Husqvarna BZ 27 User's Manual

Operator´s manual
BZ 27
BZ 34
Please read these instructions carefully and make sure
you understand them before using the machine.
English
OPERATOR’S MANUAL
RIDER
BZ SERIES
Contents
Contents...................................................................1
Introduction .............................................................3
Congratulations....................................................3
General ................................................................3
Driving and Transport on Public Roads ...............3
Towing .................................................................3
Operating .............................................................3
Good Service .......................................................4
Manufacturing Number ........................................4
Symbols and Decals ...............................................5
Safety Instructions..................................................7
General Use.........................................................7
Personal Safety Equipment .................................9
Driving on Slopes...............................................10
Children..............................................................11
Maintenance ......................................................12
Transport............................................................15
Customer responsibilities...................................16
Controls .................................................................17
Control Locations ...............................................17
Gauges ..............................................................18
Throttle Control ..................................................18
Ignition ...............................................................18
Hour Meter .........................................................18
Engaging the Mower Deck.................................19
Parking Brake ....................................................19
Seat Adjustment.................................................19
Motion Control Levers........................................20
Hydraulic Lift Switch...........................................21
Refueling............................................................22
Fuel Shut-Off......................................................22
Fuses .................................................................22
Hydraulic Lift for Mower Deck ............................23
Lifting Lever for the Mower Deck (Manual) ........23
Relays ................................................................24
Tracking .............................................................24
Accessories........................................................24
Operation ...............................................................25
Before Starting ...................................................26
Starting the Engine ............................................26
To start an engine with a weak battery ..............29
Running..............................................................30
Operating on hills ...............................................32
Mowing Tips.......................................................33
Stopping the Engine...........................................34
Moving by Hand .................................................35
Maintenance ......................................................... 36
Maintenance Schedule...................................... 36
Battery............................................................... 38
Checking the Safety System ............................. 39
Checking the Engine's Cooling Air Intake ......... 40
Clutch Service ................................................... 40
Checking and Adjusting the Throttle Cable....... 40
Air filter maintenance ........................................ 41
Replacing the Fuel Filter ................................. 43
Checking Tire Pressures................................... 43
Checking and Filling Coolant ............................ 43
Checking the Parking Brake.............................. 45
Checking the V-belts ......................................... 46
Checking the Blades ......................................... 47
Adjusting the Mower Deck ................................ 49
Checking Hydraulic System .............................. 51
Motion Control Linkage Adjustment .................. 52
Deck Lift Power Unit.......................................... 53
Mule Drive System ............................................ 53
Caster Wheels................................................... 53
Cleaning and Washing ...................................... 54
Hardware........................................................... 54
Lubrication............................................................ 55
Lubrication Schedule......................................... 55
General ............................................................. 55
Lubricating the Cables ...................................... 56
Shaft Bushings and Linkage ............................. 56
Lubricating in Accordance with the Lubrication
Schedule ........................................................... 56
Trouble Shooting Guide ...................................... 62
Storage .................................................................. 65
Winter Storage .................................................. 65
Service .............................................................. 65
Wiring diagram ..................................................... 66
Technical Data ..................................................... 67
Accessories .......................................................... 69
Torque Specifications........................................ 69
Conformity Certificates ....................................... 70
EU declaration of conformity ............................. 70
Service Journal .................................................... 71
Delivery Service ................................................ 71
25-Hour Service ................................................ 73
50-Hour Service ................................................ 74
100-Hour Service .............................................. 75
300-Hour Service .............................................. 76
At Least Once Each Year.................................. 77
English-1
WARNING!
Failure to follow cautious operating practices can result in serious injury to the
operator or other persons. The owner must understand these instructions, and must
allow only trained persons who understand these instructions to operate the mower.
Each person operating the mower must be of sound mind and body and must not be
under the influence of any mind altering substance.
English-2
INTRODUCTION
Introduction
Congratulations
Thank you for purchasing a Husqvarna ride-on mower. This machine is built for the greatest efficiency and
rapid mowing primarily of large areas. Controls in one place and a hydrostatic transmission regulated by
steering controls also contribute to the machine’s performance.
This manual is a valuable document. Following the instructions (use, service, maintenance, etc.) by all who
operate this machine can considerably increase the lifespan of your machine and even increase its resale
value. It is also very important to follow the instructions for the safety of you and others.
If you sell your machine, be sure to give the operator’s manual to the new owner.
The final chapter of this operator’s manual comprises a Service Journal. Ensure that service and repair
work is documented. A well kept service journal reduces service costs for the season-based maintenance
and affects the machine’s resale value. Take the operator’s manual along when the machine is left at the
workshop for service.
General
In this operator’s manual, left and right, backward and forward are used in relation to the machine’s normal
driving direction.
Continuous dedication to improve our products require that specifications and design are subject to change
without notice.
Driving and Transport on Public
Roads
Check applicable road traffic regulations before transporting on public roads. If the machine is transported,
you must always use approved fastening equipment and ensure that the machine is well anchored. DO
NOT operate this machine on public roadways.
Towing
Do not tow this machine, it may cause damage to the drive system.
Do not tow any trailers, etc with this mower. They may jackknife or overturn causing damage to the mower
and possibly serious injury to the operator.
Operating
This machine is constructed only for mowing grass on lawns and other free and even ground without
obstacles such as stones, tree stubs, etc. The machine can also be used for other tasks when equipped
with special accessories provided by the manufacturer, for which the operating instructions are provided in
conjunction with delivery. All other types of use are incorrect. The manufacturer’s directions concerning
operation, maintenance, and repairs must be carefully followed.
Lawnmowers and all power equipment, can be potentially dangerous if used improperly. Safety requires
good judgement, careful use in accordance with these instructions and common sense.
The machine must only be operated, maintained, and repaired by persons that are familiar with the
machine’s special characteristics and who are well versed in the safety instructions. Use only approved
repair parts to maintain this machine.
Accident prevention regulations, other general safety regulations, occupational safety rules, and traffic
regulations must be followed without fail.
Unauthorized modifications to the design of the machine may absolve the manufacturer from liability for any
resulting personal injury or property damage.
English-3
INTRODUCTION
Good Service
Husqvarna’s products are sold all over the world and only in specialized retail stores with complete service.
This ensures that you as a customer receive only the best support and service. Before the product is
delivered, the machine has, for example, been inspected and adjusted by your retailer, see the certificate
in the Service Journal in this operator’s manual.
When you need spare parts or support in service questions, warranty issues, etc., please consult
the following professional:
This Operator’s Manual belongs to the
machine with manufacturing number:
Engine
Transmission
Manufacturing Number
The machine’s manufacturing number can be found on the printed plate affixed to the left in the engine
compartment. Stated on the plate, from the top are:
•
The machine’s type designation (I.D.).
•
The manufacturer's type number (Model).
•
The machine’s serial number (Serial no.)
Please state the type designation and serial number when ordering spare parts.
The engine’s manufacturing number is stated on a barcode decal. This is placed on the left side of the
crankcase, in front of the starter. The plate states:
•
The engine’s serial number (E/NO).
•
The engine’s type designation (Code).
Please state these when ordering spare parts.
The hydraulic pump’s manufacturing number is stated on a barcode decal affixed to the left side of the
pump housing. The plate states:
•
The pump’s type designation.
•
The pump’s serial number.
The hydraulic motor’s manufacturing number is stated on a round metal plate. This is placed on the gable
inside the motor. The plate states:
•
The hydraulic motor’s type designation and design version.
•
The hydraulic motor’s serial number.
English-4
SYMBOLS AND DECALS
Symbols and Decals
These symbols are found on the machine and in the operator’s manual.
Study them carefully so that you know what they mean.
WARNING!
Xxxxxxx xxxx xxxxxxxx xxx x
Xxxxx xxxxxx xx.
xx xxxxxxxx xxxxx xxx xx.
Used in this publication to notify the reader of a risk of personal injury or death, particularly if the reader
should neglect to follow instructions given in the manual.
IMPORTANT INFORMATION
Xxxxxxx xxxx xxxxxxxx xxx xxx
xxxx xxxxxx xx.
Used in this publication to notify the reader of a risk of material damage, particularly if the reader should
neglect to follow instructions given in the manual. Used also when there is a potential for misuse or
misassembly.
Reverse
Warning!
Neutral
Fast
Parking brake
Slow
CE conformity
marking. Only for
European market.
Battery acid is corrosive, explosive,
and flammable.
Choke
Warning! Rotating
blades, keep away from
the discharge deck.
Do not stand here
Fuel
Do not touch rotating
parts.
Noise emissions to the surroundings
in accordance with the European
Union’s directive. The machine’s
emission is stated in the chapter
TECHNICAL DATA and on the decals.
Only machines for European market.
Use protective glasses.
Use protective gloves.
English-5
SYMBOLS AND DECALS
Read
Operator´s
Manual.
Whole body
exposure to
thrown
objects.
English-6
Shut off engine
and remove key
before
performing any
maintenance or
repair work.
Severing of
fingers and
toes.
Keep a safe
distance from
the machine.
Do not open
or remove
safety shields
while engine
is running.
Use on
slopes no
greater
than 10˚.
Careful
backing up,
watch for other
people.
No
passengers.
Careful going
forward, watch
for other people.
SAFETY INSTRUCTIONS
Safety Instructions
These instructions are for your safety. Read them carefully.
WARNING!
This symbol means that important safety instructions need to be emphasized. It
concerns your safety.
IMPORTANT: THIS CUTTING MACHINE IS CAPABLE OF AMPUTATING HANDS AND FEET AND
THROWING OBJECTS. FAILURE TO OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS COULD
RESULT IN SERIOUS INJURY OR DEATH.
General Operation
•
Read, understand, and follow all
instructions on the machine and in the
manual before starting.
•
Do not put hands or feet near rotating
parts or under the machine. Keep clear
of the discharge opening at all times.
•
Only allow responsible adults, who are
familiar with the instructions, to operate
the machine.
•
Clear the area of objects such as rocks,
toys, wire, etc., which could be picked up
and thrown by the blades.
•
Be sure the area is clear of bystanders
before operating. Stop machine if anyone
enters the area.
•
Never carry passengers. The machine is
only intended for use by one person.
•
Do not mow in reverse unless absolutely
necessary. Always look down and behind
before and while backing.
•
Never direct discharged material toward
anyone. Avoid discharging material
against a wall or obstruction. Material
may ricochet back toward the operator.
Stop the blades when crossing gravel
surfaces.
•
Do not operate machine without the
entire grass catcher, discharge guard, or
other safety devices in place and working
•
Slow down before turning.
•
Never leave a running machine
unattended. Always turn off blades, set
parking brake, stop engine, and remove
keys before dismounting.
8011-512
Read the operator’s manual before starting the
machine
8011-513
Clear the area of objects before mowing
8011-520
Never take passengers
English-7
SAFETY INSTRUCTIONS
•
Disengage blades when not mowing.
Shut off engine, wait for all parts to come
to a complete stop, and remove ignition
key before cleaning the machine,
removing the grass catcher, or
unclogging the discharge guard.
•
Operate machine only in daylight or good
artificial light.
•
Do not operate the machine while under
the influence of alcohol or drugs.
•
Watch for traffic when operating near or
crossing roadways.
•
Use extra care when loading or
unloading the machine into a trailer or
truck.
•
Always wear eye protection when
operating machine.
•
Data indicates that operators, age 60
years and above, are involved in a large
percentage of riding mower-related
injuries. These operators should evaluate
their ability to operate the riding mower
safely enough to protect themselves and
others from serious injury.
•
Follow the manufacturer’s
recommendation for wheel weights or
counterweights.
•
Anyone who operates this machine must
first read and understand this Operation
Manual. Local laws may regulate the age
of the user.
