY Wear lose fitting lothing 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 protetive devie suh as earplugs. Loud noise an ause impairment or loss of hearing. Maintenane and Storage Never operate mahine in a losed area where dangerous arbon monoxide fumes an ollet. Disengage drives, lower implement, lok parking brake, stop engine and remove key or disonnet spark plug (for gas engines). Wait for all movement to stop before adjusting, leaning or repairing. Clean grass and debris from utting units, drives, mufflers, and engine to help prevent fires. Clean up oil or fuel spillage. Let engine ool 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 mahine on level ground. Never allow untrained personnel to servie mahine. Understand servie proedure before doing work. Use jak stands or lok servie lathes to support omponents when required. Seurely support any mahine elements that must be raised for servie work. Before serviing mahine or attahment, arefully release pressure from any omponents with stored energy, suh as hydrauli omponents or springs. Release hydrauli pressure by lowering attahment or utting units to the ground or to a mehanial stop and move hydrauli ontrol levers bak and forth. Disonnet battery or remove spark plug (for gas engines) before making any repairs. Disonnet the negative terminal first and the positive last. Reonnet positive first and negative last. Use are when heking blades. Wrap the blades or wear gloves, and use aution when serviing them. Only replae blades. Never straighten or weld them. Keep hands, feet, lothing, 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 harger before onneting or disonneting from battery. Wear protetive lothing and use insulated tools. Keep all parts in good working ondition and all hardware tightened. Replae all worn or damaged deals. Chek grassather omponents and the disharge guard frequently and replae with manufaturer s reommended parts, when neessary. Grassather omponents are subjet to wear, damage, and deterioration whih ould expose moving parts or allow objets to be thrown. Keep all nuts and bolts tight, espeially blade attahment bolts, to be sure the equipment is in safe working ondition. Chek brake operation frequently. Adjust and servie as required. On multi-bladed mahines, take are as rotating one blade an ause other blades to rotate. Empty the grassather ompletely before storing. Always shut off fuel when storing or transporting mahine, if the mahine has a fuel shutoff. Do not store mahine near an open flame or soure of ignition, suh as a water heater or furnae. Chek fuel lines, tank, ap, and fittings frequently for raks or leaks. Replae if neessary. Tire Safety Explosive separation of a tire and rim parts an ause serious injury or death: Do not attempt to mount a tire without the proper equipment and experiene to perform the job. Always maintain the orret tire pressure. Do not inflate the tires above the reommended pressure. Never weld or heat a wheel and tire assembly. The heat an ause an inrease in air pressure resulting in a tire explosion. Welding an struturally weaken or deform the wheel. When inflating tires, use a lip-on huk and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly. Chek tires for low pressure, uts, bubbles, damaged rims or missing lug bolts and nuts. Handling Fuel Safely To avoid personal injury or property damage, use extreme are in handling fuel. Fuel is extremely flammable and fuel vapors are explosive: Extinguish all igarettes, igars, pipes, and other soures of ignition. Use only an approved fuel ontainer. Use only non-metal, portable fuel ontainers approved by the Underwriter s Laboratory (U.L.) or the Amerian Soiety for Testing & Materials (ASTM). If using a funnel, make sure it is plasti and has no sreen or filter. Never remove the fuel tank ap or add fuel with the engine running. Allow engine to ool before refueling. Never add fuel to or drain fuel from the mahine indoors. Move mahine outdoors and provide adequate ventilation. Clean up spilled fuel immediately. If fuel is spilled on lothing, hange lothing immediately. If fuel is spilled near mahine, do not attempt to start the engine but move the mahine away from the area of spillage. Avoid reating any soure of ignition until fuel vapors have dissipated. Never store the mahine or fuel ontainer where there is an open flame, spark, or pilot light suh as on a water heater or other appliane. Prevent Fires Remove grass and debris from engine ompartment and muffler area, before and after operating mahine, espeially after mowing or mulhing in dry onditions. Safety - 6

9 OPERATING Test safety systems. Chek battery. Chek for oil leaks. Chek engine oil and hydrauli oil levels. Chek all belts for damage or raking. Chek engine air filter. Chek mower level. Adjust utting height if neessary. Chek wheel bolt torque. Tighten if neessary. Chek tire air pressure. Chek tires for damage or raking. Chek and adjust speed ontrol linkages and lok. Avoid Damage to Plasti and Painted Surfaes Prevent fire and explosion aused by stati eletri disharge. Stati eletri disharge an ignite fuel vapors in an ungrounded fuel ontainer. Never fill ontainers inside a vehile or on a truk or trailer bed with a plasti liner. Always plae ontainers on the ground away from your vehile before fueling. Remove fuel-powered equipment from the truk or trailer and refuel it on the ground. If this is not possible, then refuel suh equipment with a portable ontainer, rather than from a fuel dispenser nozzle. Keep the nozzle in ontat with the rim of the fuel tank or ontainer opening at all times until the fueling is omplete. Do not use a nozzle lokopen devie. Do not wipe plasti parts unless rinsed first. Inset repellent spray may damage plasti and painted surfaes. Do not spray inset repellent near mahine. Be areful not to spill fuel on mahine. Fuel may damage surfae. Wipe up spilled fuel immediately. Prolonged exposure to sunlight will damage the hood surfae. Operator Station Controls Never overfill fuel tank. Replae fuel tank ap and tighten seurely. Replae all fuel ontainer aps seurely after use. For gasoline engines, do not use gas with methanol. Methanol is harmful to your health and to the environment. Handling Waste Produt and Chemials Waste produts, suh as, used oil, fuel, oolant, brake fluid, and batteries, an harm the environment and people: Do not use beverage ontainers for waste fluids - someone may drink from them. See your loal Reyling Center or authorized dealer to learn how to reyle or get rid of waste produts. A Material Safety Data Sheet (MSDS) provides speifi details on hemial produts: physial and health hazards, safety proedures, and emergeny response tehniques. The seller of the hemial produts used with your mahine is responsible for providing the MSDS for that produt. Operating Daily Operating Cheklist Make sure all neessary guards and shields are safely and seurely attahed. Chek for loose, missing, or damaged parts. Remove mower dek belt shields. Clean grass and debris from belt area. Remove grass and debris from mahine and mower dek. Remove grass and debris from operator station foot plate, pump drive belt ompartment, hydrauli pump and pump mounting plate. Test park brake. Piture Note: A-Speed Control Bar Lok B-Speed Control Bar C-Left Motion Control Lever D-Right Motion Control Lever E-Hydrostati Oil Reservoir Cap and Dipstik F-Ignition Key Swith G-Fuel Tank Cap H-PTO Swith I-Optional Light Swith Loation J-Hourmeter MX20138 Operating - 7

10 OPERATING K-Choke L-Throttle Lever M-Park Brake Lever Mower Dek Controls Mounting and Dismounting Mahine Safely A-Mower Dek Lift Levers B-Height-of-Cut (HOC) Pin Misellaneous Controls MX20093 MX Step on operator s platform (A) at the rear of mahine to mount the mahine. 2. Park mahine safely. (See Parking Safely in the SAFETY setion.) 3. Step off operator s platform to dismount mahine. 4. Keep operator s platform and suspension springs lean and free of debris. Raising and Lowering Thigh Pad 1. Park mahine safely. (See Parking Safely in the SAFETY setion.) A-Free-Wheeling Valves MX Raise and lower thigh pad (A) as required. MX20096 Adjusting Mower Dek Cutting Height The mower dek height adjustment onsists of seven different utting heights. The utting heights range from mm (1-1/2-4-1/2 in.) in 13 mm (1/2 in.) inrements. CAUTION: Avoid injury! Before adjusting utting height, stop engine and lok the park brake. 1. Park mahine safely. (See Parking Safely in the SAFETY setion.) 2. Disengage PTO. Operating - 8

11 OPERATING 3. Stop engine and lok park brake. NOTE: Disharge hute raised for larity. 4. Remove retaining ring (A) from HOC pin (B). 5. Push down on dek lift lever (C). 6. Remove HOC pin. 7. Plae HOC pin in desired height hole (D). 8. Release dek lift lever (C). 9. Install retaining ring (A) in HOC pin (B). 10. Repeat proedure for opposite side. Leveling Mower Dek MX20099 CAUTION: Avoid injury! Rotating blades are dangerous. Before adjusting or serviing mower: Disonnet spark plug wire(s) or battery negative (-) able to prevent engine from starting aidently. Always wear gloves when handling mower blades or working near blades. MX Position right mower blade (A) (disharge side) perpendiular to diretion of travel. NOTE: Use a short ruler or a leveling gauge to hek the mower blade level. 3. Measure distane (B) from outside blade tip to the ground. 4. Position left mower blade perpendiular to diretion of travel. 5. Measure from outside blade tip to the ground. The differene between both measurements should be no greater than 3 mm (1/8 in.). 6. If side-to-side level is not within the tolerane, an adjustment is neessary. Adjusting Level (Side-to-Side) NOTE: When adjusting U-bolts, maintain a minimum learane of 3 mm (1/8 in.) between mower dek and stop pads. NOTE: Mower dek anti-salp wheels should not ontat the ground. 1. Park mahine safely. (See Parking Safely in the SAFETY setion.) 2. Inflate tires to the orret pressure. 3. Inspet mower blades for: Blade sharpness. Blade damage. Bent blades. Cheking Level (Side-to-Side) NOTE: Mower dek anti-salp wheels should not ontat the ground. 1. Adjust mower dek to 76 mm (3 in.) utting height position. MX20099 Adjust four U-bolts (C) (two on eah side of dek) until dek is within 3 mm (1/8 in.) of level from side-to-side. Operating - 9

12 OPERATING MX20100 a. Loosen jam nuts (D) and adjust nuts (E) on eah U-bolt until side-to side level is reahed. b. Tighten jam nuts (D). Cheking Level (Front-to-Rear) 1. Set height-of-ut (HOC) to the 76 mm (3 in.) utting 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. MX Loosen jam nut (H) on both dek lift assist rods. 2. Adjust front-to-rear mower level: Turn nut (I) on both sides lokwise to raise front of mower dek, or ounterlokwise to lower front of mower dek. 3. Verify that the adjustment on right and left sides is equal. 4. Tighten jam nuts (H). 5. Chek front-to-rear mower level. Cheking and Adjusting Cutting Height CAUTION: Avoid injury! Rotating blades are dangerous. Before adjusting or serviing mower: Disonnet spark plug wire(s) or battery negative (-) able to prevent engine from starting aidentally. Always wear gloves when handling mower blades or working near blades. Cheking Overall Cutting Height MX Position right mower blade (F) (disharge side) parallel to the diretion of travel. 3. Measure distane (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 tolerane, an adjustment is neessary. 1. Inflate tires to orret pressure. 2. Lower mower dek to the 76 mm (3 in.) utting height. 3. Position right mower blade (disharge side) parallel to the diretion of travel. 4. Measure from the front of the blade tip to the ground. 5. If blade tip height is not within mm (2-7/8-3-1/8 in.), an adjustment is needed. Adjusting Level (Front-to-Rear) IMPORTANT: Avoid damage: Adjust the left and right dek lift assist rods equally. NOTE: Adjust side-to-side mower level before adjusting front-to-rear level. Adjust both sides of the mower dek equally. All lift hains must remain taut. Operating - 10