•
Keep machine free of grass, leaves or
other debris build-up which can touch hot
exhaust / engine part and burn. Do not
allow the mower deck to plow leaves or
other debris which can cause build-up to
occur. Clean any oil or fuel spillage
before operating or storing the machine.
Allow machine to cool before storage.
•
After striking object or if abnormal
machine vibration is present, disengage
drive to attachments, stop engine,
remove ignition key, and check
immediately. Inspect the machine for
damage and make repairs before
restarting and operating equipment.
•
Keep in mind that the operator or user is
responsible for accidents or hazards
occurring to other people or their
property.
English-8
WARNING!
Engine exhaust and certain
vehicle components contain
or emit chemicals considered
to cause cancer, birth defects,
or other reproductive system
damage. The engine exhaust
contains carbon monoxide,
which is a odorless, colorless,
poisonous gas. Do not use the
machine in enclosed spaces.
SAFETY INSTRUCTIONS
•
All drivers should seek and obtain
professional and practical instruction.
Such instructions should emphasize:
1.
the need for care and concentration
when working with ride-on machine;
2.
control of a ride-on machine sliding on a
slope will not be regained by the
aplication of the brake. The main reasons
for loss of control are:
a.
insufficient wheel grip;
b.
being driven too fast;
c.
inadequate braking;
d.
the type of machine is unsuitable for its
task;
e.
lack of awareness of the effect of ground
conditions, especially slopes;
f.
incorrect hitching and load distribution.
•
Watch out for traffic when crossing or
near roadways.
•
Stop the blades rotating before crossing
surfaces other than grass.
Personal Safety Equipment
WARNING!
When using the machine, approved personal protective equipment (shown in
illustrations) shall be used. Personal protective equipment cannot eliminate
the risk of injury but it will reduce the degree of injury if an accident does
happen. Ask your retailer for help in choosing the right equipment.
•
Make sure that you have first aid equipment
close at hand when using the machine.
•
Never use the machine when barefoot.
Always wear protective shoes or boots,
preferably with steel toecaps.
•
Always wear approved protective glasses
or a full visor when assembling or driving.
•
Always wear gloves when handling the
blades.
•
Never wear loose clothing that can get caught
in moving parts.
•
Use ear protectors to avoid damage to
hearing.
•
While mowing, always wear substantial
footwear and long trousers. Do not
operate the equipment when barefoot or
wearing open sandals.
8011-670
Personal protective equipment
English-9
SAFETY INSTRUCTIONS
Slope Operation
Slopes are a major factor related to loss of
control and tip-over accidents, which can
result in severe injury or death. Operation on
all slopes requires extra caution. If you cannot
back up the slope or if you feel uneasy on it,
do not mow it.
•
Mow up and down slopes (10 degrees
maxium), not across.
•
Watch for holes, ruts, bumps, rocks, or
other hidden objects. Uneven terrain
could overturn the machine. Tall grass
can hide obstacles.
•
Choose a low ground speed so that you
will not have to stop while on the slope.
•
Do not mow on wet grass. Tires may lose
traction.
•
Avoid starting, stopping, or turning on a
slope. If the tires lose traction, disengage
the blades and proceed slowly straight
down the slope.
•
Keep all movement on the slopes slow
and gradual. Do not make sudden
changes in speed or direction, which
could cause the machine to roll over.
•
Use extra care while operating machine
with grass catchers or other
attachments; they can affect the stability
of the machine. Do not use on steep
slopes.
•
Do not try to stabilize the machine by
putting your foot on the ground.
•
Do not mow near drop-offs, ditches, or
embankments. The machine could
suddenly roll over if a wheel is over the
edge or if the edge caves in.
8011-519
Be extra cautious when driving on slopes
WARNING!
Do not drive up or down hills
with slopes greater than 10
degrees. And do not drive
across any slopes.
6003-004
Mow up and down, not side-to-side
English-10
SAFETY INSTRUCTIONS
Children
Tragic accidents can occur if the operator is
not alert to the presence of children. Children
are often attracted to the machine and the
mowing activity. Never assume that children
will remain where you last saw them.
•
Keep children out of the mowing area
and in the watchful care of a responsible
adult other than the operator.
•
Be alert and turn machine off if a child
enters the area.
•
Before and while backing, look behind
and down for small children.
•
Never carry children, even with the
blades shut off. They may fall off and be
seriously injured or interfere with safe
machine operation. Children who have
been given rides in the past may
suddenly appear in the mowing area for
another ride and be run over or backed
over by the machine.
8011-517
Never allow children to operate the machine
•
Never allow children to operate the
machine.
•
Use extra care when approaching blind
corners, shrubs, trees, or other objects
that may block your view of a child.
8011-518
Keep children away from the work area
English-11
SAFETY INSTRUCTIONS
Maintenance
WARNING!
The engine must not be started when the driver’s floor plate or any protective plate
for the mower deck’s drive belt is removed.
Safe Handling of Gasoline
To avoid personal injury or property damage,
use extreme care in handling gasoline.
Gasoline is extremely flammable and the
vapors are explosive.
•
Extinguish all cigarettes, cigars, pipes,
and other sources of ignition.
•
Use only approved gasoline container.
•
Never remove gas cap or add fuel with
the engine running. Allow engine to cool
at least two (2) minutes before refueling.
•
Never fuel the machine indoors.
•
Never store the machine or fuel
container where there is an open flame,
spark, or pilot light such as on a water
heater or other appliances.
•
Before you begin refueling, minimize the
risk of static electricity by touching a
metal surface.
•
Never fill containers inside a vehicle or
on a truck or trailer bed with plastic liner.
Always place containers on the ground
away from your vehicle when filling.
•
Remove gas-powered equipment from
the truck or tailer and refuel it on the
ground. If this is not possible, then refuel
such equipment with a portable
container, rather than from a gasoline
dispenser nozzle.
•
Keep the nozzle in contact with the rim of
the fuel tank or container opening at all
times until fueling is complete. Do not
use a nozzle lock-open device.
•
If fuel is spilled on clothing, change
clothing immediately.
•
Never overfill fuel tank. Replace gas cap
and tighten securely.
•
Do not start the engine near spilled fuel.
•
Never use gasoline as a cleaning agent.
•
If leaks arise in the fuel system, the
engine must not be started until the
problem has been resolved.
English-12
8011-516
Never fill the fuel tank indoors
WARNING!
The engine and the exhaust
system, become very hot during
operation.
Risk for burns if touched.
Allow engine and exhaust
system to cool at least two (2)
minutes before refueling
SAFETY INSTRUCTIONS
•
Check the fuel level before each use and
leave space for the fuel to expand,
because the heat from the engine and
the sun may otherwise cause the fuel to
expand and overflow.
General Maintenance
•
Never operate machine in a closed area.
•
Keep all nuts and bolts tight to be sure
the equipment is in safe working
condition.
•
Never tamper with safety devices. Check
their proper operation regularly.
•
Keep machine free of grass, leaves, or
other debris build-up. Clean oil or fuel
spillage and remove any fuel-soaked
debris. Allow machine to cool before
storing.
•
If you strike a foreign object, stop and
inspect the machine. Repair, if
necessary, before restarting.
•
Never make any adjustments or repairs
with the engine running. Remove ignition
key while making adjustments or repairs.
•
Check grass catcher components and
the discharge guard frequently and
replace with manufacturer’s
recommended parts, when necessary.
•
Mower blades are sharp. Wrap the blade
or wear gloves, and use extra caution
when servicing them.
•
Check brake operation frequently. Adjust
and service as required.
•
Maintain or replace safety and instruction
labels, as necessary.
•
Do not modify safety equipment. Check
regularly to be sure it works properly. The
machine must not be driven with
defective or unmounted protective plates,
protective cowlings, safety switches, or
other protective devices.
•
Do not change the settings of governors
and avoid running the engine with overly
high engine speeds. If you run the
engine too fast, you risk damaging the
machine components.
•
Be very careful when handling battery
acid. Acid on skin can cause serious
corrosive burns. If you spill battery acid
on your skin, rinse immediately with
water.
8011-515
Never drive the machine in an enclosed space
Always use protective glasses
when handling the battery.
WARNING!
The battery contains lead and
lead compounds, chemicals that
are considered to cause cancer,
birth defects, and other
reproductive system damage.
Wash your hands after handling
the battery.
English-13
SAFETY INSTRUCTIONS
•
Acid in the eyes can cause blindness,
contact a doctor immediately.
•
Be careful when servicing the battery.
Explosive gases form in the battery. Never
perform maintenance on the battery when
smoking or near open flames or sparks.
The battery can explode and cause serious
injury/damage.
•
Ensure that nuts and bolts, especially the
fastening bolts for the blade attachments,
are properly tightened, torqued and that
the equipment is in good condition.
•
Do not modify safety equipment. Check
regularly to be sure it works properly. The
machine must not be driven with
defective or unmounted protective plates,
protective cowlings, safety switches, or
other protective devices.
•
Do not change the settings of governors
and avoid running the engine with overly
high engine speeds. If you run the
engine too fast, you risk damaging the
machine components.
•
Sparking can occur when working with
the battery and the heavy cables of the
starter circuit. This can cause battery
explosion, fire or eye injury. Sparking in
this circuit can not occur after the chassis
cable (normally negative, black) is
removed from the battery.
6003-009
Do not smoke when performing maintenance on the
battery. The battery can explode and cause serious
injury/damage
8009-728
WARNING!
Avoid electrical sparking and its
consequences by the following
routines:
•
Use protective goggles.
•
Ensure that the fuel filler cap is mounted
tightly and no flammable substances is
stored in an open vessel.
•
Never work with the starter circuit if there
is spilled fuel.
•
Disconnect the chassis cable from the
battery first and reconnect it last.
•
Do not make a bridge short circuit across
the starter relay to run the starter.
•
Never use the machine indoors or in
spaces lacking proper ventilation. The
exhaust fumes contain carbon monoxide,
an odorless, poisonous, and lethal gas.
English-14
Risk of sparking
SAFETY INSTRUCTIONS
•
Stop and inspect the equipment if you
run over or into anything. If necessary,
make repairs before starting.
•
Never make adjustments with the engine
running.
•
The machine is tested and approved only
with the equipment originally provided or
recommended by the manufacturer. Only
use approved repair parts for the
machine.
•
The blades are sharp and can cause
cuts and gashes. Wrap the blades or use
protective gloves when handling them.
•
Check the parking brake’s functionality
regularly. Adjust and service as
necessary.
•
The mulch blades should only be used in
familiar areas when higher quality
mowing is desired.
•
Reduce the risk of fire by removing
grass, leaves, and other debris that may
have accumulated on the machine. Allow
the machine to cool before putting it in
storage.
•
Regularly clean deck and underside of
deck, avoid spraying engine and
electrical components with water.
•
On multi-bladed machines, take care as
rotating one blade can cause other
blades to rotate.
8011-644
Clean the machine regularly
Transport
•
The machine is heavy and can cause
serious crushing injuries. Be extra
cautious when it is loaded on or
unloaded from a vehicle or trailer.
•
Use an approved trailer to transport the
machine. Activate the parking brake, turn
off the fuel supply, and fasten the
machine with approved fastening
devices, such as bands, chains, or
straps, when transporting.
•
Do not operate this machine on public
roadways.
•
Check and abide by local traffic
regulations before transporting the
machine on any road.
•
Do not tow this machine, it may cause
damage to the drive system.
IMPORTANT INFORMATION
The parking brake is not sufficient to lock
the machine in place during transport.
Ensure that the machine is well fastened
to the transport vehicle. Always reverse
the machine onto the transport vehicle to
avoid tipping it over.
English-15
SAFETY INSTRUCTIONS
•
Do not tow any trailers, etc. with this
mower. They may jackknife or overturn
causing damage to the mower and
possibly serious injury to the operator.
•
When machine is to be parked, stored or
left unattended, lower the cutting means
unless a positive mechanical lock is
used.
Customer responsibilities
•
Read and observe the safety rules.
•
Follow a regular schedule in maintaining,
caring for and using your mower.
•
Follow the instructions under
"Maintenance” and "Storage” sections of
this owner’s manual.
•
This machine has no brain. Use yours!
WARNING!
This mower is equipped with an internal combustion engine and should not be
used on or near any unimproved forest-covered, bush-covered or grass-covered
land unless the engine’s exhaust system is equipped with a spark arrester
meeting applicable local or state laws (if any). If a spark arrester is used, it should
be maintained in effective working order by the operator.
A spark arrester for the muffler is available through your authorized Husqvarna dealer.
English-16
CONTROLS
Controls
This operator’s manual describes the
Husqvarna Zero Turn Rider. The mower is
fitted with a liquid cooled, 3 cylinder Daihatsu
diesel engine (27 HP) or Daihatsu Turbo
diesel engine (34 HP)
Transmission from the engine is made via two
belt-driven hydrostat transaxles, which in turn
drive a hydraulic motor for each drive wheel.
Using the left and right steering controls, the
flow is regulated and thereby the direction
and speed.
BAM-1
Zero Turn Rider
13
14
15 16
18 12
17
4
9
8
2
5
7
1
10 6
11
Locations of the controls
Control Locations
Page
Page
1.
Motion control, levers
20
10.
Seat adjustment lever
19
2.
Hour meter
18
11.
12V DC adapter
3.
Parking brake
19
12.
Throttle
18
4.
Control for mower deck
19
13.
Cutting height adjuster
25
5.
Ignition
18
14.
Manual deck lift
23
6.
Relays
24
15.
Water temperature gauge
18
7.
Glow plug lamp
26
16.
Ammeter gauge
18
8.
Fuel tank caps
22
17.
Oil pressure gauge
18
9.
Fuel shut-off
22
18.
Hydraulic deck lift switch
21
English-17
CONTROLS
Gauges
1
Water temperature gauge- indicates coolant
temperature and warns of overheat situation.
Ammeter - indicates amount of electrical flow
at the battery. Under normal operating
conditions the needle will be slightly on the
plus (+) side of the gauge, showing that
current is being supplied to the battery. At idle
speed, the indicator may be at zero or on the
negative (-) side. A continuous negative
reading at normal operating speed indicates
a malfunction in the charging system that
should be checked immediately.
Oil pressure meter - tells what the pressure is
in the oil system and warns if pressure is too
low for operation.
2
3
Gauges
BAM-2
1. Water temperature
2. Ammeter
3. Oil pressure
Throttle Control
The throttle control regulates the engine
speed.
In order to increase or decrease the engine
speed, the control is moved forward or
backward respectively.
Avoid idling the engine for long periods.
Use full throttle when mowing.
Ignition
The ignition key is placed in the front console
and is used to start the machine.
1
BAM-2
Throttle control
1. Throttle control
IMPORTANT INFORMATION
Wait till the glow plug light goes out before
turning the engine over. To prolong starter
life use short starting cycles, DO NOT
exceed 30 s/min.
2
Hour Meter
The hour meter displays the totoal operating time
and reminds of service intervals.
It will flash CHG OIL (Change Oil) at 50 hour
intervals. The flash duration is one hour before
and one hour after the interval. The CHG OIL icon
will come on and shut off automatically. The hour
meter can not be manually reset.
English-18
3
1
Console
1. Hour meter
2. Glow plug light
3. Ignition
BAM-3
CONTROLS
Engaging the Mower Deck
In order to engage the mower deck, pull the
knob out; the mower deck is disengaged
when the knob is depressed.
Deck should be engaged at mid throttle and
disengaged at idle speed to prolong clutch
life.
BAM-2
Engaging the mower deck
Parking Brake
The parking brake is found on the left of the
machine. Pull the lever back to activate the
brake and push forward to release it.
BAM-4
Parking brake not activated
Seat Adjustment
Located on the left side of the seat is the seat
adjustment lever. Pull outward to slide the
seat either forward or backward.
Suspension resistence (weight) can be
adjusted at the front of the seat.
Backrest tilt and lumbar support can also be
adjusted using dials on the sides of the seat.
Seat Adjustment Lever and suspension adjustment
BAM-5
English-19
CONTROLS
Motion Control Levers
The machine’s speed and direction are
continuously variable using the two motion
control levers. The motion control levers can
be moved forward or backward from a neutral
position. Furthermore, there is a neutral
position, which is locked if the motion control
levers are moved outward into the neutral
slots.
When both controls are in the neutral position
(N), the machine stands still.
The motion control levers on each side of the
mower control the direction of movement. The
left lever controls the flow of oil from the left
hydro pump to the left wheel motor. The right
lever controls the flow of oil from the right
hydro pump to the right wheel motor.
NOTE: To begin motion, the operator must be
in the seat and the parking brake disengaged
before the motion control levers can be
moved from the neutral slots or the engine
will shut down.
1
By moving the levers an equal amount
forward or back the machine will move in a
straight line in that direction.
2
Movement of either lever forward will cause
the right or left wheel to rotate in a forward
direction. To stop movement pull both levers
into the neutral position.
To turn right while moving in a forward
direction pull the right lever back toward the
neutral position, this will slow the rotation of
the right wheel and cause the machine to turn
in that direction.
BAM-6
Motion Control Levers
3
4
8011-791
1
2
3
4
Forward
Neutral
Neutral slot, Neutral lock
Reverse
Motion control lever pattern (right side)
To turn left while moving in a forward direction
pull the left lever back towards the neutral
position, this will slow the rotation of the left
wheel and cause the machine to turn in that
direction.
To zero turn pull one lever back beyond
neutral while holding the other slightly ahead
of neutral.
NOTE: The direction of the zero turn will be
determined by which lever is pulled back
beyond neutral. Thus left lever back, left zero
turn and opposite for right zero turn. Use
extra care when using this maneuver the
machine can spin very rapidly if one lever
is positioned too far ahead of the other.
English-20
WARNING!
The machine can turn very
rapidly if one steering control
is moved much further forward
than the other.
CONTROLS
If the steering controls are in uneven
positions when standing still, they can be
adjusted using the adjustment screws,
not the link system, for the controls
Adjusting screws
BAM-7
Hydraulic Lift Switch
Used to raise and lower the mower deck
hydraulically. Only used on units with power
deck lifts. Push switch forward to lower the
deck and pull backward to raise the deck.
Hydraulic lift switch
BAM-2
English-21
CONTROLS
Refueling
The machine has two fuel tanks, one on each
side just behind the seat. The tanks hold 11.4
gallons, 5.7 gallons each.
The engine is run on clean, fresh, diesel fuel
with a minumum of 40 cetane.
.
WARNING!
Diesel fuel is highly
flammable. Observe caution
and fill the tank outdoors
(see the safety rules).
BAM-8
Fuel Tanks
Fuel Shut-Off
The fuel shut-off is placed to the right side of
the seat. The shut-off has three positions;
right tank, left tank and off position.
Fuses
BAM-9
Fuel Shut-Off
The fuses are located in a fuse block to the
right of the battery. They are flat pin fuses of
the same type used in automobiles.
There are five fuses.
50A
Fuse ratings and functions moving from the
top:
•
20A - accesory jack
•
7.5A - sub system
•
10A - PTO/clutch
•
30A - hydrualic deck lift
•
50A - main system fuse (in line)
20A
7.5A
10A
30A
BAM-10
Fuses
English-22
CONTROLS
Manual Lifting Lever with Foot
Assist for the Mower Deck
The lifting lever is used to place the mower
deck in the transport position or one of the 17
different cutting height positions.
The cutting height is set by placing a pin in
the hole for the desired cutting height and the
pin is then locked on the inside (hidden in the
illustration) with the supplied cotter pin.
1.
Pull the lever backward while pushing on
the foot pedal, lifting the deck to the
locked position. The deck is then raised.
2.
Depress the lock handle, counter hold,
and move the lifting lever forward toward
the pin to engage the set cutting height.
The deck is then lowered.
3.
BAM-11
The mower deck’s lifting lever and foot pedal
The lifting lever can also be used to
temporarily adjust the cutting height,
such as when passing a minor bump in
the lawn.
IMPORTANT INFORMATION
In order to obtain an even cutting height it
is important that the air pressure in all
four tires is the same (15 psi, 103.4 kPa).
Hydraulic Lift for the Mower Deck
1.
Place pin in the appropriate hole for
desired cutting height, secure with cotter
pin.
2.
Push switch forward on the console to
lower deck to the set cutting height.
3.
Pull backwards on the switch on the
console to raise the deck for transport.
IMPORTANT INFORMATION
Pin must be locked into a hole for
transport or mowing.
Hydraulic switch
BAM-2
English-23
CONTROLS
Relays
The relays and glow plug timer are located in
a holder to the right side of the seat.
1
2
3
RUN
RELAY
START
RELAY
BAM-12A
Relays
1. Glow plug timer
2. Glow plug relay
3. Run relay
4. Start relay
5. Seat relay
Tracking
The tracking knob is located in front of the left
control lever. Rotating this knob allows fine
tuning adjustments so that the machine
tracks straight with the drive levers in the full
forward position. Rotate the knob colockwise
(as viewed from the operating position) to
increase the speed or counterclockwise to
devrease the speed on the left control lever.
Example: If control levers are full forward and
the unit turns to the right, turn the tracking
knob counterclockwise to decrease the speed
on the left control lever.
Accessories
For mulching, there is a Mulch Kit attachment
available. This is mounted underneath the
mower deck and comprised of baffles and
mulch blades.
8011-442
Tracking knob
ROPS (Roll Over Protection System) is also
available for the unit.
A baffle kit is available for the TRD61B - 61"
and TRD72B - 72" cutting decks.
8011-566
Mulch kit attachment
English-24
OPERATION
Operation
Read "Safety Instructions" section and following pages, if you are unfamiliar with the machine.
Training
Zero turn mowers are far more manueverable than typical riding mowers due to their unique steering
capabilities.
We recommend that this section be reviewed in its entirety prior to attempting to move the mower under its
own power. Additionally, we suggest when first operating mower, use a reduced throttle speed and reduced
ground speed by NOT moving control levers to the furthest forward or reverse positions during initial
operation, or until operator becomes comfortable with controls. We also suggest first time users, or new
users to ZeroTurn mowers to become familiar with the mowers movement on a hard surface, such as
concrete or blacktop PRIOR to attempting to operate on turf. Until operator becomes comfortable with
mower controls and zero turning capability, they may damage turf due to over aggressive maneuvers.
To move forward and backward
The direction and speed of the mowers movements is effected by the movement of the control lever(s) on
each side of mower. The left control lever controls the left wheel motor. The right control lever controls the
right wheel motor.
IMPORTANT INFORMATION
When control levers are in the reverse
position they return to neutral when
released. This may cause the mower to
suddenly stop.
First time users should push mower (see "Moving by Hand" in the "Operation" section) to an open, flat area,
without other people or vehicles/obstacles near by. In order to move unit under its own power, the operator
must be in the seat, start engine (see "Before Starting in the "Operation" section), adjust engine speed to
idle, disengage park brake, do not engage blades at this time, rotate control levers inward. As long as the
control levers have not been moved forward or backwards, mower will not move. Slowly move both control
levers forward slightly, this will allow mower to start moving forward in a straight line. Pull back on control
levers to the neutral position and mower should stop moving. Pull back slightly on control levers, this will
allow mower to start moving backwards. Push forward on control levers to the neutral position and mower
should stop moving.