13 OPERATING Adjusting Overall Cutting Height Testing Safety Systems NOTE: When adjusting U-bolts, maintain a minimum learane of 3 mm (1/8 in.) between mower dek and stop pads. Adjust both sides of the mower dek equally. All lift hains must remain taut. CAUTION: Avoid injury! Engine exhaust fumes ontain arbon monoxide and an ause serious illness or death. Move the mahine to an outside area before running the engine. Do not run an engine in an enlosed area without adequate ventilation. Connet a pipe extension to the engine exhaust pipe to diret the exhaust fumes out of the area. Allow fresh outside air into the work area to lear the exhaust fumes out. MX Adjust four U-bolts (A) (two on eah side of dek) until blade tip height is within mm (2-7/8-3-1/8 in.) of the 76 mm (3 in.) setting. Adjusting Mower Dek Anti-Salp Wheels NOTE: The flattest ut an be ahieved by having all anti-salp wheels adjusted off the ground. Chek anti-salp wheel adjustments eah time the mower dek utting height is hanged. It is reommended that all anti-salp wheels be kept off the ground to minimize suffing. 1. Inflate tires to orret pressure. 2. Adjust mower dek to desired utting height. The safety systems installed on your mahine should be heked before eah mahine use. Be sure you have read the mahine operator manual and are ompletely familiar with the operation of the mahine before performing these safety system heks. Use the following hekout proedures to hek for normal operation of mahine. If there is a malfuntion during one of these proedures, do not operate mahine. See your authorized dealer for servie. Perform these tests in a lear open area. Keep bystanders away. Testing PTO Swith 1. Stand on operator s platform with motion ontrol levers in the neutral position. 2. Lok park brake. 3. Pull PTO swith up to engage. 4. Turn key swith to the start position. Result: The engine must not rank. Testing Park Brake Swith 3. Adjust anti-salp wheel (A) to one of three positions (D). MX Push PTO swith down to disengage. 2. Unlok park brake. 3. Turn key swith to the start position. Result: The engine must not rank. Testing Neutral Swith (Start) 1. Lok park brake. 2. Push PTO swith down to disengage. 3. Push one motion ontrol lever forward. 4. Turn key swith to the start position. Result: The engine must not rank. Remove srew (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 surfae. 4. Install wheel with attahing hardware. 5. Adjust all wheels to the same height. Testing Neutral Swith (Run) 1. Lok park brake. 2. Push PTO swith down to disengage. 3. Start engine. 4. Push one motion ontrol lever forward. 5. Repeat proedure using the other lever. 6. Repeat proedure pushing eah motion ontrol lever rearward. Result: The engine must stop when either lever is moved from neutral position. Operating - 11

14 OPERATING Testing Operator Presene Swith NOTE: Ensure OPC swith braket is depressed when standing on operator s station. 1. Stand on operator s platform with motion ontrol levers in the NEUTRAL position. 2. Start engine. 3. Unlok park brake. 4. Step ompletely off operator s platform. Result: The engine must stop. NOTE: Ensure OPC swith braket is depressed when standing on operator s station. 5. Stand on operator s platform with motion ontrol levers in the NEUTRAL position and start engine. 6. Pull PTO swith up to engage. 7. Step ompletely off operator s platform. Result: The engine must stop. Testing the Park Brake CAUTION: Avoid injury! Thrown objets an be dangerous. Before operating the attahment: Clear area of bystanders, espeially hildren. Pik up objets whih may be thrown by the attahment. Using Park Brake Loking Park Brake Raise park brake lever (A) to lok park brake. Unloking Park Brake: Lower park brake lever (A) to unlok park brake. MX20102 Using the PTO Engage PTO: 1. Stand on operator s platform with motion ontrol 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. MIF 1. Stop mahine on a 17 slope (30% grade) faing downhill. Stop the engine and lok the park brake. 2. Repeat proedure with mahine faing uphill. Result: Park brake must hold the mahine stationary. (Mahine should move no more that 61m (24 in.) in one hour.) If mahine 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 setion. 5. Pull PTO knob (A) up to engage mower dek. 6. Move throttle lever forward to the fast position for mowing. Disengage PTO: 1. Push PTO knob (A) down. 2. Set park brake. MX12854 Operating - 12

15 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) bakward to the slow position (D) to idle engine. Do not run engine at slow idle any longer than neessary for ooldown after mowing. Using the Hourmeter NOTE: The mahine is equipped with an eletri start. The hourmeter will ontinue to run with the key swith in the run position. MX20091 Piture Note: Motion ontrol levers (A) shown in the neutral position. Mahine speed, motion and diretion an be ontrolled when the engine is running and park brake is unloked. Operator an exit the mower with the engine running when the park brake is loked and the PTO swith is disengaged. Forward and Reverse Motion: CAUTION: Avoid injury! Children or bystanders may be injured by runover and rotating blades. Before traveling forward or rearward: Carefully hek the area around the mahine. Disengage the mower before baking up. 1. Move throttle lever to the fast position. 2. Unlok park brake. 3. Push motion ontrol levers forward to begin forward motion. The further forward the ontrol levers are moved, the faster the mahine will travel. Forward speed range: km/h (0 9.2 mph) MX20091 Hourmeter (A) shows number of hours the mahine has been operated. Use hourmeter and SERVICE INTERVAL setion to determine when mahine needs servie. Using the Motion Control Levers The funtions of the motion ontrol levers are: 4. Pull both motion ontrol levers rearward at the same time to begin reverse motion. Reverse speed range: km/h (0 4 mph) 5. To stop motion, move both motion ontrol levers forward or rearward until the mahine omes to a stop. NOTE: The motion ontrol linkages are adjustable. If adjustment is required, see Cheking and Adjusting Motion Control Linkages in the SERVICE TRANSMISSION setion. CAUTION: Avoid injury! Learn use of the motion ontrol levers and pratie at half throttle until beoming profiient and omfortable with the operation of the mahine. Do not move motion ontrol levers from forward to reverse or reverse to forward position rapidly. Sudden diretion hanges ould ause loss of ontrol or damage the mahine. Steering. Aeleration. Deeleration. Operating - 13

16 OPERATING Forward: Gentle Right Turn: Push both motion ontrol levers forward at the same time. Reverse: MX12788 MX12791 Push left motion ontrol lever further forward than the right motion ontrol lever. Sharp Left Turn: MX12789 Pull both motion ontrol levers past enter rearward at the same time. Gentle Left Turn: MX12792 Push right motion ontrol lever forward and pull left motion ontrol lever rearward at the same time. Sharp Right Turn: MX12790 Push right motion ontrol lever further forward than the left motion ontrol lever. MX12793 Push left motion ontrol lever forward and pull right motion ontrol lever rearward at the same time. Operating - 14

17 OPERATING Starting Engine Engaging Mower 1. Stand on operator s platform. 2. Lok park brake. CAUTION: Avoid injury! Engine exhaust fumes ontain arbon monoxide and an ause serious illness or death. Move the mahine to an outside area before running the engine. Do not run an engine in an enlosed area without adequate ventilation. Connet a pipe extension to the engine exhaust pipe to diret the exhaust fumes out of the area. Allow fresh outside air into the work area to lear the exhaust fumes out. CAUTION: Avoid injury! Clear mowing area of all bystanders when operating this mahine. Thrown objets ould ause serious injury or death. Keep hands and feet away from blades and disharge opening. Do not mow in reverse unless absolutely neessary. IMPORTANT: Avoid damage! To help prevent damage to PTO luth: Do not engage PTO with throttle in the fast position. 1. Adjust mower dek to desired utting height. 2. Start engine. MX Put motion ontrol levers (A) in the NEUTRAL position. 4. Push PTO swith 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 hoke knob (D): Cold engine: Pull knob up to the CHOKE position. Warm/Hot engine: If neessary, pull knob up to the CHOKE position. 7. Turn key swith (E) to the START position. 8. Release key to the RUN position when engine starts. 9. With engine started: Push hoke knob to the OFF position. Move throttle lever to the FAST position. Unlok park brake. MX Move throttle lever (A) to the 1/2 to 3/4 fast position. 4. Unlok park brake. NOTE: In old weather or with a new mahine, allow engine to reah operating temperature before engaging PTO to prevent engine from stalling. 5. Pull PTO knob (B) up to engage mower dek. 6. Move throttle lever to the fast position (C). NOTE: The travel speed and turn rate will vary with the amount that the motion ontrol levers are moved. 7. Push motion ontrol levers (D) forward slowly. Mow at a safe travel speed. Stopping the Engine IMPORTANT: Avoid damage! To help prevent engine bakfiring, 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 arburetor and muffler. 1. Lok park brake. 2. Redue engine speed to half-throttle. 3. Turn key swith to STOP position (C). 4. Remove key. Operating - 15

18 OPERATING Using Pump Free-Wheel Valves NOTE: The pump free-wheel valves must be turned fully lokwise (losed) during normal mahine operation. When the mahine needs to be moved without starting the engine, use the pump free-wheel valves: 1. Lok park brake. NOTE: The pumps (A) are loated in the bak of the mahine, behind the rear shield (B). CAUTION: Avoid injury! With the free-wheeling valve open, the mahine will have unrestrited motion. The mahine may free-wheel out of ontrol if the freewheeling valve is opened with the mahine on an inline. Park the mahine on a level surfae before opening the free-wheeling valve. IMPORTANT: Avoid Damage! Transmission damage may our if the mahine is towed or moved inorretly: Move mahine by hand only. Do not use another vehile to move mahine. Do not tow mahine. 3. Stop engine and lok park brake. 4. Remove key. 5. Fasten mahine to trailer with heavy-duty straps, hains or ables. Both front and rear straps must be direted downward and outward from mahine. Mowing Tips Mow grass with throttle lever in the full fast position. Cut grass when it is dry. Keep mower dek and disharge hute lean. Mow with sharp blades. Properly level mower dek for a smooth ut. Mow grass high and often. Use a travel speed that fits the onditions: Mow tall or wet grass twie. Cut grass at half desired height then ut at desired height. Travel slow when mowing tall, thik or wet grass. Avoid damaging grass by slipping or skidding mahine drive wheels. Pratie smooth ontrol lever movements. When performing sharp turns, do not allow inside mahine 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 Inspet Mower MX Turn both pump free-wheel valves (C) ounterlokwise approximately one full turn (open position). 3. Unlok park brake. 4. Push mahine to desired loation. Due to hydrauli system drag, mahine will move slowly. 5. Turn pump free-wheel valves (C) on both pumps one full turn lokwise (losed position). Tighten valves to 11 N m (100 lb-in.). 6. Lok park brake. Transporting Mahine on a Trailer Use a heavy-duty trailer to transport your mahine. Trailer must have signs and lights required by law. CAUTION: Avoid injury! Help prevent serious injury. Keep hands and feet away from blades and the disharge opening. Do not step on either side of the mower dek when mounting and dismounting the mahine. Mount and dismount the mahine using the front foot plate. 1. Park mahine on a hard, level surfae. 2. Disengage PTO. 3. Move motion ontrol levers to the neutral position. 4. Lok park brake. 5. Stop engine and remove key. Wait for mower blades to stop turning before leaving operator s position. CAUTION: Avoid injury! Use extra are when loading or unloading the mahine into a trailer or truk. Close fuel shut-off valve, if your mahine is equipped. 1. Raise mower dek to the transport position. 2. Drive mahine onto a trailer. Operating - 16

19 SERVICE INTERVALS Servie Intervals Serviing Your Mahine IMPORTANT: Avoid Damage! Operating in extreme onditions may require more frequent servie intervals: Engine omponents may beome dirty or plugged when operating in extreme heat, dust or other severe onditions. Engine oil may lose effiieny if vehile is operated onstantly at slow or low engine speeds or with frequent short trips. Please use the following timetables to perform routine maintenane on your mahine. Serviing Engine See engine manufaturer s owner s manual provided with your mahine for engine servie information. Break-In (After First 10 Hours) Chek air pressure in tires. Chek wheel bolt torque. Chek and adjust park brake. Change engine oil and filter. Chek mower dek drive belt tension. Chek hydrauli pump drive belt. Chek transmission neutral adjustment. Every 40 Hours Chek air pressure in tires. Chek wheel bolt torque. Chek and adjust park brake. Change engine oil and filter. Chek foam and paper air leaner elements. Clean engine shrouds as needed. Lubriate front aster spindles and wheels. Lubriate mower dek lift pivot tubes. Lubriate mower dek idler pivot. Lubriate mower dek push arms. Chek mower dek drive belt tension. Lubriate hydrauli pump idler pivot. Chek hydrauli pump drive belt. Chek hydrauli fluid level. If operating mahine in extremely dusty or dirty onditions: Clean behind engine shrouds and exposed fins. Remove srews on blower fan sreen and lean behind. Every 500 Hours Change hydrauli oil and filter. Yearly Change fuel filter. Clean battery. Change engine oil and filter at least one per season. Change hydrauli oil and filter at least one per season. Replae spark plugs. Servie Lubriation Grease Use a general all-purpose grease with an NLGI grade No.2 rating. Wet or high speed onditions may require use of a speial-use grease. Contat your Serviing dealer for information. Lubriating Front Caster Spindles and Wheels IMPORTANT: Avoid Damage! The reommended grease is effetive within an average air temperature range of -29 to 135 degrees C (-20 to 275 degrees F). If operating outside that temperature range, ontat your serviing dealer for a speial-use grease. CAUTION: Avoid injury! Fingers or loose lothing an get aught in rotating parts. Stop engine and wait for all moving parts to stop before serviing. MX15286 Lubriate two spindle grease fittings (A) and two wheel grease fittings (B). Every 100 Hours Lubriate mower dek spindles. Clean and gap spark plugs. Chek hydrauli pump drive belt. Clean behind engine shrouds and exposed fins. Remove srews on blower fan sreen and lean behind. Servie Intervals - 17