To turn to the right
While moving in a forward direction, pull the right lever back towards the neutral position while maintaining
the position of the left lever, this will slow the rotation of the right wheel and cause the machine to turn in
that direction.
To turn to the left
While moving in a forward direction pull the left lever back towards the neutral position while maintaining the
position of the right lever, this will slow the rotation of the left wheel and cause the machine to turn in that
direction.
To zero turn
While moving in a forward direction, first pull both control levers back until the mower stops or slows
dramatically. Then by alternating one lever slightly to the forward position and the other in the reverse
position.
English-25
OPERATION
Before Starting
•
Read the sections Safety Instructions
and Controls before starting the
machine.
•
Perform the daily maintenance before
starting (see Maintenance Schedule
in the Maintenance section).
•
Check that there is sufficient fuel in the
fuel tanks.
•
Adjust the seat to the desired position.
The following conditions must be fulfilled
before the engine can be started:
•
the driver must be seated on the seat,
•
the blade switch for engaging the mower
blades must be depressed,
•
the parking brake must be on,
•
both steering controls must be in the
locked (outer) neutral position.
Starting the Engine
BAM-10
1.
Sit on the seat.
2.
Raise the mower deck by pulling the
lifting lever backward to the locked
position (transport position).
3.
Activate the parking brake.
Start conditions
8011-552
Raise the mower deck
English-26
OPERATION
4.
Disengage the mower blades by
depressing the blade switch.
2
1
1. Deck lift switch
2. Mower deck knob
5.
BAM-2
Move the steering controls outward to
the locked (outer) neutral position.
8011-526
Steering controls in the outward, locked neutral
position
6.
Move the throttle to the middle position.
BAM-2
Set the throttle
English-27
OPERATION
7.
Open the fuel valve for the selected fuel
tank.
BAM-9
Open the fuel valve
8.
Press in and turn the ignition key to the
start position.
GLOW PLUG
INDICATOR
IMPORTANT INFORMATION
Wait till the glow plug light goes out or
damage could result to the engine
STOP
CONSOLE2
Start position
9.
When the engine starts, immediately
release the ignition key back to the run
position.
IMPORTANT INFORMATION
To prolong starter life, use short starting
cycles, not to exceed 30 secs./min.
Extended cranking can damage starter
motor.
English-28
OPERATION
10. Set the desired engine speed with the
throttle.
Allow the engine to run at a moderate
speed, ”half throttle”, for 3-5 minutes
before loading it too heavily.
USE FULL THROTTLE WHEN
MOWING.
WARNING!
Engine exhaust and certain
vehicle components contain or
emit chemicals considered to
cause cancer, birth defects, or
other reproductive system
damage. The engine exhaust
contains carbon monoxide,
which is a odorless, colorless,
poisonous gas. Do not use the
machine in enclosed spaces.
BAM-2
Set the engine speed
To start an engine with a weak
battery
WARNING!
Lead-acid batteries generate
explosive gases. Keep sparks,
flame and smoking materials
away from batteries. Always
wear eye protection when
around batteries.
If your battery is too weak to start the engine,
it should be recharged. (See "Battery" in the
"Maintenance" section).
If “jumper cables” are used for emergency
starting, follow this procedure:
IMPORTANT INFORMATION
Your mower is equipped with a 12-volt
negative grounded system. The other
vehicle must also be a 12-volt negative
grounded system. Do not use your mower
battery to start other vehicles.
8011-642
Jumper cables connection
English-29
OPERATION
To attach jumper cables
•
Connect each end of the RED cable to
the POSITIVE (+) terminal on each
battery, taking care not to short against
chassis.
•
Connect one end of the BLACK cable to
the NEGATIVE (-) terminal of the fully
charged battery.
•
Connect the other end of the BLACK
cable to a good CHASSIS GROUND on
the mower with the discharged battery,
away from the fuel tank and battery.
To remove cables, reverse order
•
Remove BLACK cable first from chassis
and then from the fully charged battery.
•
Remove RED cable last from both
batteries.
Running
1.
Release the parking brake by moving the
lever forward.
Your mower is equipped with an operator
presence system. When the engine is
running, any attempt by the operator to
leave the seat without first setting the
park brake will shut off the engine.
2.
Move the steering controls to the neutral
position (N).
3.
Select the cutting height by placing the
peg in one of the holes. Lock the peg on
the inside with the pin.
4.
Press in the stop handle, counter hold,
and carefully move the lifting lever
forward from the transport position
toward the peg.
IMPORTANT INFORMATION
The mower deck’s anti-scalp rollers should
be evenly adjusted. See Maintenance
section.
English-30
BAM-4
Released parking brake
CUTTING HEIGHT
Cutting height selection
OPERATION
5.
On power units push the hydraulic lift
switch froward to lower the deck to the
selected pin position.
WARNING!
Make sure that no one is near
the machine when engaging
the blade switch.
6.
Engage the mower deck by pulling out
the blade switch.
7.
Move the throttle control to full throttle.
8.
The machine’s speed and direction are
continuously variable using the two
steering controls. When both controls are
in the neutral position, the machine
stands still.
By moving both controls an equal
amount forward or backward, the
machine moves in a straight line forward
or backward respectively.
In order, for example, to turn right while
moving forward, move the right control
towards the neutral position. The rotation
of the right wheel is reduced and the
machine turns to the right.
BAM-2
Hydraulic switch
Turning on the spot can be achieved by
moving one control backward (behind the
neutral position) and carefully moving the
other steering control forward from its
neutral position.
NOTE: The direction of the zero turn will be
determinded by which lever is pulled back
beyond neutral. Thus left lever back, left zero
turn and opposite for right zero turn. Use
extra care when using this maneuver the
machine can spin very rapidly if one lever
is positioned too far ahead of the other.
BAM-2
Engaging the mower deck
NOTE: To begin motion, the operator must be
in the seat and the parking brake disengaged
before the motion control levers can be
moved from the neutral slots or the engine
will kill.
English-31
OPERATION
Operating on hills
Read the Safety Instructions "Driving on
Slopes" in the "Safety Instructions" section.
WARNING!
Do not drive up or down
hills with slopes greater
than 10 degrees. And do not
drive across any slopes.
•
The slowest speed possible should be
used before starting up or down hills.
•
Avoid stopping or changing speed on
hills.
•
If stopping is absolutely necessary, pull
drive levers into the neutral position and
push to the outside of the unit and
engage the park brake.
IMPORTANT INFORMATION
Control levers return to neutral when
released. This may cause the mower to
suddenly stop.
•
To restart movement, release the park
brake.
•
Pull the control levers back to the center
of the mower and press forward to regain
forward motion.
•
Make all turns slowly.
BAM-10
Stopping conditions
BAM-4
Released parking brake
English-32
OPERATION
Mowing Tips
•
Observe and flag rocks and other fixed
objects to avoid collisions.
•
Begin with a high cutting height and
reduce it until the desired mowing result
is attained.
WARNING!
Clear the area of objects such
as rocks, toys, wire, etc., which
could be picked up and thrown
by the blades.
The average lawn should be cut to 2 1/2"
(64 mm) during the cool season and over
3" (76 mm) during the hot months. For
healthier and better looking lawns, mow
often after moderate growth.
For best cutting performance, grass over
6" (15 cm) in height should be mowed
twice. Make the first cut relatively high;
the second to the desired height.
•
The mowing result will be best with a
high engine speed (the blades rotate
rapidly) and low speed (the rider moves
slowly). If the grass is not too long and
dense, the driving speed can be
increased without negatively affecting
the mowing result.
•
The finest lawns are obtained by mowing
often. The lawn becomes more even and
the grass clippings more evenly
distributed over the mown area. The total
time taken is not increased as a higher
operating speed can be used without
poor mowing results.
•
Avoid mowing wet lawns. The mowing
result is poorer because the wheels sink
into the soft lawn, clumps build, and the
grass clippings fasten under the cowling.
•
Hose the mower deck underside with
water after each use. When cleaning, the
mower deck shall be raised into the
transport position. Make sure the mower
is cooled and the engine is off.
•
Use compressed air to clean top surface
of the deck. Avoid flooding water on top
surface.
•
When the mulching kit is used, it is
important that the mowing interval is
frequent.
8011-603
Mowing patterns
WARNING!
Never drive the rider on terrain
that slopes more than 10°.
Mow slopes up and down,
never side-to-side. Avoid
sudden directional changes.
English-33
OPERATION
Stopping the Engine
Allow the engine to idle a minute in order to
attain normal operating temperature before
stopping it, if it has been worked hard. Avoid
idling the engine for longer periods, as there
is a risk of the spark plugs fouling.
1.
Disengage the mower deck by
depressing the blade switch.
BAM-2
Disengage the mower deck
2.
On manual decks raise the mower deck
by pulling the lifting lever backward to the
transport position.
3.
On power decks raise the deck by pulling
back the hydraulic switch on the console.
4.
When the machine is standing still,
activate the parking brake by pulling the
lever backward.
5.
Move the throttle to the minimum position
(tortoise symbol). Turn the ignition key to
the stop position. Never use choke to
stop engine.
6.
Move the steering controls outward.
7.
Remove key. Always remove key when
leaving the mower to prevent
unauthorized use.
8011-552
Raise the mower deck with the lifting lever
IMPORTANT INFORMATION
Leaving the ignition switch in any other
position than "OFF" will cause the battery
to be discharged and the hour meter to
accumulate hours.
BAM-2
Hydraulic switch
English-34
OPERATION
Moving by Hand
In order for the machine to be moved with the
engine turned off, the vent screws on both hydraulic
pumps must be opened 1/4-1/2 turn.
WARNING!
No adjustments or
maintenance to be carried out
unless:
- the engine stopped,
- the ignition key has been
removed,
- the parking brake is on.
BAM-11
Vent screw on the hydraulic pump
English-35
MAINTENANCE
Maintenance
Maintenance Schedule
The following is a list of maintenance procedures that must be performed on the machine. For those points
not described in this manual, visit an authorized service workshop. An annual service carried out by an
authorized service workshop is recommended to maintain your machine in the best possible condition and
to ensure safe operation.
Read “Maintenance” in the “Safety Instructions” section.
● = Described in this manual
❍ = Not described in this manual
Daily
maintenance
Weekly At
mainte- least
nance once
each
Page Before After
year
Maintenance
Check the parking brake
45
Check the engine’s oil level (every refueling)
53
Check the hydraulic system’s oil level
52
Check the safety system
39
Check for fuel and oil leakages
-
Check rubber valve for sand trap
41
Check/clean the engine’s cooling air intake
40
Check the mower deck
47
Check hardware (screws, nuts, etc.)
54
Clean under the mower deck
54
Start the engine and blades, listen for unusual
sounds
Check for damage
-
Thoroughly clean around the engine
-
Thoroughly clean around the hydraulic system
-
Clean around belts, belt pulleys, etc.
-
-
Check the tire pressures
43
Check battery
38
Sharpen/Replace mower blades
47
2)
42
Check the fuel pump’s air filter
Clean the engine’s cooling air intake 2)
Clean cyclon air filter dust cap
25
●
●
●
●
●
❍
❍
❍
❍
❍
●
●
●
●
●
●
42
●
❍
❍
●
-
Inspect muffler/Spark arrester
-
50
●
●
●
●
❍
40
Check/adjust the parking brake
English-36
Maintenance interval
in hours
❍
❍
100
300
MAINTENANCE
Daily
maintenance
Weekly At
mainte- least
nance once
each
Page Before After
year
Maintenance
Check/adjust throttle
40
Check the condition of belts, belt pulleys, etc.
46
Change the engine oil 1)
Replace the engine oil filter (every 200 hours)
53
Clean/replace the spark plugs
38
Replace the fuel filter
58
43
2)
Replace the air filter (main cartridge)
(every 200 hours)
Check the caster wheels (every 200 hours)
42
Maintenance interval
in hours
25
50
●
●
●
●
●
●
●
●
●
●
●
●
●
❍
●
❍
53
Clean the cooling fins 2)
Clean fins of oil cooler (Kohler)
-
Check/adjust the mower deck
49
100
300
Change the hydraulic oil (every 300 hours)
-
Replace the hydraulic oil filter (every 300 hours)
-
●
●
❍
❍
●
-
❍
❍
73
❍
❍
●
❍
❍
❍
Dismantle and inspect starter 4) (every 500 h)
Check the engine valve clearance4)
Perform the 300-hour service 4)
Lubricate according to Lubrication Schedule
51
●
●
●
●
●
●
●
1)
First change after 8 hours. When operating with a heavy load or at high ambient temperatures, replace every 50 hours. 2) In dusty conditions, cleaning
and replacement are required more often. 3) For daily use, the machine should be lubricated twice weekly. 4) Performed by authorized service workshop.
● = Described in this manual
❍ = Not described in this manual
WARNING!
No adjustments or maintenance to be carried out unless:
• The engine is stopped.
• The ignition key has been removed.
• The parking brake is on.
English-37
MAINTENANCE
Battery
Your mower is equipped with a maintenance
free battery and does not need servicing.
However, periodic charging of the battery with
an automotive type battery charger will
extend its life.
•
Keep battery and terminals clean.
•
Keep battery bolts tight.
•
Recharge at 6-10 amperes for 1 hour.
To clean battery and terminals
Always use protective glasses
when handling the battery.
IMPORTANT INFORMATION
Do not attempt to open or remove caps
or covers. Adding or checking level of
electrolyte is not necessary.
Always use two wrenches for the
terminal screws.
Corrosion and dirt on the battery and
terminals can cause the battery to “leak”
power.
1.
Lift seat and rotate forward.
2.
Remove the red terminal guard.
3.
Disconnect BLACK battery cable first,
then the RED battery cable and remove
the battery from the machine.
4.
Rinse the battery with plain water and
dry.
5.
Clean terminals and battery cable ends
with wire brush until shiny.
6.
Coat terminals with grease or petroleum
jelly
7.
Reinstall battery.
WARNING!
Do not short battery terminals
by allowing a wrench or any
other object to contact both
terminals at the same time.
Before connecting battery,
remove metal bracelets,
wristwatch bands, rings, etc.
Positive terminal must be
connected first to prevent
sparks from accidental
grounding.
Replacing battery
1.
Lift seat and rotate forward.
2.
Remove the red terminal guard.
3.
Using two 1/2" wrenches disconnect
BLACK battery cable then RED battery
cable.
4.
Remove the knobs and remove battery
hold downs.
5.
Carefully remove the battery from the
mower.
6.
Install new battery with terminals in the
same position as the old battery.
7.
Reinstall battery hold downs.
8.
First connect RED battery cable to
positive (+) battery terminal with hex bolt
and hex nut.
English-38
BAM-21
Battery installation
MAINTENANCE
9.
Connect BLACK grounding cable to
negative (-) battery terminal with
remaining hex bolt and hex nut.
10. Fit the terminal guard.
11. Lower seat.
Checking the Safety System
The machine is equipped with a safety
system that prevents starting or driving under
the following conditions.
The engine can only be started when:
1.
The mower deck is disengaged.
2.
The steering controls are in the outer,
locked neutral position.
3.
The driver is sitting in the driver’s seat.
4.
The parking brake is on.
Make daily inspections to ensure that the
safety system works by attempting to start the
engine when one of the conditions is not met.
Change the conditions and try again.
If the machine starts when one of these
conditions is not met, turn the machine off
and repair the safety system before using the
machine again.
Make sure the engine stops when the park
brake is not engaged and the operator leaves
the seated position.
BAM-10
Conditions for starting
IMPORTANT INFORMATION
In order to be able to drive, the driver
must sit in the seat and release the
parking brake before the steering
controls can be moved into the neutral
position, otherwise the engine will stop.
Check that the engine stops if the mower
blades are engaged and the driver
temporarily stands up.
English-39
MAINTENANCE
Checking the Engine's Cooling Air Intake
Check that the engine’s cooling air intake is
free from leaves, grass, and dirt.
If the cooling air intake is clogged, engine
cooling deteriorates, which can lead to
engine damage.
BAM-13
Check and clean the cooling air intake
Checking and Adjusting the
Throttle Cable
Check that the engine responds to throttle
increases and that a good engine speed is
attained at full throttle.
If doubts arise, contact the service workshop.
If adjustments are necessary, they can be
made as follows for the lower cable:
1.
Loosen the clamping screw for the
cable’s outer casing and move the
throttle to the full throttle position.
2.
Check that the throttle cable is mounted
in the correct hole in the lower lever, see
illustration.
3.
Push the throttle cable’s outer casing as
far to the left as possible and tighten the
clamping screw.
Clutch Service and Maintenance
The clutch has an adjustable air gap that
should not require adjustment for the life of
the machine. Refer to the manufacture’s
specifications sheet included with the mower.
English-40
BAM-14
Adjusting the throttle cable
MAINTENANCE
Replacing the Air Filter
If the engine seems weak or runs unevenly
and the dust load indicator has turned red the
air filter may be clogged. If run with a clogged
air filter, disruption of operation can occur. For
this reason, it is important to replace the air
filter regularly (see the heading Maintenance
Schedule for the proper service interval).
WARNING!
The engine and the exhaust
system, become very hot
during operation.
Risk for burns if touched.
Allow engine and exhaust
system to cool at least two (2)
minutes.
Cleaning/replacing the air filter is carried out
as follows:
IMPORTANT INFORMATION
Do not used compressed air to clean the
air filter.
Do not wash the paper filter.
Do not oil the paper filter. Do not tap filter
to clean this could cause damage to the
sealing.
Dust cap
Check the dust cap every day by pressing the
rubber valve with two fingers to let out the
dirt.
8011-447
Pressing the rubber valve
IMPORTANT INFORMATION
The end cover must be installed with the
rubber valve pointing downwards,
otherwise the rubber valve will not
function.
Clean the dust cap by removing the end cover
of the the air cleaner and clean inside.
English-41
MAINTENANCE
Filter replacement
1.
Unfasten the two plastic clamps on the
sides of the air filter cover. Remove the
air filter cover.
2.
Remove the main filter (outer filter) by
pulling it out by hand. Lightly brush or
use mild air pressure to clean.
3.
Only remove and replace safety element
after the paper filter has been replaced 3
or 4 times.
4.
Clean inside of the filter housing. Wipe
dry only.
5.
Install the inner filter with the open end
first. Ensure that it enters its recess at
the end of the housing and push it in to
the end.
6.
1
2
1. Dust Load Indicator
2. Clamp
BAM-15
Removing the air filter cover
Install the main filter with the open end
first. Ensure that it enters its recess at
the end of the housing and push it in to
the end.
IMPORTANT INFORMATION
The end cover must be installed with the
rubber valve pointing downwards,
otherwise the rubber valve will not
function.
BAM-16
Paper filter
7.
Replace the cover over the air filter
housing. Fasten the two plastic clamps
making sure the cover is snapped into
position.
8.
Turn the end cover with the rubber valve
pointing downwards and install it.
9.
Push top of dust load indicator to reset it.
Safety element
English-42
BAM-17
MAINTENANCE
Replacing the Fuel Filter
The fuel filter is located with the priming
pump.
Replace the fuel filter every 800 hours (once
per season) or more regularly if it becomes
clogged.
Replace the filter as follow:
Unscrew fuel filter from pump and replace.
Every 50 hours check for water in the fuel
filter. Empty if necessary. Refer to the engine
manual.
BAM-18
Fuel filter and fuel pump
Checking Tire Pressures
All four tires should have a pressure of 15 psi
/ 103 kPa / 1 bar.
8011-564
Tire pressures
Check and Filling Coolant System
WARNING!
ALWAYS make sure the engine
is stopped and cool before
removing radiator pressure
cap. To prevent scalding by hot
fluid, NEVER remove the
radiator cap while engine is
hot.
NOTE: Failure to follow the recommended
procedure for filling the cooling system will
cause engine overheating and possible
engine failure.
BAM-19
Radiator
ALWAYS check coolant level at the overflow
reservoir. The correct level of coolant in the
over flow tank does NOT assure the radiator
is full.
English-43
MAINTENANCE
It is extremely important that when antifreeze
is used, that it be mixed with water in a
separate container before adding. NEVER
add straight antifreeze to the radiator.
Recommended mix is 50/50 lowtox
(propylene glycol) phosphate-free antifreeze
with tap water. DO NOT mix in ethylene
glycol. Refer to engine operatorís manual.
The radiator for this cooling system is
provided with two drain valves; one at each
end of the lower tank. When draining the
system, it is necessary to open both these
valves to drain the radiator completely.
Add coolant to the bottom of the fill cap again.
Install radiator pressure cap. Add coolant to
the proper line on the over flow tank between
FULL and LOW.
When refilling the system, it is important that
all trapped air be purged. The following
procedure will help to insure this:
1.
Make sure the engine is level. Fill the
overflow reservoir up to the MAX mark
with coolant mixture.
2.
Slowly fill the radiator to the bottom of the
filler neck with coolant mixture.
3.
With radiator cap off, start the engine
and let it warm up (no-load). Then, if
necessary, add more coolant mixture to
bring the level back up to the bottom of
the filler neck.
4.
Reinstall the radiator cap and run the
engine a short time with the system
sealed while watching the temperature
gauge. If the temperature gauge goes
past 230 degrees and does not drop
back to approximately 190 degrees,
indicating the thermostat has opened,
allow the engine to cool down, check for
leaks and repeat the procedure.
This is a sealed system. If it becomes
necessary to add coolant mixture at a later
date, check for leaks and if the overflow
reservoir has not been drained completely,
add coolant mixture to the reservoir only. This
will help prevent air pockets in the radiator top
tank and lessen the chance of introducing
contaminates to the system.
English-44
BAM-20
Overflow bottle
MAINTENANCE
Checking the Parking Brake
Visually check that no damage is found on
the lever, links, or switch belonging to the
parking brake. Perform a test drive and check
that there is sufficent braking action.
To adjust the parking brake:
1.
Set brake lever (D) fully forward against
stop.
NOTE: Brake cross shaft MUST be properly
lubricated and both cross shaft and overcenter assemblies (F) MUST rotate freely.
2.
Loosen jam nut (A) at rear of clevis (B)
and remove clevis pin (C) both sides of
mower.
3.
Rotate over-center assembly (F) in
correct direction (clockwise on left
counter-clockwise on right) to pull brake
actuating arm (E) forward until firm
contact between brake shoes and drum
can be felt. Hold in this position.
4.
Rotate clevis until clevis pin can just be
inserted thru clevis and brake lever with
pin resting against rear of the hole in
brake lever.
5.
Remove clevis pin and rotate clevis two
(2) full turns toward rear to allow correct
clearance between brake shoes and
drum.
6.
Temporarily reinstall clevis pin (do not
install cotter pin) to keep clevis from
turning and tighten jam nut.
7.
Remove pin and repeat above procedure
on opposite side.
8.
Reinstall clevis pins and secure with new
cotter pins.
9.
Set brake lever rearward to fully engaged
position.
Park brake linage
Parking brake linkage
10. Adjust spring (G) to correct tension by
turning rear jam nut until spring
measures 1 1/8".
WARNING!
Faulty adjustment can cause
an accident.