20 SERVICE ENGINE Lubriating Dek Lift Pivot Points Lubriating Mower Dek Idler Pivot MX20104 Lubriate two front dek lift pivot grease fittings (A) and two rear dek lift pivot grease fittings (B). Lubriating Pump Idler Pivot Lubriate one dek idler pivot grease fitting (A). Lubriating Mower Dek Push Arms MX20106 Lubriate one pump idler pivot grease fitting (A). Lubriating Mower Dek Spindles MX15095 MX20107 Lubriate two push arm grease fittings (A), one loated on eah side of the mahine. Servie Engine Avoid Fumes Lubriate three mower dek spindle grease fittings (A). MX15287 CAUTION: Avoid injury! Engine exhaust fumes ontain arbon monoxide and an ause serious illness or death. Move the mahine to an outside area before running the engine. Do not run an engine in an enlosed area without adequate ventilation. Connet a pipe extension to the engine exhaust pipe to diret the exhaust fumes out of the area. Allow fresh outside air into the work area to lear the exhaust fumes out. Engine Oil Use oil visosity based on the expeted air temperature range during the period between oil hanges. Use oil that meets the following speifiation: See the engine manufaturer s owner s manual provided with your mahine for the orret speifiations. Servie Engine - 18

21 SERVICE ENGINE Cheking Engine Oil Level IMPORTANT: Avoid Damage! Failure to hek the oil level regularly ould lead to serious engine problems if oil level is low: Chek oil level before operating. Keep oil level between the FULL and the ADD marks. Chek oil level when engine is stopped, level, and is ooled so oil has had time to drain into the sump. NOTE: Chek oil twie a day if you run engine over 4 hours in a day. Make sure engine is ool when heking engine oil level. 1. Park mahine safely. (See Parking Safely in the SAFETY setion.) 2. Allow engine to ool. 3. Clean area around dipstik to prevent debris from falling into rankase. 1. Clean area around dipstik ap and filter. 2. Start engine and run until it reahes normal operating temperature. 3. Park mahine safely. (See Parking Safely in the SAFETY setion.) IMPORTANT: Avoid Damage! Change the oil more often if the mahine is used in extreme onditions: Extremely dusty onditions. Frequent slow or low-speed operation. Frequent short trips. MX Remove dipstik (A). Wipe with a lean loth. NOTE: Allow dipstik ap to rest on threads of filler tube when heking oil level. Do not tighten dipstik ap when heking oil level. 5. Install dipstik and allow the ap to rest on the threads of the tube. Do not tighten the ap. 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 seurely tighten drain plug (A). MX 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 dipstik and hek oil level on dipstik. Oil must be between the ADD and FULL marks. NOTE: Refer to engine manufaturers operating manual for orret type and grade of oil. If oil is low, add oil to bring oil level no higher than the FULL mark on dipstik. If oil level is above the FULL mark, drain to proper level. 7. Install and tighten dipstik. Changing Engine Oil and Filter CAUTION: Avoid injury! Touhing hot surfaes an burn skin. The engine, omponents, and fluids will be hot if the engine has been running. Be autious and wear protetive lothing when serviing or working near a hot engine and omponents. 8. Turn oil filter (B) ounterlokwise to remove. 9. Apply a film of lean engine oil to gasket of new filter. MX20149 IMPORTANT: Avoid Damage! Do not use wrenh to tighten oil filter. 10. Install filter. Turn filter lokwise until gasket makes ontat with mounting surfae. Tighten 1/2 to 3/4 turn after gasket ontat. 11. Raise thigh pad. 12. Remove dipstik ap. NOTE: Refer to engine manufaturers operating manual for orret type and grade of oil. 13. Add approximately 1.7 L (1.75 qt) of oil. Servie Engine - 19

22 SERVICE ENGINE 14. Insert dipstik. Tighten ap. 15. Start engine and run at slow throttle for approximately two minutes. Chek for leaks around filter and drain valve. 16. Stop engine. 17. Chek oil level: Remove dipstik ap. Wipe dipstik lean. NOTE: Allow dipstik ap to rest on threads of filler tube when heking oil level. Do not tighten dipstik ap when heking oil level. Insert dipstik and allow ap to rest on threads of filler. Do not tighten ap. Remove dipstik. Add oil as needed to bring level to the full mark without overfilling. 18. Insert dipstik. Tighten ap. Cleaning Engine Air Intake Sreen and Fan Keep air intake sreens and engine ooling fins lear of debris to ensure proper ooling. See the engine manufaturer s owner s manual provided with your mahine for the omplete proedure. Cheking and Cleaning Air Filter Elements 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. CAUTION: Avoid injury! Compressed air an ause debris to fly a long distane. Clear work area of bystanders. Wear eye protetion when using ompressed air for leaning purposes. Redue ompressed air pressure to 210 kpa (30 psi). IMPORTANT: Avoid damage! An obstruted air intake sreen an ause engine damage due to overheating. Keep air intake sreen and other external surfaes of the engine, inluding ooling fins, lean at all times to allow adequate air intake. CAUTION: Avoid injury! Touhing hot surfaes an burn skin. The engine, omponents, and fluids will be hot if the engine has been running. Allow the engine to ool before serviing or working near the engine and omponents. IMPORTANT: Avoid damage! Dirt and debris an enter the engine through a damaged filter element: Do not wash paper element. Do not attempt to lean paper element by tapping against another objet. Do not use pressurized air to lean element. Replae element only if it is very dirty, damaged or the seal is raked. operating mahine in dusty onditions. Chek and lean air filter elements at the intervals reommended in the Servie Intervals setion. See the engine manufaturer s owner s manual provided with your mahine for the omplete proedure. Cheking Spark Plug Chek spark plugs at the intervals reommended in the Servie Intervals setion. See the engine manufaturer s owner s manual provided with your mahine for the omplete proedure. Cleaning Engine Oil Cooler - Kohler Engines Keep engine oil ooler fins lear of debris to ensure proper ooling. See the engine manufaturer s owner s manual provided with your mahine for the omplete proedure. Adjusting Carburetor Carburetor is alibrated by the engine manufaturer and is not adjustable. If engine is operated at altitudes above 1829 m (6,000 ft), some arburetors may require a speial high altitude main jet. See your authorized dealer. If engine is hard to start or runs rough, hek the TROUBLESHOOTING setion of this manual. Possible engine surging will our at high throttle with transmission in N neutral and mower engagement lever disengaged. This is a normal ondition due to the emission ontrol system. After performing the heks in the troubleshooting setion and your engine is still not performing orretly, ontat your authorized dealer. Replaing Fuel Filter CAUTION: Avoid injury! Touhing hot surfaes an burn skin. The engine, omponents, and fluids will be hot if the engine has been running. Allow the engine to ool before serviing or working near the engine and omponents. 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 serviing. Cool engine before serviing. 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 diretion of the fuel flow. 1. Park mahine safely. (See Parking Safely in the SAFETY setion.) 2. Allow engine to ool. NOTE: It may be neessary to hek the air filter more frequently if Servie Engine - 20

23 SERVICE TRANSMISSION NOTE: Do not tighten dipstik ap when heking oil level. 4. Insert dipstik into reservoir filler nek (B). Do not tighten ap. 5. Remove dipstik. Chek oil level on dipstik. Oil level should be in rosshath area between ADD and FULL marks. If oil is low, add oil to bring oil level no higher than FULL mark on dipstik. If oil is above FULL mark, drain oil to proper level. 6. Insert dipstik. Tighten ap. Changing Hydrauli Oil and Filter MX Slide hose lamps (A) away from fuel filter (B). 4. Plae drain pan under hoses to ath any fuel that may be left in the hoses. 5. Disonnet hoses from fuel filter (B). 6. Install new fuel filter (B). Make sure fuel filter (B) is installed with arrow pointing in diretion of fuel flow. 7. Connet hoses to new fuel filter (B). 8. Install hose lamps (A). 9. Start engine and hek for fuel leaks. Servie Transmission Hydrauli Oil Use only 5W-50 or 15W-50 all syntheti oil. Cheking Hydrauli Oil Level 1. Park mahine safely. (Refer to Parking Safely in the SAFETY setion.) 2. Allow engine and hydrauli oil reservoir to ool. CAUTION: Avoid injury! Esaping fluid under pressure an penetrate the skin ausing serious injury. Avoid the hazard by relieving pressure before disonneting hydrauli or other lines. Tighten all onnetions before applying pressure. Searh for leaks with a piee of ardboard. Protet hands and body from high pressure fluids. Use aution when filling and draining hydrauli oil. During periods of mahine operation the hydrauli oil reservoir an get hot. Allow engine and oil reservoir to ool before serviing. IMPORTANT: Avoid Damage! Contamination of hydrauli fluid ould ause transmission damage or failure. Do not open oil reservoir ap unless absolutely neessary. Severe or unusual onditions may require a more frequent servie interval. IMPORTANT: Avoid Damage! Chek oil level in reservoir tank when oil is old. Do not overfill oil reservoir tank. Oil will expand during operation and ould overflow. 1. Park mahine safely. (Refer to Parking Safely in SAFETY setion.) 2. Clean area around reservoir dipstik ap (A). 3. Remove dipstik ap (A). Wipe dipstik lean. MX20114 MX Clean area around reservoir dipstik ap and oil filter. 4. Turn metal ap (A) on bottom of hydrauli reservoir ounterlokwise to remove. 5. Allow hydrauli oil to drain into a drain pan with a apaity of at least 3.8L (1.0 gal). 6. Turn oil filter (B) ounterlokwise to remove. 7. Apply a film of lean hydrauli oil to gasket of new filter. 8. Install new filter. Turn filter lokwise until gasket makes ontat with mounting surfae. Tighten 1/2 to 3/4 turn after gasket ontat. 9. Remove dipstik ap from hydrauli reservoir filler nek. Servie Transmission - 21

24 SERVICE TRANSMISSION IMPORTANT: Avoid Damage! Do not add oil beyond FULL mark. Oil apaity after draining may be less than dry fill apaity. Chek oil level before filling ompletely. NOTE: Dry fill apaity for hydrauli system is 3.1L (3.3 qt). 10. Fill oil reservoir with approximately 1.9L (2 qt) of oil. 11. Insert dipstik. Tighten ap. 12. Start engine. 13. Move throttle lever to 1/2 to 2/3 position. 14. Unlok park brake. Cheking and Replaing Pump Tration Drive Belt NOTE: The tration drive belt will not require a tension adjustment. Belt is self-adjusted using a spring tensioner. Cheking Tration Drive Belt: 1. Park mahine safely. (See Parking Safely in the SAFETY setion.) CAUTION: Avoid injury! Fingers or loose lothing an get aught in rotating parts. Stop engine and wait for all moving parts to stop before serviing. CAUTION: Avoid injury! Help prevent serious bodily injury. Remain alert to other people and the surroundings when operating the mahine. 15. Cyle motion ontrol levers forward and rearward several times. Chek for leaks around filter. 16. Stop engine. Chek oil level. Add oil as neessary to bring oil level to FULL mark on dipstik. Cleaning Hydrauli Oil Pump Cooling Fins CAUTION: Avoid injury! Compressed air an ause debris to fly a long distane. Clear work area of bystanders. Wear eye protetion when using ompressed air for leaning purposes. Redue ompressed air pressure to 210 kpa (30 psi). 2. Remove four ap srews (A). 3. Remove rear shield (B). MX20126 IMPORTANT: Avoid Damage! To ensure proper ooling, keep the ooling fins lean at all times. Operating the mahine with obstruted ooling fins ould ause damage due to overheating. 1. Park mahine safely. (See Parking Safely in the SAFETY setion.) MX Inspet belt (C) through frame openings (D) for exessive wear, damage or strething. Removing Tration Drive Belt: 1. Park mahine safely. (See Parking Safely in the SAFETY setion.) 2. Remove mower dek drive belt. (See Replaing Mower Dek Drive Belt in the SERVICE MOWER setion.) MX Remove four ap srews (A). 3. Remove rear shield (B) to aess hydrauli pumps (C). 4. Clean hydrauli oil ooling fins on eah hydrauli pump with a rag, brush or ompressed air. 5. Clean area around hydrauli pumps and frame. Servie Transmission - 22

25 SERVICE TRANSMISSION tration drive belt is positioned in front of anhor ap srew (F). 2. Insert 1/2 in. breaker bar into hole (C) and rotate idler pulley (D) forward for additional learane to install tration drive belt. 3. Install rear shield. 4. Install mower dek drive belt. Cheking and Adjusting Motion Control Linkages 3. Remove four ap srews (A). 4. Remove rear shield (B). MX20126 CAUTION: Avoid injury! Tensioning spring is under high tension. Wear gloves and safety glasses, and use a spring puller to install and remove spring. CAUTION: Avoid injury! Engine exhaust fumes ontain arbon monoxide and an ause serious illness or death. Move the mahine to an outside area before running the engine. Do not run an engine in an enlosed area without adequate ventilation. Connet a pipe extension to the engine exhaust pipe to diret the exhaust fumes out of the area. Allow fresh outside air into the work area to lear the exhaust fumes out. NOTE: Chek and adjust motion ontrol linkages with the mahine parked on a hard, level surfae. Cheking Motion Control Linkages: 1. Park mahine safely. (See Parking Safely in the SAFETY setion.) MX20167 Piture Note: Tration drive belt idler pulley bottom view. 5. Insert 1/2 in. breaker bar into hole (C) and rotate idler pulley (D) forward to ease tension on tration drive belt. 6. Remove tration drive belt (E). Installing Tration Drive Belt: NOTE: Install the tration drive belt (E) in front of anhor ap srew (F). G D MX Rotate speed ontrol bar (A) to full forward position. 3. With engine off, move motion ontrol levers (B) until they ontat the speed ontrol bar (A). A slight defletion should be seen in the linkage rod (C). NOTE: Chek mahine traking after making adjustments. Start the engine and run until it reahes normal operating temperature. CAUTION: Avoid injury! Be aware of bystanders. F C G MX Install tration drive belt (E) on drive sheaves (G) as shown. Ensure that 5. Stand on the operator s platform and, with the park brake released, move the motion ontrol levers (B). 6. Observe wheel movement as motion ontrol levers are moved bak and forth. Wheels should travel in the orret diretion as the levers are moved. 7. Move motion ontrol levers to neutral position. If rear wheels ontinue to rotate, a return to neutral (RTN) adjustment is required. Servie Transmission - 23

26 SERVICE TRANSMISSION Adjusting Motion Control Return to Neutral (RTN) Linkages: CAUTION: Avoid injury! Fingers or loose lothing an get aught in rotating parts. Stop engine and wait for all moving parts to stop before serviing. 1. Stop engine. 2. Lok park brake. 3. Lift mahine with a safe lifting devie entered under rear tire support frame. 4. Start the mahine with motion ontrol levers in neutral. 5. Stand on the operator s platform and release park brake. 6. If rear wheels rotate when motion ontrol levers are in neutral, a neutral adjustment is required. 7. Stop engine. NOTE: Chek and adjust transmission traking on a hard, level surfae. Cheking Transmission Traking: 1. Chek and adjust motion ontrol linkages. See Cheking and Adjusting Motion Control Linkages in the SERVICE TRANSMISSION setion. 2. Start engine and run until it reahes normal operating temperature. 3. Move mahine to an open, level area for operation. MX Drive mahine forward, pushing both ontrol levers (A) all the way to speed ontrol bar (B). 5. If mahine does not drive in a straight line, an adjustment is required. MX20161 Piture Note: Side frame removed for piture larity. 8. Slightly loosen ap srew (A) to allow rotation of neutral return plate. If wheel is rotating forward, rotate neutral return plate ounterlokwise until wheel rotation stops. If wheel is rotating in reverse, rotate neutral return plate lokwise until wheel rotation stops. 9. Tighten ap srew (A). 10. Rehek neutral. If wheels ontinue to rotate, readjust. 11. With the engine running, operate the motion ontrol levers to verify adjustment. If engine will not rank over after adjustments are made, adjust the neutral swith. Cheking and Adjusting Transmission Traking Adjusting Transmission Traking: 1. Adjust appropriate ontrol rod swivel (C) loated on eah side of mahine. If mahine traks to the right, remove spring pin (D) and rotate left ontrol rod swivel one turn lokwise. Install spring pin (D). If mahine traks to the left, remove spring pin (D) and rotate right ontrol rod swivel one turn lokwise. Install spring pin (D). 2. Chek transmission traking again and adjust as required until mahine drives in a straight line. Adjusting Forward and Reverse Speeds Adjusting Forward Speed: Park mahine safely. (See Parking Safely in the SAFETY setion.) CAUTION: Avoid injury! Engine exhaust fumes ontain arbon monoxide and an ause serious illness or death. Move the mahine to an outside area before running the engine. Do not run an engine in an enlosed area without adequate ventilation. Connet a pipe extension to the engine exhaust pipe to diret the exhaust fumes out of the area. Allow fresh outside air into the work area to lear the exhaust fumes out. Servie Transmission - 24

27 SERVICE STEERING & BRAKES 4. Tighten nuts (A). Servie Steering & Brakes Adjusting Park Brake Testing Park Brake: 1. Inflate tires to orret pressures. MX20115 Piture Note: Arrow shows diretion of speed ontrol bar (A) movement when dereasing forward speed. 2. Loosen lok lever (B) on speed ontrol bar (A). To derease forward speed, pull speed ontrol bar (A) toward the operator s station. To inrease forward speed, push speed ontrol bar (A) forward (away from operator s station). 3. Tighten lok lever (B). Adjusting Reverse Speed: 1. Park mahine safely. (See Parking Safely in the SAFETY setion.) 2. Loosen jam nut (C) on ap srew (D) on eah side of mahine. To derease reverse speed, turn ap srew (D) ounterlokwise. To inrease reverse speed, turn ap srew (D) lokwise. 3. Tighten jam nut (C) on ap srew (D) on eah side of mahine. MX Stop mahine on a maximum 17 slope. 3. Lok park brake. A properly adjusted park brake must prevent the drive wheels from turning. If the drive wheels turn, a brake adjustment will be neessary. Adjusting Park Brake: 1. Park mahine safely. (Refer to Parking Safely in the SAFETY setion.) 2. Unlok park brake. Adjust Neutral Swith MX20161 Piture Note: Side frame removed for piture larity. 1. Park mahine safely. (See Parking Safely in the SAFETY setion.) 2. Loosen nuts (A). 3. Adjust neutral swith (B). If neutral swith sensitivity needs to be inreased, adjust swith (B) down in slots. If neutral swith sensitivity needs to be dereased, adjust swith (B) up in slots. MX Loosen jam nut (A). 4. Remove hair pin and washer (B). 5. Turn brake linkage rod (C) in one-turn inrements lokwise to inrease braking fore; ounterlokwise to derease braking fore. 6. Install hair pin and washer (B). 7. Tighten jam nut (A). 8. Test park brake. Adjust again, if required. Servie Steering & Brakes - 25

28 SERVICE MOWER Servie Mower Removing and Installing Mower Dek Shield Removing Mower Dek Shield: 1. Park mahine safely. (See Parking Safely in the SAFETY setion.) CAUTION: Avoid injury! Help prevent serious personal injury. Do not operate the mower without the mower dek shield installed. MX Remove belt shield loking knobs (A). 3. Remove belt shields (B) by sliding shield from mower dek stud. Installing Belt Shields: 1. Install belt shields (B) by sliding shield over mower dek stud. 2. Install belt shield loking knobs (A). Adjusting Drive Belt Tension 1. Park mahine safely. 2. Adjust mower dek to the 76 mm (3 in.) utting height position. 3. Remove mower dek shield. MX Remove two knobs (A). 3. Lift shield (B) and pull forward to disengage from under tabs (C) on the frame. 4. Remove mower dek shield (B). Installing Mower Dek Shield: 1. Insert rear of shield (B) under tabs on frame and lower shield into position. 2. Seure with knobs (A). Removing and Installing Mower Dek Drive Belt Shields CAUTION: Avoid injury! Help prevent serious personal injury. Do not operate the mower without the belt shields installed. Removing Belt Shields: 1. Park mahine safely. (See Parking Safely in the SAFETY setion.) MX Measure length (C) of tension spring from inside of hook to inside of hook. The spring should meaure 21.6 to 22.6 m (8-1/2 in. to 8-7/8 in.). To add tension to spring: Loosen jam nut (B). Turn nut (A) lokwise. Tighten jam nut (B). To release tension from spring: Loosen jam nut (B). Turn nut (A) ounterlokwise. Tighten jam nut (B). Replaing Mower Dek Drive Belt Removing Mower Dek Drive Belt: 1. Park mahine safely. (See Parking Safely in the SAFETY setion.) 2. Lower mower dek to the lowest utting height position. 3. Remove mower dek shield. 4. Remove both mower dek belt shields. CAUTION: Avoid injury! Tensioning spring is under high tension. Wear gloves and safety glasses, and use a spring puller to install and remove spring. Servie Mower - 26

29 SERVICE MOWER Installing Mower Dek Drive Belt: NOTE: If neessary, see drive belt installation label on mower dek. MX Release mower dek drive belt tension by turning adjuster nut (A) ounterlokwise until two threads remain protruding through adjuster nut (A). 6. Disonnet idler spring (B) from idler arm (C) using a spring puller tool. MX Install replaement drive belt (A) as shown on mower dek drive belt label. Make sure drive belt is installed properly on PTO luth sheave, spindle sheaves and idler pulleys. 2. Tighten idler pulley retaining bolt to 34 N m (25 lb-ft) ensuring idler pulley belt is aptured between idler pulley flange and belt guide. MX Loosen idler pulley retaining nut (D) just enough to allow idler pulley (E) to tilt, allowing belt (F) to lear fixed belt guide (G). 8. Remove mower dek drive belt (F). MX Connet idler tension spring and adjust tension. The length (B) of the tension spring should measure 21.6 to 22.6 m (8-1/2 in. to 8-7/8 in.) from inside of hook to inside of hook. 4. Install both mower dek belt shields. 5. Install mower dek shield. 6. Adjust mower dek to desired utting height. Cheking for Bent Mower Blades CAUTION: Avoid injury! Mower blades are sharp. Always wear gloves when handling mower blades or working near blades. Replae blades if defetive. Never straighten or weld them. 1. Park mahine safely. (See Parking Safely in the SAFETY setion.) 2. Raise mower to highest position to aess blades. Servie Mower - 27

30 SERVICE MOWER MX20122 Piture Note: Mower dek with side disharge used for illustration. 3. Measure distane (A) between blade tip and flat ground surfae. 4. Rotate blade 180 and measure distane between other blade tip and flat ground surfae. 5. Install new blade if the differene between the two measurements is more than 3 mm (1/8 in.). 6. Repeat for all blades. Cheking and Replaing Mower Blades CAUTION: Avoid injury! Do not work near raised mower dek unless it is safely supported. Mower blades are sharp. Wrap blades or wear gloves when serviing. Before performing any servie funtion, wait for all moving parts to stop turning. Disonnet battery or remove spark plug wire before making repairs. IMPORTANT: Avoid Damage! When replaing mower blades, always use genuine Great Dane Servie Parts. NOTE: Only replae blades. Never straighten or weld them. Cheking Mower Blades 1. Park mahine safely. (See Parking Safely in the Safety Setion). 2. Raise the mower dek to the transport position (also the 12.7 m [5 in.] utting height position). 3. Raise front of mahine with a safe lifting devie. Support with jak stands and/or wooden bloks. 4. Chek mower blades: Mower blades should be sharp and free of any damage. Inspet blades; sharpen/balane or replae as neessary. 1. Remove blade bolt (A), three 1/4 in. washers (B) and blade (C). 2. Install replaement blade: Blade wing must fae toward top of mower dek. Install blade bolt (A), blade (B) and three 1/4 in. washers (C). Tighten blade bolt to 163 N m (120 lb-ft). 3. Lower mahine. 4. Adjust mower dek to a desirable utting height. Sharpening Blades Sharpen blades with grinder, hand file, or eletri blade sharpener. IMPORTANT: Avoid Damage! When installing the blade: Make sure the blade is properly seated on the spindle. Make sure the onave side of the large washer faes towards the blade. CAUTION: Avoid injury! Mower blades are dangerous! Always wear gloves while working on blades. Always wear safety eye protetion when grinding. A Replaing Mower Blades B MIF Servie Mower - 28