English-45
MAINTENANCE
Checking the V-belts
Deck belt
Check every 100 hours of operation. Check
for severe cracking and large nicks.
NOTE: The belt will show some small cracks
in normal operation.
To replace belt lower the deck to its lowest
position. Remove the foot plate and belt
shields.
Use a ratchet with a 9/16” socket on the
spring idler bolt to relieve the tension on the
belt. Slide the belt off of pulley and remove
the belt.
8011-622
Slackening the belt tensioner
Reverse the proceedure for installation. See
the decal on the top of deck for belt routing
information.
After installation is complete check the belt for
twists.
8011-580
Belt routing, deck belt
Pump belt
Check belt every 100 hours for excessive
wear.
To replace belt. Relieve tension on the deck
belt and remove deck belt from clutch. See
“Deck belt” on page 46. Loosen bolt on the
clutch tie down and rotate out of the way.
Using a 1/2” drive ratchet inserted into the
square hole in the pump idler arm relieve the
tension on the pump belt and remove belt.
English-46
8011-623
Slackening the belt tension
MAINTENANCE
To reinstall belt: Swing pump idler pulley
toward engine to route belt around it. Then
route belt around the pulley for left pump first.
Reinstall idler spring and use the ratchet to
rotate idler so the belt may be installed all the
way around the last pulley.
Checking the Blades
In order to attain the best mowing
performance, it is important that the blades
are well sharpened and not damaged.
WARNING!
Blades are sharp. Protect your
hands with gloves and/or wrap
blades with a heavy cloth when
handling.
Bent or cracked blades or blades with large
nicks should be replaced.
8011-604
Check the blade mounts.
Check the blades
IMPORTANT INFORMATION
The sharpening of blades should be
carried out by an authorized service
workshop.
Damaged blades should be replaced when hitting
obstacles that result in a breakdown. Let the service
workshop decide whether the blade can be
repaired/ground or must be discarded.
English-47
MAINTENANCE
Blade replacement:
3
1
WARNING!
Blades are sharp. Protect your
hands with gloves and/or wrap
blades with a heavy cloth when
handling.
2
4
5
•
•
•
Remove blade bolt by turning
counterclockwise.
Tunnel deck blades are sharpened on
both sides and can be installed either
way. Combi deck blades are not
sharpened on both sides.
Install and tighten blade bolt securely.
Tunnel Ram Deck - Torque blade bolt to
90 ft/lbs (122 Nm).
Combi Deck - Torque blade bolt to 57-61
ft/lbs (77-82 Nm).
English-48
8011-671
1. Blade
2. Center hole
3. Cutter housing
4. Blade bolt (special)
5. Lockwasher
Blade attachment, principal
MAINTENANCE
Adjusting the Mower Deck
WARNING!
Before performing any service or adjustment checklist:
1. Engage the parking brake.
2. Place the blade-switch in the disengaged position.
3. Turn ignition switch to “OFF” position and remove the key.
4. Make sure the blades and all moving parts have completely stopped.
5. Disconnect the spark plug wire from all spark plugs and place the wire where it
cannot come in contact with the plug.
Leveling
1.
Position the mower on a level, preferably
concrete, surface.
2.
Check the pressure in all four tires. See
“Technical Data” section.
3.
Raise the mower on lengths of 2" x 4"
placed edgewise under the cutting deck
from front to rear (see diagram).
4.
Lower the deck onto the 2” x 4”´s. The
rear of the deck is approxemately 1/4”
deeper than the front. This gives the deck
a proper pitch front to back when lowered
onto the 2” x 4” guides.
5.
Set the cutting height to 4”.
6.
Adjust the four lower chain bolts so that
they are centered in the oblong slots.
7.
Move the lifting lever and check that all
the chains are equally tensioned. If they
are not, adjust the appropriate lower
chain bolt in its slot.
WARNING!
Blades are sharp. Protect your
hands with gloves and/or wrap
blades with a heavy cloth when
handling.
8011-601
Leveling the mower deck, hang chain version
Adjusting Cutting Height
1.
Raise and secure the deck height lever
to the transport position (Tunnel Ram
Deck - 6"(150mm), Combi Deck - 5 3/
4”(146mm).
2.
Position blade tip so it is straight forward.
3.
Measure from the cutting edge of the
blades to a flat level surface. The
distance should be (Tunnel Deck - 6"
(150 mm), Combi Deck - 5 3/4”(146mm).
4.
Drop and secure the lever at (for
example) the 2" cutting height. Measure
as above. The distance should be 2"
(50 mm).
English-49
MAINTENANCE
To adjust anti-scalp rollers
Anti-scalp rollers are properly adjusted when
they are just slightly off of the ground when
the deck is at the desired cutting height in the
operating position. Anti-scalp rollers then
keep the deck in the proper position to help
prevent scalping in most terrain conditions.
IMPORTANT INFORMATION
Adjust Anti-scalp rollers with the mower
on a flat level surface.
CZ-9
Anti-scalp roller
Tunnel Ram Deck The anti-scalp rollers can be set in three
positions:
•
Upper position 1.5” to 3”/38 to 76 mm
grass.
•
Middle position 3” to 4.5”/76 to 114 mm
grass.
•
Lower position 4.5” to 6”/114 to 152 mm
grass.
Combi Deck •
Upper position 1.5” to 3.0” (38 to 76mm)
grass.
•
Lower position 3.0” to 4.5” (76 to
114mm) grass.
The rollers should be approximately 1/4”/6.5
mm from ground. Do not adjust the rollers to
support the deck.
IMPORTANT INFORMATION
The anti-scalp rollers must not be used
for gauge wheels or the roller and deck
may be damaged.
English-50
CZ-9
Anti-scalp roller - Combi Decks
MAINTENANCE
Checking the Hydraulic System
Total System Capacity..................1.125 gal.
To check the hydraulic fluid level, locate the
hydraulic reservoir under the seat. Remove
cap and check level. Fill to 1/4" from top of
tank
WARNING!
If a leak is suspected, use a
piece of cardboard or wood,
NOT your hands. to check for
leaks.
Escaping hydraulic oil under
pressure can have sufficient
force to penetrate the skin,
causing serious injury.
If injured by escaping fluid, see
a doctor at once. Serious
infection or reaction can
develop if proper medical
treatment is not administered
immediately.
BAM-21
Hydraulic reservoir
English-51
MAINTENANCE
Motion Control Linkage Adjustment
This adjustment must be made with the rear
wheels rotating. Raise the rear of the
machine and block it up so the wheels are
free to rotate
1
WARNING!
Keep hands, feet and clothing
away from rotating tires.
Place a 2 x 4 board between the foot plate
and the center of the seat to engage the seat
safety switch.
Loosen the nuts (A and B) directly behind
each ball joint on linkages (C). See
illustration.
Start the engine. The park brake must be
engaged and the motion control levers in the
neutral slots to start the engine. Run the
engine approximately half throttle. Release
park brake to allow the wheels to rotate.
Begin with either side and put the motion
control lever into the neutral position. Adjust
the motion control linkage by rotating the
double nuts (D) in the proper direction until
the wheel stops rotating. See illustration.
Move the motion control lever forward then
into the neutral position and place it into the
neutral slot. The wheel must be stopped
completely at this point. Now do the same in
reverse and release the lever. The lever
should return to neutral on its own.
Run engine full throttle to make sure wheels
do not rotate. Readjust if any rotation occurs.
Repeat the whole process for the opposite
side and tighten the nuts against the ball
joints.
Turn machine off.
Cutter Housings
Grease housings once weekly or every 40 to
50 hours of use. Use a good synthetic
grease. Pump grease in until a small amount
purges from the popet on the underside of the
deck. Check the torque of the pulley bolt 45 ft/
lbs should be maintained.
English-52
3
A
C
D
B
2
4
1. Left hand threads
2. Pump arm
3. Motion control lever
4. Turn here to adjust
Motion control linkage adjustment
motioncontroladj
MAINTENANCE
Deck Lift Power Unit
The system is pre-filled and factory sealed. In
the event it becomes necessary to replace oil
in the reservoir, the cylinder or cylinders must
be in the retracted position. Carefully remove
all dirt and debris from around the fill plug and
remove the plug. Fill to the lower edge of the
hole with 15W-50 synthetic oil and replace
the plug firmly to reseal the system.
deckventplug
Deck Lift Power Unit Vent Plug
Mule Drive System Adjustment
Only for the 72” deck.
As the mule drive belt wears and elongates,
some spring tension must be maintained on
the left (self-adjusting) mule drive idler.
2
1
For best performance, occasionally adjust the
right (fixed) mule drive idler position in the slot
so central axis of idler pulleys align.
mule drive
1. Self-adjusting
2. Fixed
Mule Drive Adjustment
Caster Wheels
Check every 200 hours. Lift front of unit off of
ground so caster wheels can rotate freely.
Tighten caster bolt (34) then back off 1/2 turn.
Check that wheel rotates freely. If wheel does
not rotate freely back the caster bolt off in 1/4
turn increments until wheel rotates freely.
IMPORTANT INFORMATION
DO NOT add any type of tire liner or foam
fill material to the tires. Excessive loads
created by foam filled tires will cause
premature failures.
Only use O.E.M. specified tires.
8011-619
Caster wheels
Foam filled tires or solid tires will void the
warranty.
English-53
MAINTENANCE
Cleaning and Washing
Regular cleaning and washing, especially
under the mower deck, will increase the
machine’s lifespan. Make it a habit to clean
the machine directly after use (after it is
cooled), before the dirt sticks.
Do not spray water on the top of the mower
deck. Use compressed air to clean the top
side of mower deck. Regulary clean deck and
underside of deck, avoid spraying engine and
electrical components with water.
8011-644
Cleaning
Use protective glasses when
cleaning and washing.
Hardware
Check daily. Inspect the entire machine for
loose or missing hardware.
English-54
LUBRICATION
Lubrication
Lubrication Schedule
lubechart
Lubrication schedule
12/12 Every year
1/52 Every week
Lubricate with grease gun
Oil change
Lubricate with oil can
Level check
1/365 Every day
Filter change
General
Remove the ignition key to prevent unintentional movements during lubrication.
When lubricating with an oil can, it must be filled with engine oil.
When lubricating with grease, unless otherwise stated, use a high grade molybdenum disulfide grease.
For daily use, the machine should be lubricated twice weekly.
Wipe away excess grease after lubrication.
It is important to avoid getting lubricant on the belts or the drive surfaces on the belt pulleys. Should this
happen, attempt to clean them with spirits. If the belt continues to slip after cleaning, it must be replaced.
Gasoline or other petroleum products must not be used to clean belts.
English-55
LUBRICATION
Lubricating the Cables
If possible, grease both ends of the cables and move the controls to end stop positions when lubricating.
Refit the rubber covers on the cables after lubrication. Cables with sheaths will bind if they are not
lubricated regularly. If a cable binds, it can disrupt operation.
If a cable binds, remove the cable and hang it vertically. Lubricate it with light engine oil until the oil begins
to escape from the bottom.
Tip: Fill a small plastic bag with oil and tape it so that it seals against the sheath and allow the cable to hang
vertically from the bag overnight. If you do not succeed in lubricating the cable, it must be replaced.
Shaft Bushings and Linkage
Lubricate the bearing of the shafts and
linkage for brake system and steering with oil
spray or oil can.
Lubricating in Accordance with the
Lubrication Schedule
8011-565
1. Hydraulic System, Oil Level
The hydraulic oil and filter must be replaced
every 300 hours, and at least once a year.
Contact an authorized service workshop.
Check the oil level in the hydraulic tank daily.
The level shall be about 3/4"-1"
(19 - 25 mm) below the top of the tank.