31 SERVICE ELECTRICAL Keep original bevel (A) when grinding. Blade should have 0.40 mm (1/64 in.) utting edge (B) or less. Balane blades before installing. Balaning Blades CAUTION: Avoid injury! Mower blades are sharp. Always wear gloves when handling mower blades or working near blades. 1. Clean blade. 2. Put blade on nail in a vise. Turn blade to horizontal position. 3. Chek balane. If blade is not balaned, heavy end of blade will drop. 4. Grind bevel of heavy end. Do not hange blade bevel. Servie Eletrial WARNING: Battery posts, terminals and related aessories ontain lead and lead omponents, hemials known to the State of California to ause aner and reprodutive harm. Wash hands after handling. Servie the Battery Safely Servie Eletrial - 29

32 SERVICE ELECTRICAL CAUTION: Avoid injury! Battery eletrolyte ontains sulfuri aid. It is poisonous and an ause serious burns: Wear eye protetion and gloves. Keep skin proteted. If eletrolyte is swallowed, get medial attention immediately. If eletrolyte is splashed into eyes, flush immediately with water for minutes and get medial attention. If eletrolyte is splashed onto skin, flush immediately with water and get medial attention if neessary. Cheking the Battery (Sealed Batteries) NOTE: Do not attempt to open, add fluid or servie battery. Any attempt to do so will void warranty. Keep battery and terminals lean. Keep battery bolts tight. Keep small vent holes open. Reharge, if neessary, at 6 10 amperes for 1 hour. Removing and Installing Battery Removing: 1. Park mahine safely. (See Parking Safely in the SAFETY setion.) The battery produes a flammable and explosive gas. The battery may explode: Do not smoke near battery. Wear eye protetion and gloves. Do not allow diret metal ontat aross battery posts. Remove negative able first when disonneting. Install negative able last when onneting. IMPORTANT: Avoid Damage! The battery omes fully harged. If the mahine is not used by the servie expiration date indiated on the battery, harge the battery. 4. Loosen nut on front long arriage bolt (E). 5. Remove rear long arriage bolt (F) and nut. 6. Lift and slide battery (G) out from bak of battery tray (H). 7. Inspet isolator pad (I). Replae as needed. Installing: 1. Plae isolator pad (I) in battery tray (H). Ensure that isolator pad is on the bottom and sides of battery tray. 2. Install battery (G) in battery tray (H) with positive terminal in rear. 3. Install rear long arriage bolt (F) and nut. Do not overtighten. 4. Tighten nut on long arriage bolt (E) to seure battery (G) in battery tray (H). Do not overtighten. 5. Apply dieletri grease to terminals to prevent orrosion. 6. Connet the positive (+) battery able (D) and install over (C). 7. Connet negative (-) battery able (B) and install over (A). Cleaning Battery and Terminals 1. Park mahine safely. (See Parking Safely in the SAFETY setion.) 2. Disonnet and remove battery. 3. Wash battery with solution of four tablespoons of baking soda to one gallon of water. Be areful not to get the soda solution into the ells. 4. Rinse the battery with plain water and dry. 5. Clean terminals and battery able ends with wire brush until bright. 6. Apply general purpose grease or silione spray to terminal to prevent orrosion. 7. Install battery. Using Booster Battery CAUTION: Avoid injury! The battery produes a flammable and explosive gas. The battery may explode: Do not smoke or have open flame near battery. Wear eye protetion and gloves. Do not jump start or harge a frozen battery. Warm battery to 16 C (60 F). 2. Slide bak blak over (A) and disonnet negative (-) battery able (B). 3. Slide bak red over (C) and disonnet positive (+) battery able (D). Do not onnet the negative (-) booster able to the negative (-) terminal of the disharged battery. Connet at a good ground loation away from the disharged battery. Servie Eletrial - 30

33 SERVICE MISCELLANEOUS Chek metal lip in fuse window. Disard fuse if lip is broken. Install new 20 Amp fuse in soket. Install soket with fuse in over. Ensure that plasti tab of fuse holder is seurely fastened to fuse soket. A - Booster Battery B - Disabled Vehile Battery 1. Connet positive (+) booster able to booster battery (A) positive (+) post (C). 2. Connet the other end of positive (+) booster able to the disabled vehile battery (B) positive (+) post (D). 3. Connet negative ( ) booster able to booster battery negative ( ) post (E). 4. Connet the other end (F) of negative ( ) booster able to a metal part of the disabled mahine engine blok away from battery. 5. Start the engine of the disabled mahine and run mahine for several minutes. 6. Carefully disonnet the booster ables in the exat reverse order: negative able first and then the positive able. Replaing Fuse The eletri start iruit is proteted by one 20 Amp fuse. 1. Loate eletri start fuse holder under onsole on right side of mahine. IMPORTANT: Avoid Damage! Eletri harge from booster battery an damage mahine omponents. Do not install negative booster able to mahine frame. Install only to the engine blok. Install negative booster able away from moving parts in the engine ompartment, suh as belts and fan blades. IMPORTANT: Avoid Damage! Help prevent mahine iruit damage. Make sure replaement fuse is the orret size. Servie Misellaneous Using Proper Fuel Use regular grade unleaded fuel with an otane rating of 87 otane or higher. Fuel blends ontaining up to 10% ethanol or up to 15% MTBE reformulated fuel are aeptable. Do not use fuel or additives ontaining methanol as engine damage an our. Always use fresh, lean fuel that is purhased in a quantity that an be used within approximately 30 days, or add fuel stabilizer. Fuel is blended to give best seasonal performane. To avoid engine performane problems suh as hard starting or vapor lok, use in-season fuel. Use fuel during warm weather that was purhased during that season, and use fuel during old weather that was purhased during that season. Fuel an beome stale in mahines with engines that are used seasonally or infrequently during a season. Stale fuel an produe varnish and plug arburetor omponents whih an affet engine performane. Keep fuel storage ontainer tightly overed and in a ool area out of diret sunlight. Fuel an break down and degrade if not sealed properly or exposed to sun and heat. Condensation may ollet in the fuel tank beause of a variety of operating or environmental onditions and, over time, may affet your mahine s operation. Fill fuel tank at the end of daily use and store fuel in plasti ontainers to redue ondensation. For best year-round performane and fuel-handling, add stabilizer to fuel immediately after fuel purhase. Suh pratie helps prevent engine performane problems and allows fuel storage in the mahine all year without draining. Filling Fuel Tank CAUTION: Avoid injury! Fuel vapors are explosive and flammable: Shut engine off before filling fuel tank. Do not smoke while handling fuel. Keep fuel away from flames or sparks. Fill fuel tank outdoors or in well ventilated area. Clean up spilled fuel immediately. Use lean approved non-metal ontainer to prevent stati eletri disharge. Use lean approved plasti funnel without sreen or filter to prevent stati eletri disharge. Open fuse holder (A) and remove soket with fuse. Servie Misellaneous - 31

34 SERVICE MISCELLANEOUS Important: Avoid damage! Dirt and water in fuel an ause engine damage: Clean dirt and debris from the fuel tank opening. Use lean, fresh, stabilized fuel. Fill the fuel tank at the end of eah day s operation to keep ondensation out of the fuel tank. Use a non-metalli funnel with a plasti mesh strainer when filling the fuel tank or ontainer. Fill fuel tank at the end of eah day s operation to prevent ondensation and freezing during old weather. 1. Park mahine safely. (See Parking Safely in the SAFETY setion.) 2. Allow engine to ool. 3. Remove any trash from area around fuel tank ap. 4. Remove fuel tank ap slowly to allow any pressure built up in tank to esape. 5. Fill fuel tank only to bottom of filler nek. 6. Install fuel tank ap. Installing: 1. Install wheel with valve stem (C) faing out. 2. Install and tighten wheel nuts alternately until reommended torque value is reahed. Tighten nuts to 102 N m (75 lb-ft). 3. Lower mahine. Removing and Installing Front Caster Wheels Removing: 1. Park mahine safely. (Refer to Parking Safely in the SAFETY setion.) 2. Lift front of mahine with a safe lifting devie. Removing and Installing Rear Drive Wheels Removing: 1. Park mahine safely. (Refer to Parking Safely in the SAFETY setion.) 3. Remove nut (A) and wheel ap srew (B). 4. Remove wheel and spaers from yoke assembly (C). Installing: 1. Install replaement wheel and original spaers. 2. Install wheel ap srew (B) and nut (A). 3. Tighten nut until wheel develops slight rolling resistane. 4. Lower mahine. Tightening Rear Drive Wheel Hardware 1. Tighten rear wheel nuts to 102 N m (75 lb-ft). 2. Lift mahine with a safe lifting devie entered under tire support frame (A) on the side where tire is being removed. 2. Tighten wheel nuts in numbered sequene shown for safe wheel installation. Tighten alternately until reommended torque value is reahed. 3. Remove wheel nuts (B). 4. Remove wheel. Servie Misellaneous - 32

35 SERVICE MISCELLANEOUS Cheking Tire Pressure CAUTION: Avoid injury! Explosive separation of tire and rim parts is possible when they are servied inorretly: Do not attempt to mount a tire without the proper equipment and experiene to perform the job. Do not inflate the tires above the reommended pressure. 1. Chek tires for damage. 2. Chek tire pressure with an aurate gauge. 3. Add air, if neessary: Tire Size Front: 13 x 5-6 Rear: 20 x 10-8 Rear: 20 x5.3c Do not weld or heat a wheel and tire assembly. Heat an ause an inrease in air pressure resulting in an explosion. Welding an struturally weaken or deform the wheel. Do not stand in front or over the tire assembly when inflating. Use a lip-on huk and extension hose long enough to allow you to stand to one side. Pressure kpa (16 20 psi) kpa (10 14 psi) kpa (10 14 psi) Serviing Caster Wheel Roller Bearings 1. Park mahine safely. (See Parking Safely in the SAFETY setion.) 2. Raise and seurely support front of mahine. 3. Remove loknut (A), ap srew (B), two seal spaers (C) and wheel assembly (D). NOTE: Bearing raes (G) are pressed in plae and will be damaged when removed. Do not remove bearing raes (G) unless they need to be replaed with new. 4. Remove seals (E), bearings (F) and if needed, bearing raes (G) from wheel. 5. Clean and inspet bearings (F) and raes (G). Replae as needed. 6. Repak bearings with lean grease. 7. Install bearings (F) and raes (G) (if removed), and new seals (E). 8. Install wheel assembly (D), two seal spaers (C), ap srew (B) and loknut (A). 9. Use a grease gun to fill hub until grease just appears at one of the seals (E). 10. Lower mahine. Cleaning and Repairing Plasti Surfaes Your authorized dealer has the professional materials needed to properly remove surfae srathes from any plasti surfaes, do not attempt to paint over marks or srathes in plasti parts. IMPORTANT: Avoid Damage! Improper are of mahine plasti surfaes an damage that surfae: Do not wipe plasti surfaes when they are dry. Dry wiping will result in minor surfae srathes. Use a soft, lean loth (bath towel, diaper, automotive mitt). Do not use abrasive materials, suh as polishing ompounds, on plasti surfaes. Do not spray inset repellent near mahine. 1. Wash surfae with lean water and a mild liquid automotive washing soap. Servie Misellaneous - 33

36 TROUBLESHOOTING 2. Dry thoroughly to avoid water spots. Cleaning and Repairing Metal Surfaes Cleaning: Follow automotive praties to are for your vehile painted metal surfaes. Use a high-quality automotive wax regularly to maintain the fatory look of your vehile s painted surfaes. Repairing Minor Srathes (surfae srath): 1. Clean area to be repaired thoroughly. IMPORTANT: Avoid damage! Do not use rubbing ompound on painted surfaes. 2. Use automotive polishing ompound to remove surfae srathes. 3. Apply wax to entire surfae. Repairing Deep Srathes (bare metal or primer showing): 1. Clean area to be repaired with rubbing alohol or mineral spirits. 2. Use paint stik with fatory-mathed olors available from your authorized dealer to fill srathes. Follow diretions inluded on paint stik for use and for drying. 3. Smooth out surfae using an automotive polishing ompound. Do not use power buffer. 4. Apply wax to surfae. Troubleshooting Using Troubleshooting Chart If you are experiening a problem that is not listed in this hart, see your authorized dealer for servie. When you have heked all the possible auses listed and you are still experiening the problem, see your authorized dealer. Engine If Poor Engine Performane Chek Fuel: Dirt in fuel system or fuel is old. Replae fuel with fresh stabilized fuel. Obtain fuel from another supplier before suspeting mahine problems. Suppliers blend fuels differently and hanging suppliers will generally solve any performane problems. Fuel blended with alohol or ether may ontribute to performane problems by ausing gum and varnish deposits, espeially if fuel is stored for several weeks or more. Obtain fresh fuel. If Engine Will Not Start Or Is Hard To Start Engine Will Not Slow Idle Engine Runs Rough or Stalls Engine Knoks Engine Overheats Chek Park brake lever not in the proper position. Chek that motion ontrol levers are in neutral and neutral swithes are orretly adjusted. PTO engaged. Stale or improper fuel/fuel level. Plugged fuel filter. Plugged air intake filter. Spark plug wires loose or disonneted. Spark plugs not gapped orretly. Blown fuse. Eletrial problem dead battery. Choke adjusted inorretly. See your authorized dealer. Carburetion problems. See your authorized dealer. Bent or kinked throttle able. Bent governor ontrol. Inorret governor idle ontrol. Plugged fuel filter. Plugged air intake system. Fuel ap vent dirty. Stale or improper fuel/fuel level. Spark plugs not gapped orretly. Replae spark plugs. Choke adjusted inorretly. See your authorized dealer. Engine oil level low. Redue load. (Slower ground speed.) Fuel is bad. Fill tank with fresh fuel, orret otane. Idle speed too slow. Clean ooling fins. Low oil level. Do not operate at slow idle. Operate at fast idle. Cooling air intake sreen is dirty. Plugged arburetor air intake filter. Plugged air intake filter. Operating at too fast ground speed for onditions. Troubleshooting - 34

37 TROUBLESHOOTING If Chek If Chek Engine Laks Power Redue load. Plugged air intake system. Plugged fuel filter. Improper type of fuel. Drain tank and fill with orret fuel. Clean ooling fins to help prevent overheating. Replae spark plugs. Starter Turns Slowly Mahine Loose or orroded battery onnetions. Low battery power-harge battery. Engine oil visosity too heavy. Hydrauli pump linkage out of adjustment-pumps engaged. Engine Uses Too Muh Oil Find and orret oil leaks. If Chek Inorret engine oil. Exessive Mahine Vibration Engine speed too slow. Plugged oil filter. Plugged air intake filter. Worn engine omponents. Dek drive belt not tensioned orretly. Mower blades not balaned. Engine Bakfires Through Muffler High Fuel Consumption Other Symptoms Throttle lever should be at low idle for thirty seonds before turning off mahine. Improper type of fuel. Plugged air intake system. Operating at too fast ground speed for onditions. Improper valve learane. See your authorized dealer. Restrited air intake system. See engine manufaturer s owner s manual provided with your mahine for additional information. Mahine Will Not Move With Engine Running Mahine Creeps With Engine Running and Motion Control Levers in a Neutral Position Park brake loked. Transmission oil level low. Transmission oil old allow engine to warm up. Pump drive belt slipping or broken. Pump drive belt spring broken. Pump free-wheel valves open. Transmission problems. See your authorized dealer. Needs motion ontrol linkage adjustment. Needs? Adjustment. Eletrial System Park Brake If Starter Will Not Work Battery Will Not Charge Chek Blown fuse. Park brake swith is faulty. Loose or orroded battery onnetions. Neutral swithes faulty or not adjusted properly. See your authorized dealer. Key swith or starter faulty. See your authorized dealer. PTO engaged. Motion ontrol levers and park brake lever not in proper position. Loose or orroded onnetions. If Park Brake Not Working Corretly Steering If Steering Not Working Chek Park brake out of adjustment adjust linkage. Chek Pump free-wheel valves partially open. Improper tire inflation. Hydrostati transmission oil level low. Tration drive loose or broken. Hydrauli pump or wheel motor faulty. Blown fuse or fusible link. See your authorized dealer. PTO Swith Does Not Work Blown fuse. PTO swith faulty. Troubleshooting - 35

38 Mower Dek If Chek STORAGE Storage Storing Safety Disharge Chute Plugged Mower Dek Vibrates Mower Blades Do Not Engage Mower Mows Unevenly Grass is wet-mow grass only when dry. Raise utting height. Mow with engine at full fast throttle. Ground speed too fast for onditions. Corret installation of dek drive belt. Run engine at fast throttle. Loose hardware. Chek/replae dek drive belt. Blade bolts are loose. Blades are bent or worn. Sharpen and balane blades. Remove belt shields and lean debris from sheaves. Chek sheaves for proper alignment or damage. See authorized dealer. Dek drive belt slipping or broken. Dek belt tension spring not installed or broken. PTO swith faulty. Fuse blown. Loose eletrial onnetions. PTO luth faulty. Mower dek not properly leveled. Ground speed too fast for onditions. Run engine at fast throttle. Redue ground speed when making turns. Sharpen or replae blades. Change mowing pattern. Chek air pressure in all tration unit tires. Anti-salp rollers not adjusted orretly. Preparing Mahine for Storage 1. Repair any worn or damaged parts. Replae parts if neessary. Tighten loose hardware. 2. Repair srathed or hipped metal surfaes to prevent rust. 3. Remove grass and debris from mahine. 4. Clean under the dek and remove grass and debris from inside hute and bagger. 5. Wash the mahine and apply wax to metal and plasti surfaes. 6. Run mahine for five minutes to dry belts and pulleys. 7. Apply light oat of engine oil to pivot and wear points to prevent rust. 8. Lubriate grease points and hek tire pressure. Preparing Fuel and Engine For Storage Fuel: If you have been using Stabilized Fuel, add stabilized fuel to tank until the tank is full. NOTE: Filling the fuel tank redues the amount of air in the fuel tank and helps redue deterioration of fuel. If you are not using Stabilized Fuel: 1. Park mahine safely in a well-ventilated area. (See Parking Safely in the SAFETY setion.) NOTE: Try to antiipate the last time the mahine will be used for the season so very little fuel is left in the fuel tank. 2. Turn on engine and allow to run until it runs out of fuel. 3. For mahines equipped with key swith, turn key to off position. CAUTION: Avoid injury! Fuel vapors are explosive and flammable. Engine exhaust fumes ontain arbon monoxide and an ause serious illness or death: Run the engine only long enough to move the mahine to or from storage. Do not store vehile with fuel in the tank inside a building where fumes may reah an open flame or spark. Allow the engine to ool before storing the mahine in any enlosure. IMPORTANT: Avoid Damage! Stale fuel an produe varnish and plug arburetor or injetor omponents and affet engine performane. Add fuel onditioner or stabilizer to fresh fuel before filling tank. 4. Mix fresh fuel and fuel stabilizer in separate ontainer. Follow stabilizer instrutions for mixing. 5. Fill fuel tank with stabilized fuel. 6. Run engine for a few minutes to allow fuel mixture to irulate through arburetor on gas engine or fuel injetors on diesel engine. Engine: Engine storage proedure should be used when vehile is not to be used for longer than 60 days. Storage - 36

39 ASSEMBLY 1. Change engine oil and filter while engine is warm. 2. Servie air filter if neessary. 3. Clean debris from engine air intake sreen. 4. On gas engines: Remove spark plugs. Put 30 ml (1 oz) of lean engine oil in ylinders. Install spark plugs, but do not onnet spark plug wires. Crank the engine five or six times to allow oil to be distributed. 5. Clean the engine and engine ompartment. 6. Remove battery. 7. Clean the battery and battery posts. Chek the eletrolyte level, if your battery is not maintenane free. 8. Close fuel shut-off valve, if your mahine is equipped. 9. Store the battery in a ool, dry plae where it will not freeze. NOTE: The stored battery should be reharged every 90 days. 10. Charge the battery. IMPORTANT: Avoid Damage! Prolonged exposure to sunlight ould damage the hood surfae. Store mahine inside or use a over if stored outside. 11. Store the vehile in a dry, proteted plae. If vehile is stored outside, put a waterproof over over it. Removing Mahine From Storage 1. Chek tire pressure. 2. Chek engine oil level. 3. Chek battery eletrolyte level, if your battery is not maintenane free. Charge battery if neessary. 4. Install battery. 5. On gas engines: Chek spark plug gap. Install and tighten plugs to speified torque. 6. Lubriate all grease points. 7. Open fuel shut-off valve, if your mahine is equipped. 8. Run the engine 5 minutes without the mower or any attahments running to allow oil to be distributed throughout engine. 9. Be sure all shields and guards or defletors are in plae. Assembly Chek Hydrauli Oil Level 1. Clean area around dipstik ap (A). 2. Remove dipstik ap (A). Wipe dipstik lean. NOTE: Do not tighten dipstik ap when heking oil level. 3. Insert dipstik in filler nek (B). Do not tighten ap. 4. Remove dipstik. Chek oil level on dipstik. Oil level should be between the ADD and FULL marks on dipstik. If oil is level is below ADD mark, fill to proper level. If oil level is above FULL mark, drain to proper level. 5. Insert dipstik. Tighten ap. Chek Engine Oil Level 1. Lift thigh pad. 2. Clean area around dipstik ap (A). 3. Remove dipstik ap (A) from tube. Wipe dipstik lean. NOTE: Do not tighten dipstik ap when heking oil level. 4. Insert dipstik in tube. Do not tighten ap. 5. Remove dipstik. Chek oil level on dipstik. Oil level should be between the ADD and FULL marks. If oil is level is below ADD mark, fill to proper level. If oil level is above the FULL mark, drain to proper level. 6. Insert dipstik. Tighten ap. Assembly - 37

40 SPECIFICATIONS Connet Battery Starter Solenoid Shift CAUTION: Avoid injury! Prevent Battery Explosions: Keep sparks, lighted mathes, and open flame away from the top of battery. Battery gas an explode. Never hek battery harge by plaing a metal objet aross the posts. Use a volt-meter or hydrometer. Do not harge a frozen battery; it may explode. Warm battery to 16 degrees C (60 degrees F). Fuel System Fuel Type Gasoline, Regular Unleaded Fuel Tank Loation On Right Side of Operator Fuel Capaity L (6.0 gal) Steering and Brakes Steering Dual Control Levers Steering Hydrauli Park Brake Tire Contat Tires Rear (Model 647) x 8-8 (with 48 in. dek) Front x 5-6 Rear (Models 657, 667) x 10-8 (with 54 in. and 60 in. dek) Inflation Rear (Maximum) kpa (10 14 psi) Inflation Front (Maximum) kpa (16 20 psi) Battery Voltage volt CCA amp Reserve Capaity minutes BCI Group Size U1L 1. Connet positive (red) able to battery positive (+) terminal. Install red terminal over (A). 2. Connet negative (blak) able to battery negative (-) terminal. Install blak terminal over (B). Chek Mower Dek Level The mower dek is assembled and adjusted at the fatory. After mahine is ompletely assembled, hek the mower front-to-rear and side-to-side dek level. Chek Mahine Safety Systems Perform safety system hek to make sure the eletroni safety interlok iruit is funtioning properly. Speifiations Engine Note: See engine manufaturer s owner s manual provided with your mahine for engine speifiations. Drivetrain Type Dual Hydrostati Pumps Hydro-Gear BDP-10A Wheel Motors Hydro-Gear HGD Number of Speeds Infinitely Variable Eletrial System Charging System Amp Ignition Flywheel Capaities Fuel Tank L (6 gal) Hydrauli Oil (With Filter) L (3.3 qt) Engine Oil (With Filter) L (2.0 qt) Travel Speeds at Full Engine RPM Forward km/h (0 9.2 mph) Reverse km/h (0 4 mph) Dimensions Wheel Base m (52 in.) Overall Height m (45 in.) Overall Length (Model 647) m (65.5 in.) Overall Length (Model 657 and Model 667) m (68.5 in.) Overall Width (48 inh dek with hute up) m (53.5 in.) Overall Width (48 inh dek with hute down) m (62 in.) Overall Width (54 inh dek with hute up) m (57.5 in.) Overall Width (54 inh dek with hute down) m (68 in.) Overall Width (60 inh dek with hute up) m (63.5 in.) Overall Width (60 inh dek with hute down) m (74 in.) Reommended Lubriants Engine Oil See Appliable Engine Manual Hydrauli Oil W-50 or 15W-50 All Syntheti Oil Grease: (This may hange for high-speed appliations suh as utting units) All-Purpose Grease with an NLGI Grade No. 2 Rating (Speifiations and design subjet to hange without notie.) Speifiations - 38