Check connections, hoses, and tubes for
damage or leaks. Replace or repair if
doubtful.
Changing Oil and Filters
Oil and filter changes should be carried out
by an authorized service workshop due to the
risk of impurities enter the system.
Checking the hydraulic oil
WARNING!
If a leak is suspected, use a piece
of cardboard or wood, NOT your
hands, to check for leaks.
Escaping hydraulic oil under
pressure can have sufficient
force to penetrate the skin,
causing serious injury.
If injured by escaping fluid, see a
doctor at once. Serious infection
or reaction can develop if proper
meical treatment is not
administered immediately.
2. Driver’s Seat
Tip the seat.
Lubricate the front hinges using an oil can.
Lubricate the lengthways adjustment
mechanism with the oil can.
Lubricate the lengthways adjustment runners
with the oil can.
8011-571
Lubricating the lengthways adjuster under the seat
English-56
LUBRICATION
3. Engine Oil
Changing the Engine Oil
The engine oil shall be changed for the first
time after 50 hours of operation. Thereafter, it
should be changed every 150 hours.
WARNING!
The engine and the exhaust
system, become very hot
during operation.
Risk for burns if touched.
Allow engine and exhaust
sytem to cool at least two (2)
minutes.
1.
Place the machine on a flat surface.
2.
Place a container under the engine drain
plug.
3.
Remove the dipstick and open the drain
plug.
4.
Allow the oil to run out into the container.
5.
Install and tighten the oil drain plug.
6.
Replace the oil filter if necessary.
7.
Fill with new engine oil in accordance
with Checking the Oil Level.
8.
Start the engine. Run it for a few
seconds. Stop and re-check the oil level.
IMPORTANT INFORMATION
Used engine oil is a health hazard and
must not be disposed of on the ground or
in nature; it should always be disposed
of at a workshop or appropriate disposal
location.
Avoid skin contact; wash with soap and
water in case of spills.
BAM-22
Oil drain plug
Checking the Oil Level
Check the oil level in the engine when the
machine is standing level and the engine is
stopped.
Remove the dipstick, wipe it clean, and then
replace it.
Take the dipstick out again and read the oil
level.
BAM-23
Remove the dipstick
English-57
LUBRICATION
The oil level shall lie between the markings
on the dipstick. If the level is approaching the
”ADD” mark, top up the oil to the ”FULL” mark
on the dipstick.
Never fill above the ”FULL” mark.
The oil is filled through the hole for the
dipstick.
8009-159
The dipstick markings
Use engine oil SAE 30 or SAE 10W-30 or,
alternately, 10W/40, class CF–4, CI-4
(over +32 °F/0 °C).
Over +68 °F /+20 °C SAE 40 can be used.
Use engine oil SAE 5W-20, class CF–4, CI-4
(under +32 °F/0 °C).
The engine holds 3.5qt/3.3 liters of oil
including the filter.
8009-140
Engine oils
4. Throttle Cable, Lever Bearings
Lubricate the cable ends by the lever with an
oil can. Move the controls to the end points
and lubricate again.
The throttle cable is also lubricated by the
control when the control console is removed.
8011-605
Throttle and choke cables by the carburetor
5. Front Wheel Mount
Lubricate with a grease gun, one zerk for
each wheel mount, use 10 pumps of the
grease gun at the recommended service
intervals. Use only good quality lithium based
grease.
Use only good quality molybdenum
disulphide grease.
English-58
LUBRICATION
6. Front Wheel Bearings
Lubricate with a grease gun, one zerk for each
set of wheel bearings, until the grease is forced
out.
Use only good quality molybdenum
disulphide grease.
Grease from well-known brand names
(petrochemical companies, etc.) usually
maintains a good quality.
8011-573
Lubricating the front wheels
7. Belt Adjuster, Mower Deck
Remove the foot plate (two screws) and
lubricate with a grease gun, one zerk, until
grease is forced out.
Use only good quality molybdenum
disulphide grease.
Grease from well-known brand names
(petrochemical companies, etc.) usually
maintains a good quality.
IMPORTANT INFORMATION
Be careful and remove excess lubricant
so that it does not come into contact with
belts or belt pulley drive surfaces.
8011-461
Deck belt pulley
8. Mower Deck Height Adjuster
Lubricate using a grease gun, one zerk,
until the grease squeezes out.
Use only good quality molybdenum
disulphide grease.
Grease from well-known brand names
(petrochemical companies, etc.) usually
maintains a good quality.
8011-574
Lubricating the cutting height adjuster
English-59
LUBRICATION
9. Steering Control Shafts
Tip the driver’s seat.
Lubricate with a grease gun, one zerk for
each steering control shaft, until the grease is
forced out.
Use only good quality molybdenum
disulphide grease.
Grease from well-known brand names
(petrochemical companies, etc.) usually
maintains a good quality.
8011-578
Lubricating the steering control shafts
10. Mower Deck Struts
Lubricate with a grease gun, one zerk for
each strut, until the grease is forced out.
Use only good quality molybdenum
disulphide grease.
Grease from well-known brand names
(petrochemical companies, etc.) usually
maintains a good quality.
8011-577
Lubricating struts
11. Belt Adjuster- Mule Drive Idler Arm
Lubricate with a grease gun, one zerk, until
the grease is forced out.
Use only good quality molybdenum
disulphide grease.
Grease from well-known brand names
(petrochemical companies, etc.) usually
maintains a good quality
IMPORTANT INFORMATION
Be careful and remove excess lubricant
so that it does not come into contact with
belts or belt pulley drive surfaces.
English-60
BAM-25
Lubricating mule dirve idler arm
LUBRICATION
12. Belt Adjuster, Hydraulic Pumps
Lubricate using a grease gun, one zerk, until
the grease squeezes out.
Use only good quality molybdenum
disulphide grease.
Grease from well-known brand names
(petrochemical companies, etc.) usually
maintains
a good quality.
BAM-24
IMPORTANT INFORMATION
Use minimal lubrication and remove excess
lubricant so that is does not come into
contact with belts or belt pulley drive
surfaces.
Lubricating the belt adjuster
13. Changing the Oil Filter
1.
Drain the engine oil in following the
procedure in the section, Engine Oil/
Change Engine Oil.
2.
Disassemble the oil filter. If necessary,
use a filter remover.
3.
Partially fill the new filter with oil.
4.
Wipe new, clean engine oil onto the seal
for the new filter.
5.
Mount the filter by hand with + 3/4 turn.
6.
Run the engine warm, then check that
there are no leaks around the oil filter
seal.
7.
BAM-23
Changing the oil filter
Check the oil level in the engine, top off if
necessary.
English-61
TROUBLE SHOOTING GUIDE
Trouble Shooting Guide
Problem
Cause
The engine will not start.
•
The blade switch is engaged.
•
The steering controls are not locked in the
neutral position.
•
The driver is not sitting in the driver’s seat.
•
The parking brake is not activated.
•
The battery is dead.
•
Contamination in the carburetor or fuel line.
•
The fuel supply is closed or the tap
for the fuel tanks is in the wrong position.
•
Clogged fuel filter or fuel line.
•
Dead battery.
•
Poor contacts on the battery terminal
cable connections.
•
Fuse blown.
•
Ignition system faulty.
•
Fault in the starter safety circuit.
See Checking the Safety System in the
The starter does not turn the engine over.
Maintenance section.
The engine runs rough.
The engine seems weak.
English-62
•
Defective valves.
•
Defective piston, cylinder, piston ring, or
cylinder head seal.
•
The cylinder head bolts are loose.
•
Clogged fuel filter or jet.
•
Clogged ventilation valve on the fuel cap.
•
Fuel tank nearly empty.
•
Defective ignition cable.
•
Rich fuel mixture or fuel-air mixture.
•
Wrong fuel type.
•
Water in the fuel.
•
Clogged air filter.
•
Clogged air filter.
TROUBLE SHOOTING GUIDE
The engine overheats.
•
Clogged air intake or cooling fins.
•
Engine overloaded.
•
Poor ventilation around engine.
•
Defective engine speed regulator.
•
Soot in the combustion chamber.
•
Too little or no oil in the engine.
•
Pre-ignition incorrect.
•
Water pump not working.
•
Coolant system clogged.
•
Coolant level low.
Battery not charging.
•
Poor contact with battery terminal
cable connectors.
The machine moves slowly, unevenly,
•
Parking brake on.
or not at all.
•
Bypass valve on pump open.
•
Drive belt for the pump slack or
has come off.
•
Defective hydraulic system.
•
Air in the hydraulic system.
•
Drive belt for the mower deck has come loose.
•
Contact for the electromagnetic coupling
has loosened.
•
The blade switch is faulty or has come loose
from the cable contact.
•
The fuse has blown.
Mower deck not engaging.
English-63
TROUBLE SHOOTING GUIDE
Uneven mowing results.
The machine vibrates.
English-64
•
Different air pressure in the tires on the left and
right sides.
•
Bent blades.
•
The chains for suspending the mower deck
are uneven.
•
The chain fixture has come loose.
•
The blades are blunt.
•
Driving speed too high.
•
The grass is too long.
•
Grass collected under the mower deck.
•
The blades are loose.
•
The blades are incorrectly balanced.
•
The engine is loose.
•
Wheel is loose.
STORAGE
Storage
Winter Storage
At the end of the mowing season, the machine
should be readied for storage (or if it will not be in
use for longer than 30 days). Fuel allowed to
stand for long periods of time (30 days or more)
can leave sticky residues that can plug the
carburetor and disrupt engine function.
Fuel stabilizers are an acceptable option as
regards sticky residues during storage.
Add stabilizer to the fuel in the tank or in the
storage container. Always use the mixing ratios
specified by the manufacturer of the stabilizer.
Run the engine for at least 10 minutes after
adding the stabilizer so that it reaches the
carburetor. Do not empty the fuel tank and the
carburetor if you have added stabilizer.
WARNING!
Never store an engine with fuel
in the tank indoors or in poorly
ventilated spaces where fuel
vapor can come in contact with
open flames, sparks, or a pilot
light such as in a boiler, hot
water tank, clothes drier, etc.
Handle the fuel with care. It is
very flammable and careless
use can cause serious personal
injury and property damage.
Drain the fuel into an approved
container outdoors and far
away from open flame. Never
use gasoline for cleaning. Use
a degreaser and warm water
instead.
To ready the machine for storage, follow these
steps:
1.
Thoroughly clean the machine, especially
under the mower deck. Touch up damage to
the paint and spray a thin layer of oil on the
underside of the mower deck to avoid
corrosion.
2.
Inspect the machine for worn or damaged
parts and tighten any nuts or screws that may
have become loose.
3.
Change the engine oil; dispose of properly.
4.
Empty the fuel tanks or add a fuel stabilizer.
Start the engine and allow it to run until the
carburetor is drained of fuel or the stabilizer
has reached the carburetor.
5.
Remove the glow plugs and pour about a
tablespoon of engine oil into each cylinder.
Turn over the engine so that the oil is evenly
distributed and then refit the glow plugs.
6.
Lubricate all grease nipples, joints, and axles.
7.
Remove the battery. Clean, charge, and store
the battery in a cool place, but protect it from
direct cold.
8.
Store the machine in a clean, dry place and
cover it for extra protection.
Service
When ordering spare parts, please specify the
purchase year, model, type, and serial number.
Always use genuine Husqvarna spare parts.
An annual check-up at an authorized service
workshop is a good way to ensure that your
machine performs its best the following season.