41 GETTING QUALITY SERVICE Getting Quality Servie Servie Literature If you would like to order a opy of the Parts Catalog or Operator Manual for this mahine, ontat your Great Dane Dealer. Parts atalogs and operator manuals are also available online at GreatDaneMowers.om. Parts We reommend Great Dane quality parts available at your Great Dane dealer. Part numbers may hange, use part numbers listed below when you order. If a number hanges, your dealer will have the latest number. When you order parts, your Great Dane dealer needs your mahine serial number and engine serial number. These are the numbers that you reorded in the Produt Identifiation setion of this manual. Great Dane Quality Continues with Quality Servie Great Dane provides a proess to handle your questions or problems, should they arise, to ensure that produt quality ontinues with your authorized Great Dane dealer s parts and servie support. Follow the steps below to get answers to any questions you may have about your produt. Refer to your attahment and mahine operator manuals. Contat your authorized Great Dane dealer with unanswered questions. Part Numbers Item Mower Blades: 48-Inh Dek 54-Inh Dek 60-Inh Dek Hydrauli Oil Filter Battery Fuse - 20 amp Belts: Hydrauli Drive Belt 48-Inh Mower Dek Belt 54-Inh Mower Dek Belt 60-Inh Mower Dek Belt Part Number GDU10230 GDU10231 GDU10232 GDU10137 TY M7120 GDU10025 TCU18847 TCU18848 TCU18849 (Part numbers are subjet to hange without notie. Part Numbers may be different outside the U.S.A.) Getting Quality Servie - 39

42 SERVICE MISCELLANEOUS Servie Misellaneous Wiring Shematis Servie Misellaneous - 40

43 SERVICE MISCELLANEOUS Servie Misellaneous Kawasaki Wiring Shematis Servie Misellaneous - 41

44 SERVICE MISCELLANEOUS Servie Misellaneous Hydrauli Shematis Left Hydrostati Pump Assembly Pump Blok Charge Pump System Charge Chek Shok Valve (Reverse) Manual Bypass Left Wheel Motor Cooling Orifie System Charge Chek Shok Valve (Forward) Charge Relief Valve Right Hydrostati Pump Assembly Right Wheel Motor Inlet Filter Hydrauli Reservoir Servie Misellaneous - 42

45 SERVICE MISCELLANEOUS Servie Misellaneous - 43

46 MAIN FRAME, TRACTION DECK, CONSOLE AND OPC PLATFORM Main Frame, Tration Dek, Console and OPC Platform - 44

47 MAIN FRAME, TRACTION DECK, CONSOLE AND OPC PLATFORM Ref. No. Part No. Desription Qty. Remarks 1 TCA14936 Frame - 1 W/ 48"-52" Dek TCA14946 Frame - 1 W/ 61" Dek 2 D15356 Fender, Left 1 D15355 Fender, Right Weight M7270 Cap Srew 6 M8 x 1.25 x M7803 Cap Srew 6 M8 x 1.25 x M7396 Nut 12 M8 x JD7842 Lubriation Fitting Dek Shield Assembly 1 48" and 52" dek TCA15350 Dek Shield Assembly 1 61" dek 9 M Knob M7299 Nut 6 M12 x TCA14912 Control Console 1 12 TCA14919 Side Braket, Left 1 13 TCA14918 Side Braket, Right 1 14 TCA15348 Handle Mount 1 15 D15368 Plate, Thigh Pad 1 16 TCA15060 Pad, Thigh 1 17 TCA15371 Shield 1 18 D15305 Plate 1 19 TCA14856 Engine/Tration Dek M7191 Carriage Bolt 6 M10 x 1.5 x M7400 Flange Nut, Loking 6 M10 x H1948 Cap Srew 4 1/4" x 3/4" 23 12H302 Lok Washer 4 1/4" 24 19M7784 Cap Srew, Flange Head 6 M10 x 1.5 x M7785 Cap Srew 4 M10 x 1.5 x M7400 Flange Nut, Loking 4 M10 x M7784 Cap Srew, Flange Head 4 M10 x 1.5 x T34037 Cap Srew 4 3/8"-16 x 3/4" 29 19M7784 Cap Srew, Flange Head 2 M10 x 1.5 x M7400 Flange Nut, Loking 2 M10 x M7784 Cap Srew, Flange Head 6 M10 x 1.5 x M Plug 1 Optional light swith hole Main Frame, Tration Dek, Console and OPC Platform - 45

48 DRIVE CONTROLS AND LINKAGE Drive Controls and Linkage - 46

49 DRIVE CONTROLS AND LINKAGE Ref. No. Part No. Desription Qty. Remarks 1 D18069 Speed Limiter Steering Controller, RH Steering Controller, LH 1 3 D13029 Control Rod M7303 Flange Nut 2 M6 x J16913 Spring Pin 2 6 D13028 Swivel 2 7 D38157 Rod End 2 8 D18093 Grip M7547 Cap Srew, Reverse Stop 2 M6 x 1.0 x M7400 Flange Lok Nut 3 M10 x D13308 Base, Speed Control Lok 1 12 D13309 Handle H60 Spring Pin 1 5/32 x 1 14 TCA15195 Shaft, Pivot M7862 Cap Srew 1 M6 x 1.0 x M7397 Lok Nut 1 M6 x M7785 Cap Srew 3 M10 x 1.5 x Swith, Neutral H1905 Cap Srew 2 5/16-18 x Bushing H650 Jam Nut 2 5/ M7372 Cap Srew 2 M5 x 0.8 x M7360 Nut 2 M5 x D14081 Lok Nut 2 5/ * TCU19201 Arm, Control RTN 2 26* TCU19202 Arm, Return 2 27* TCU18929 Arm, RH Inner RTN 2 TCU18931 Arm, LH Inner RTN 2 28* TCU18932 Arm, LH Outer RTN 2 TCU18930 Arm, RH Outer RTN 2 29* TCU19203 Spaer 2 30* TCU19204 Spring 2 31* TCU19209 Srew 2 5/16 x 1 path lok 32* TCU19205 Washer 4 33* TCU19206 Washer, Nylon 4 34* TCU19207 Lok Nut 2 5/ * TCU19208 Spaer H1305 Washer x.812 x.065 Flat * Inluded with new Hydrostati Pump. NOTES Drive Controls and Linkage - 47

50 PARK BRAKE MX Park Brake - 48

51 PARK BRAKE Ref. No. Part No. Desription Qty. Remarks 1 D18038 Swith M7373 Cap Srew 2 M5 x 0.8 x M7360 Nut 2 M5 x K40003 Lok Nut 1 3/8"-16" 5 19H1801 Cap Srew 1 3/8"-16 x 2" 6 TCU12713 Spaer 1 7 GDU10037 Bushing 1 8 AM Swivel 1 9 TCU20956 Rod 1 10 D12352 Lever H846 Nut 2 3/8" 12 J16931 Spring Pin H268 Roll Pin 1 14 TCA15174 Arm 1 15 TCA15070 Shaft H1413 Bushing " x 1.375" x 0.048" 17 D18079 Grip H1341 Washer 1 17/32" x 15/16" x 0.060" 19 19M3804 Cap Srew 1 M10 x 1.5 x M7518 Flange Lok Nut 1 M10 x H1305 Washer 1 22 M94087 Spaer Plate 3 23 TCU20955 Turn Bukle 1 NOTES Park Brake - 49

52 HYDROSTATIC PUMP DRIVE AND PTO Hydrostati Pump Drive and PTO - 50

53 HYDROSTATIC PUMP DRIVE AND PTO Ref. No. Part No. Desription Qty. Remarks 1 GDU10025 V-Belt 1 2 TCA15316 Pulley, RH Pump 2 Set srews inluded 3 D28091 Pulley, Engine Drive 1 4 GDA10017 PTO Cluth 1 All Units Exept KAI 5 GDA10006 Braket 1 All Units Exept KAI 6 D18314 Idler 1 7 GDA10004 Idler Post 1 8 D18403 Bushing 2 9 GDA10005 Idler Arm 1 10 D18071 Spring, Idler 1 11 D14213 Cap Srew 2 12 E63526 Flange Nut 1 M10 x Ring H3031 Cap Srew 1 3/8" x 2-1/2" 15 14M7400 Lok Nut 3 M10 x M7191 Carriage Bolt 1 M10 x 1.5 x D24022 Cap Srew, PTO Cluth 1 7/16" x 2.5" Kohler D14252 Cap Srew, PTO Cluth 1 7/16" x 3" Kawasaki 18 D14208 Washer, Split Lok H907 Set Srew 4 20 D14160 Washer 2 21 D18067 Key, Speial 2 M5 x M7810 Cap Srew, Spring Anhor 1 M10 x 1.5 x H1305 Washer M7191 Carriage Bolt 2 M10 x 1.5 x JD7842 Grease Fitting 1 26 K40003 Lok Nut 2 27 D44003 Washer 1 28 D18145 Key, Speial 1 29 D18056 Spaer, PTO Cluth PTO Cluth Cluth Dog Plate Bolt, Hex 2 7/16"-14 x Bolt, Hex 2 5/16"-18 x Loknut 2 5/16"-18 NOTES Hydrostati Pump Drive and PTO - 51

54 HYDROSTATIC COMPONENTS MX20223 Hydrostati Components - 52

55 HYDROSTATIC COMPONENTS Ref. No. Part No. Desription Qty. Remarks 1 TCA15122 Cap 1 2 TCA15373 Hydrauli Reservoir 1 Inludes deals 3 D18379 Hose Clamp 12 4 TCA15078 Wheel Motor 2 5 D14196 Elbow Fitting, Pump End 4 Inludes O-ring 6 TCA14966 Pump, LH 1 Inludes items on page 5 7 TCA14965 Pump, RH 1 Inludes items on page M7518 Nut 4 M10 x M7192 Carriage Bolt, Pump Mounting 4 M10 x 1.5 x GDA10137 Oil Filter 1 11 GDA10066 Elbow Fitting Elbow Fitting M7517 Lok Nut, Reservoir Mounting 2 M10 x M7784 Cap Srew, Reservoir Mounting 2 M10 x 1.5 x M86863 Tee Fitting 2 16 D24028 Fitting 4 17 D18394 Hose, High Pressure 4 18 TY22552 Hose, Return AR 25 ft bulk (ut to length) 19 GDA10065 Adapter 1 20 R26375 O-Ring 8 Inluded with fitting Fitting, Upper 2 Inludes O-ring Straight Adapter, Lower 2 Inludes O-ring Fitting, Lower 2 24 D18206 Key Hub M7158 Washer H237 Cotter Pin 2 28 TCU19166 Castle Nut 2 M78480 Tie Straps AR Not shown 29 D14280 Bolt 8 3/8-16 x 1 NOTES Hydrostati Components - 53

56 HYDRAULIC SCHEMATIC A B C D E F I H G J B C D E K G I H MX20151 L M A - Left Hydrostati Pump Assembly B- Pump Blok C- Charge Pump D - System Charge Chek Shok Valve (Reverse) E - Manual Bypass F - Left Wheel Motor G - Cooling Orifie H - System Charge Chek Shok Valve (Forward) I - Charge Relief Valve J - Right Hydrostati Pump Assembly K - Right Wheel Motor L - Inlet Filter M - Hydrauli Reservoir Hydrauli Shemati - 54