English-65
WIRING DIAGRAMS
Wiring diagram
6. Seat unoccupied
11. Brake switch OFF pos.
8. Blade switch in OFF position
14-15. Motion control levers OUT
1. Battery
2. Accessory outlet
3. Key switch
4. To engine pigtail
5. Hour meter
6. Seat switch
7. Run relay
8. Blade switch
9. Brake relay
10. Electric clutch
11. Brake switch
12. Start relay
13. Starter solenoid
14. Left motion control lever
15. Right motion control lever
BLK = Black
BLU = Blue
BRN = Brown
GRN = Green
GRY = Grey
LT.BLU = Light Blue
ORG = Orange
PUR = Purple
RED = Red
WHT = White
YEL = Yellow
NO = Normally Open
NC = Normally Closed
COM = Common
8011-650
English-66
TECHNICAL DATA
Technical Data
BZ27
BZ34
Engine
Manufacturer
Diahatsu
Diahatsu
Type
DM 950D
DM 954TD
Power
27 HP
34 HP
Lubrication
Pressure with oil filter
Pressure with oil filter
Oil capacity incl filter
3.5 qt
3.5 qt
Engine oil
(See viscocity digram)
SAE 10W30, SAE 30,
10W40 class SC-SH,
SAE 10W30, SAE 30,
10W40 class SC-SH,
Fuel
Diesel with a minimum of 40
octane
Diesel with a minimum of 40
octane
Fuel tank capacity
11.4 gallons / 43 liters.
11.4 gallons / 43 liters
Cooling
Liquid-cooled
Liquid-cooled
Air filter
Heavy duty canister
Heavy duty canister
Alternator
12 V 15 A
12 V 15 A
Starter
Electric
Electric
Transmission
Hydro gear Ross / Dual
pumps, Wheel drive motor
Hydro gear Ross / Dual
pumps, Wheel drive motors
Speed and direction controls
Dual levers, foam gripped
Dual levers, foam gripped
Speed forward
0-11.5 mph
0-11.5 mph
Speed reverse
0-5 mph
0-5 mph
Oil capacity excl filter
Transmission
Brakes
Hydrostatic/brake linings
Hydrostatic/brake linings
Front caster tires, Smooth tread
13x6.50-6 Tubeless
13x6.50-6 Tubeless
Rear tires, Turf pneumatic
26x12.00-12 Tubeless
26x12.00-12 Tubeless
Tire pressure, front and rear
15 PSI / 103 kPa / 1 bar
15 PSI / 103 kPa / 1 bar
Hydraulic reservoir + system
1 1/8 gallon
1 1/8 gallon
Hydraulic oil
Full synthetic 15W-50
Full synthetic 15W-50
English-67
TECHNICAL DATA
BZ27
BZ34
Equipment
Cutting width
61 in
61 in and 72 in.
Cutting height (Tunnel Ram Deck)
1.5”- 6” / 3.8 - 15.5 cm
1.5”- 6” / 3.8 - 15.5 cm
Cutting height (Combi Deck)
1.25”- 5.75” / 3.2 - 14.6 cm
Uncut circle
0
0
Number of blades
3
3
Blade length (Tunnel Ram Deck)
21”/533 mm - 61”
25”/635mm - 72”
Blade length (Combi Deck)
22.17”/536 mm - 61”
Blade tip speed
Anti-scalp rollers-Tunnel Ram Deck
N/A
6-adjustable
Anti-scalp rollers-Combi Deck
N/A
8, 6-adjustable
4-adjustable
Frame construction
Steel uni-frame
Steel uni-frame
Ball beared wheels
Yes
Yes
Sprung standard seat
Standard High-Back
Hinged armrests
Yes
Hour meter
Digital with service intervals
Blade engagement
Deck construction-Tunnel Ram Deck
300 ft/lb Warner Mag-stop Electromagnetic clutch
7 Gauge tunnel and sides, 10 Gauge top and spindle reinforcement
Deck construction-Combi Deck
4.5 mm Stamped Shell
Productivity
Productivity
N/A
Overall dimensions
Weight
1540 lbs.
1620 lbs.
Base maschine lenght
95”
95”
Base machine height
46.5”
46.5”
Overall width, Chute up
Tunnel Ram Deck
62”
73”
Overall width, Chute up
Combi Deck
63”
74”
Overall width, Chute downTunnel Ram Deck
74”
85”
Overall width, Chute downCombi Deck
N/A
N/A
Base machine width
English-68
TECHNICAL DATA
Accessories
Front baffle kit
Mulch kits
ROPS Roll Over Protection System
Torque Specifications
·Engine crankshaft bolt
50 ft/lb (67 Nm)
·Deck pulley bolts-Tunnel Ram Deck
45 ft/lb (61 Nm)
·Deck pulley bolts-Combi Deck
57-61 ft/lb (77-82 Nm)
·Hydraulic tube nuts
30 ft/lb (41 Nm)
·Wheel motor hub nut
90 ft/lb (122 Nm)
·Lug nuts
75 ft/lb (100 Nm)
·Blade bolt -Tunnel Ram Deck
90 ft/lb (122 Nm)
·Blade bolt -Combi Deck
57-61 ft/lb (77-82 Nm)
·Standard 1/4” fasteners
9 ft/lb (12 Nm)
·Standard 5/16” fasteners
18 ft/lb (25 Nm)
·Standard 3/8” fasteners
33 ft/lb (44 Nm)
·Standard 7/16” fasteners
52 ft/lb (70 Nm)
·Standard ∫” fasteners
80 ft/lb (110 Nm)
When this product is worn out and no longer used, it shall be returned to the reseller or other party for
recycling.
In order to implement improvements, specifications and designs can be altered without prior
notification.
Note that no legal demands can be placed based on the information contained in these
instructions.
Use only original parts for repairs. The use of other parts voids the warranty.
Do not modify or install non-standard equipment to the unit without consent from the
manufacturer. Modifications to the unit may cause unsafe operation or damage the unit.
English-69
CONFORMITY CERTIFICATES
Conformity Certificates For Models Listed Below:
Model 968999315/BZ27 (Serial Numbers: 054600001 – 065299999)
Model 968999316/BZ34 (Serial Numbers: 054600001 – 065299999)
With Deck Model 968999345 TRD61B
Deck Model 968999346 TRD72B
Deck Model 968999350 CD61B
EU declaration of conformity
Only applicable to European versions
Husqvarna AB, Beatrice NE USA declares under sole responsibility that the machine types stated on page
1 of this manual, from 2005's serial numbers and onwards (the year is clearly stated in plain text on the
rating plate with subsequent serial number), complies with the requirements of the COUNCIL'S
DIRECTIVES:
-
of June 22, 1998 "relating to machinery" 98/37/EC, annex IIA.
-
of May 3, 1989 "relating to electromagnetic compatibility" 89/336/EEC, and applicable supplements.
-
of May 8, 2000 "relating to the emission of noise to surroundings" 2000/14/EC. Conformity assessment
according to Annex V.
The following harmonised standards have been applied: EN292-2, EN836.
Noise emissions and cutting width:
Measured noise level:
Bio 90: 99 dB(A)
Combi 103: 99 dB(A)
Combi 103:100 dB(A)
Guaranteed noise level:
100 dB(A)
Cutting width:
900 - 1120 mm/35.5-44”
Beatrice January 3, 2005
Husqvarna 401 North Commerce Street, Beatrice, NE 68310 USA
Richard Bednar, Design Manager
English-70
SERVICE JOURNAL
Service Journal
Action
Date, mtr reading, stamp, sign
Delivery Service
1. Charge the battery.
2. Mount the rear wheels.
3. Adjust the tire pressure of all wheels to 15 PSI (1 bar).
4. Mount the steering controls in the normal position.
5. Connect the seat fold-up stop.
6. Connect the cable to the safety switch under the seat.
7. Mount the arm rests on the seat’s back support.
8. Check that the right amount of oil is in the engine.
9. Check that the right amount of oil is in the hydraulic tank.
10. Adjust the position of the steering controls.
11. Fill with fuel and open the fuel valve.
12. Check that the machine has no transport damage.
13. Start the engine.
14. Check that there is drive to both wheels.
15. Vent the hydraulic system if necessary.
16. Check the mower deck adjustment.
17. Check:
The safety switch for the parking brake.
The safety switch for the mower deck.
The safety switch in the seat.
The safety switch in the steering controls.
Parking brake functionality.
Driving forward.
Driving backward.
Engaging the blades.
18. Check the idle speed.
19. Check the engine high idle speed.
English-71
SERVICE JOURNAL
Action
Date, mtr reading, stamp, sign
20. Inform the customer about:
Delivery service has been carried
out.
The need and advantages of following the service schedule.
The need and advantages of leaving the machine
for service every 300 hours.
The effects of service and maintaining a service journal on
the machine’s resale value.
Application areas for BioClip.
21. Fill in the sales papers, etc.
After the First 50 Hours
1.
Change engine oil and filter.
English-72
No remaining notes.
Certified:
SERVICE JOURNAL
Action
Date, mtr reading, stamp, sign
25-Hour Service
1.
Check the hydraulic system’s oil level.
2.
Check the tire pressures.
3.
Lubricate the belt adjuster, mower deck.
4.
Lubricate the belt adjuster, hydraulic pumps.
5.
Check/clean the engine’s cooling air intake.
6.
Clean cyclon air filter dust cap.
7.
Lubricate the belt adjuster, mule drive - 72” only.
English-73
SERVICE JOURNAL
Action
50-Hour Service
1.
Perform the 25-hour service.
2.
Lubricate the front wheel bearings.
3.
Lubricate the steering control shafts.
4.
Lubricate the mower deck struts.
5.
Lubricate the cutting height adjuster.
6.
Change oil and oil filter for the first time. See engine manual.
7. Check dust load indicator on air filter. Change filter only if
indicator is red. See engine manual.
8.
Check/adjust the parking brake.
English-74
Date, mtr reading, stamp, sign
SERVICE JOURNAL
Action
Date, mtr reading, stamp, sign
100-Hour Service
1.
Perform the 25-hour service.
2.
Perform the 50-hour service.
3.
Change engine oil at 150 hours. See engine manual.
4.
Check fuel pump filter. See engine manual.
5.
Check fam belt clearance. See engine manual.
6.
Clean the cooling fins on the engine and transmission.
English-75
SERVICE JOURNAL
Action
300-Hour Service
1.
Inspect the machine. Come to agreement with the customer
as to which additional work is to be carried out.
2.
Perform the 25-hour service.
3.
Perform the 50-hour service.
4.
Perform the 100-hour service.
5.
Change the oil and filter in the hydraulic system.
6.
Clean the combustion chamber and grind the valve seats.
7.
Check the engine valve clearance.
8.
Dismantle, clean and inspect starter (500 hours).
9.
Check/replace the air cleaner’s safety element.
English-76
Date, mtr reading, stamp, sign
SERVICE JOURNAL
Action
Date, mtr reading, stamp, sign
At Least Once Each Year
1.
Clean the engine’s cooling air intake (25 hours).
2.
Replace the air cleaner’s paper cartridge.
3.
Replace the air filter’s main cartridge (200 hours).
4.
Change the engine oil (150 hours).
5.
Replace the engine oil filter (300 hours).
6.
Change the oil and filter in the hydraulic system (300 hours).
7.
Check/adjust the cutting height.
8.
Check/adjust the parking brake (50 hours).
9.. Change the fuel filter (100 hours).
10. Clean the cooling fins (100 hours).
11. Check the play in the engine valves (300 hours).
12. Perform the 300-hour service at an authorized service workshop.
English-77
SERVICE JOURNAL
Action
English-78
Date, mtr reading, stamp, sign
SERVICE JOURNAL
Action
Date, mtr reading, stamp, sign
English-79
SERVICE JOURNAL
Action
Date, mtr reading, stamp, sign
English-80
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SERVICE JOURNAL
Action
Date, mtr reading, stamp, sign
English-81
115 02 43-26
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2006W18