57 PLATFORM COMPONENTS Ref. No. Part No. Desription Qty. Remarks 1 D18038 Park Brake Swith 1 2 D38128 Com. Spring 1.22x.162x Platform Weldment Platform Plate Platform Tab LH Plate Miner GBR-6 Bumper Platform Wedge Platform Tab Plate OPC Anhor Spring Washer OPC Cover Bolt 4 1/4-20 x.750 Hex Gr Carriage Bolt 2 5/16-18 x Bolt 2 3/8-16 x 1.00 Hex Gr Bolt 1 3/8-16 x 3.25 Hex Gr Nut 1 3/8-16 Hex Gr Washer 2 3/8 Reg. Flat Carriage Bolt 6 3/8-16 x Carriage Bolt 2 3/8-16 x 3/ Loknut Nylok Loknut 4 1/4-20 Nylo Loknut 2 5/16-18 Nylo Srew x.625 PAN PHL MAC Loknut 10 3/8-16 Nylo Platform Components - 55

58 FUEL TANK AND LINES MX20229 Fuel Tank and Lines - 56

59 FUEL TANK AND LINES Ref. No. Part No. Desription Qty. Remarks 1 TCA15021 Fuel Tank Cap, Fuel 1 No Lanyard 3 D18144 Grommet 1 4 TCA15048 Fuel Pikup 1 5 M68342 Clamp 5 6 M88753 Hose, Fuel, 1/4 in. SAE 30-R7 AR 10 Ft. Hose 7 14M7400 Nut 4 8 AM Filter M7191 Cap Srew M7865 Cap Srew 6 11 TCU18489 Braket 1 NOTES Fuel Tank and Lines - 57

60 KOHLER ENGINE AND RELATED COMPONENTS KOHLER Engine and Related Components - 58

61 KOHLER ENGINE AND RELATED COMPONENTS Ref. No. Part No. Desription Qty. Remarks 1 D28121 Muffler 1 2 * Gasket 1 3 TCA15389 Oil Drain Hose 1 4 X6PMTX-S Oil Drain Plug M7188 Carriage Bolt, Engine Mounting 1 M8 x 1.25 x M8317 Cap Srew, Engine Mounting 3 M8 x 1.25 x M7396 Flange Lok Nut, Engine Mounting 4 M8 x M7298 Flange Nut, Muffler 4 M8 x D18427 Cable, Choke 1 10 D18359 Cable, Throttle 1 11 D24020 Bolt, Throttle Cable " x 1/2" 12 M63431 Lok Nut, Throttle Cable " 13 14H846 Nut, Choke Cable 1 3/8" 14 12M7032 Washer 1 * NOTE: See authorized KOHLER serviing engine dealer for engines and engine related servie items. Always referene the engine model number when ordering parts. NOTES KOHLER Engine and Related Components - 59

62 KAWASAKI ENGINE AND RELATED COMPONENTS

63 KAWASAKI ENGINE AND RELATED COMPONENTS Ref. No. Part No. Desription Qty. Remarks 1 TCA15321 Muffler Gasket Kit, 2 Inludes Items 2, 8, & 17 3 TCA16240 Oil Drain Fitting 1 4 TCU19288 Shield, Muffler M7188 Carriage Bolt, Engine Mounting 1 M8 x 1.25 x M8317 Cap Srew, Engine Mounting 3 M8 x 1.25 x M7396 Flange Lok Nut, Engine Mounting 4 M8 x M7065 Lok Washer 4 5/16" 9 D18427 Cable, Choke 1 10 TCA15051 Cable, Throttle 1 11 D24020 Bolt, Throttle Cable " x 1/2" 12 M63431 Lok Nut, Throttle Cable " 13 14H846 Nut, Choke Cable 1 3/8" 14 TCU15761 Braket, Muffler Support Rh 1 15 TCU15762 Braket, Muffler Support Lh H303 Washer, Helial Spring Lok M7273 Nut 4 M M7139 Srew, Hex, Iso M8 x 1.25 x M7865 Srew, Hex, Fl 2 M8 x 1.25 x M8040 Srew, Flanged Metri 2 M6 x 60 (HS, Head Marked 10.9) Shield, Heat 1 22 M Spaer M7298 Nut 1 M8 x 1.25 Flange * NOTE: See authorized Kawsaki serviing engine dealer for engines and engine related servie items. Always referene the engine model number when ordering parts. NOTES

64 KOHLER LOGIC SCHEMATIC MX20146 KOHLER Logi Shemati - 62 NOTES

65 Kawasaki Logi Shemati - 63 KAWASAKI LOGIC SCHEMATIC

66 BATTERY, ELECTRICAL HARNESS AND COMPONENTS Battery, Eletrial Harness and Components - 64

67 BATTERY, ELECTRICAL HARNESS AND COMPONENTS Ref. No. Part No. Desription Qty. Remarks 1 TCA15061 Wiring Harness 1 Main Kohler Wiring Harness 1 Main Kawasaki 2 19M7372 Cap Srew 2 M5 x 0.8 x M7360 Nut 2 M5 x AM Relay M7120 Fuse 2 20A 6 24H1283 Washer 1 7 AM Hour Meter 1 8 TCU13098 Clip 1 9 TCA15075 Key Swith 1 10 M Nut 1 11 TCU17401 Ignition Key 1 12 AM Swith, PTO 1 13 M72685 Spaer 1 14 D28159 Isolator Pad 1 Battery Battery Box 1 16 D18318 Cable, Positive Cable, Negative M7396 Flange Nut 2 M8 x M7184 Carriage Bolt 2 M8 x 1.25 x M7184 Carriage Bolt 4 M8 x 1.25 x H Flange Nut 2 5/16" 22 03H1832 Cap Srew 2 5/16" x 6" 23 14M7396 Nut 4 M8 24 N/A Dry Charged Battery Adapter Assy, Kawasaki Solenoid Mounting Plate Start Solenoid Starter Cable 1 12" Fusible Link Capsrew, 1/4 x Loknut, 1/4" Whiz 2 M78480 Tie Strap AR Not shown NOTES Battery, Eletrial Harness and Components - 65

68 CASTER WHEELS AND REAR WHEELS MX20207 Caster Wheels and Rear Wheels - 66

69 CASTER WHEELS AND REAR WHEELS Ref. No. Part No. Desription Qty. Remarks 1 TCU17863 Spaer, Caster Bushing 2 2 E14625 Seal 2 3 D38035 Bearing Assembly, Caster Wheel 4 Cup and one 4 D28051 Bearing Assembly, Caster Yoke 4 Cup and one 5 11M7083 Cotter Pin 2 6 A12188 Castle Nut 2 1"-14 7 M Cap, Bearing 2 8 JD7844 Grease Fitting 2 9 D25004 Yoke 2 10 D33007 Spaer, Caster Wheel 4 11 D28097 Cap Srew 2 3/4"-16 x 8" 12 D24008 Nut 2 3/4" D38009 Caster Wheel and Tire Assembly 2 Inludes items 3 and TCA15086 Caster Arm M7785 Cap Srew 12 M10 x 1.5 x M7518 Nut 12 M10 x D38065 Seal 4 18 TCA15147 Wheel and Tire Assembly, Rear 2 48" dek, 20 x 8-8 tire TCA15148 Wheel and Tire Assembly, Rear 2 52" & 61" dek, 20 x 10-8 tire JD26 Lug Nut, Rear Wheel 8 Not shown NOTES Caster Wheels and Rear Wheels - 67

70 MOWER DECK LIFT LINKAGE MX20232 Mower Dek Lift Linkage - 68

71 MOWER DECK LIFT LINKAGE Ref. No. Part No. Desription Qty. Remarks 1 D18225 Grip 2 2 E63526 Nut 4 M10 Nut 3 GDA10010 Lift Arm, LH Rear 1 GDA10009 Lift Arm, RH Rear 1 4 P46402 Snap Ring H1413 Washer 16 6 R27434 Snap Ring 4 7 N10215 Nut 8 3/8" Chain, Dek Lift M8162 Cap Srew 4 M10 x 1.5 x GDU10048 U-Bolt H1058 Nut 8 3/4" 13 TCU15817 Rod, Dek Lift Swivel 4 15 GDA10008 Lift Arm, LH Front 1 GDA10007 Lift Arm, RH Front 1 16 E63526 Nut 4 M10 x TCA14877 Thrust Arm, LH, 48" Dek 1 TCA14876 Thrust Arm, RH, 48" Dek 1 TCA14879 Thrust Arm, LH, 52" Dek 1 TCA14878 Thrust Arm, RH, 52" Dek 1 TCA14881 Thrust Arm, LH, 61" Dek 1 TCA14880 Thrust Arm, RH, 61" Dek 1 18 M83541 Bushing 4 19 JD8744 Grease Zerk H3280 Bolt 2 3/4-16 x 3 HHCS 21 D24008 Nut 2 3/4-16 PTHN 22 TCA13292 Pivot Pin, Thrust Arm M7185 Bolt 2 1/4-20 x 1 CHCS 24 14M7396 Nut 2 1/ M Pin, Clevis 2 26 TCU15892 Bushing 2 27 H Nut, Push 2 28 M88183 Ring, Loking 2 NOTES Mower Dek Lift Linkage - 69

72 MOWER DECK MX20240 Mower Dek - 70

73 MOWER DECK Ref. No. Part No. Desription Qty. Remarks 1 TCA15385 Mower Dek, 48" S/O 1 TCA15386 Mower Dek, 52" S/O 1 TCA15387 Mower Dek, 61" S/O 1 2 TCU14540 Bushing 2 3 TCU18344 Support Strap 1 4 TCU18847 Belt, Engine-to-Blades, 48" Dek 1 TCU18848 Belt, Engine-to-Blades, 52" Dek 1 TCU18849 Belt, Engine-to-Blades, 61" Dek 1 5 TCU18744 Roller, Anti-Salp 2 48" and 52" dek TCU18744 Roller, Anti-Salp 6 61" dek Belt Cover, LH 1 48" and 52" dek TCU18413 Belt Cover, LH 1 61" dek Belt Cover, RH 1 48" dek TCU18411 Belt Cover, RH 1 52" dek TCU18413 Belt Cover, RH 1 61" dek 8 M Knob, Belt Cover 2 9 GDA10103 Pivot, Anti-Salp Roller H1729 Bolt 2 1/4-20 x 1 CHCS 11 H Nut 2 1/4-20 PTFHN 12 TCA15346 Arm, Idler Engine-to-Blade 1 13 D18032 Pulley, Flat Tension Idler H1658 Bolt 1 3/8-16 x 2-1/4 CHCS 15 24H1305 Washer 1 3/8 SAE 16 K40003 Nut 4 3/8-16 PTHN 17 03H1836 Bolt 1 3/8-16 x 4.00 CHCS 18 AM Disharge Chute 1 48" dek AM Disharge Chute 1 52" and 61" dek 19 M Spring, Torsional Disharge Chute 1 20 H Clip, Retainer H1809 Bolt 1 3/8-16 x 3-3/4 CHCS 22 D23058 J-Hook 1 23 N Spring, Dek Belt Tension H1090 Nut 1 3/8-16 Nylo 25 N10215 Nut 1 3/8-16 PTHN 26 D28050 Pulley, Flat Blade-to-Blade 1 27 TCU18742 Spaer, Blade-to-Blade Pulley H1480 Bolt 1 3/8-16 x 1-1/4 CHCS 29 03H1853 Bolt 4 61" dek only, 1/2 x 4-1/2 x 13 CHCS 30 E62934 Flange Lok Nut 4 61" dek only, 1/ JD7844 Grease Zerk Braket, Chute Support 1 48" Only NOTES Mower Dek - 71

74 MOWER DECK SPINDLES Mower Dek Spindles - 72

75 MOWER DECK SPINDLES Ref. No. Part No. Desription Qty. Remarks Spindle Assembly 1 Inludes items 2, 3, 4, 5, 6, Ball Bearing Housing Spaer x x Shaft, Spindle Bolt 6 3/8-16 x 1.25 Rib Nut, Pulley 3 3/4-16 Flange 8 D18209 Pulley, Cutter Housing, 48" Dek 3 D18084 Pulley, Cutter Housing, 52" Dek 3 D18211 Pulley, Cutter Housing, 61" Dek 3 9 D13024 Spaer, Pulley Bolt, Blade 3 5/8-11 x 2 Grade Nut 18 3/8-16 Std Hex Gr5 12 D18055 Spaer, Blade Bolt 9 13 GDU " Blade, 48" Dek 3 GDU " Blade, 52" Dek 3 GDU " Blade, 61" Dek Zerk, Grease S/O 1 NOTES Mower Dek Spindles - 73

76 LABELS AND DECALS Labels and Deals - 74