HDE Operators Manual 50077697_HDE ZT OP MAN

Published: 03/15/17

HDE SERIES

ZERO TURN MOWERS

MODELS:

HDE2049PS, HDE2049KT, HDE2555PS,

HDE2255FS, HDE2561CT, HDE2561KP,

HDE2361FS, HDE2461FS

Manual Number 50077697

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Operating of this Zero Turn Mower on a Slope Exceeding 15 Degrees is unsafe and can cause upset or loss of traction resulting in serious injury or death.

SLOPE INDICATOR

This page may be copied for personal use outside of this manual.

q

E q

Fold along the dashed line to measure the slope being checked.

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Align this edge with a vertical reference point, a tree, building, power pole, etc.

e

Shows example of how to compare the slope with the folded edge.

To the Owner/Operator/Dealer

This Operator's Manual is an integral part of the safe operation of this Zero Turn Mower and must be maintained with the Zero Turn Mower at all times. A Manual holder is provided on the Zero Turn Mower where this manual can be properly stored. If you lose or damage this manual a free replacement manual can be obtained from an authorized

Bush Hog dealer or by down loading the manual from the Bush Hog website www.bushhog.com

BEFORE YOU START! READ, UNDERSTAND, and FOLLOW the information provided in this manual and the Engine manual carefully to learn how to operate and service your Zero Turn Mower properly. Failure to do so could result in personal injury to you and bystanders. All Zero Turn Mowers with moving parts are potentially hazardous. Every effort has been made to ensure that the Zero Turn Mower is safe but operators must avoid engaging in unsafe practices and follow the written instructions provided. The manufacturer has designed this Zero Turn Mower to be used with all its safety equipment properly attached to minimize the chance of accidents.

SAFETY FIRST. Completely read and understand the safety section of this manual before operating this equipment.

Do not allow anyone to operate this equipment who has not fully read and understood this manual. Contact your

Dealer to explain any instructions that you do not fully understand.

The care you give your Bush Hog Zero Turn Mower will greatly determine your satisfaction with its performance and its service life. Carefully read and follow the instructions in this manual to provide you with a thorough understanding of your new Zero Turn Mower and its intended use and service requirements.

All references made in this manual to right, left, front, rear, top or bottom are as viewed facing the direction of forward travel with the Zero Turn Mower.

Replacement Parts information is located in a separate Parts Manual. Bush Hog parts are made and tested to Bush

Hog specifications. Non-genuine “will fit” parts do not consistently meet these specifications. The use of “will fit” parts may reduce Zero Turn Mower performance, void warranties, and present a safety hazard. Use genuine Bush Hog

Zero Turn Mower parts for economy and safety. For future reference, record your Bush Hog product model number and serial number.

Manual Holder located on back of seat.

Serial Number located on right hand side on the frame.

LIMITED WARRANTY

Bush Hog warrants to the original purchaser of any new Bush Hog HDE Series Zero Turn Mower purchased from an Authorized Bush Hog Dealer. This shall warranty that the Zero Turn Mower is free from defects in material and workmanship.

Non-Commercial Warranty is for a period of Three, (3) years from the date of retail sale. (Third year parts only.)

Commercial Warranty is for a period of One, (1) year or 400 Hours from date of retail sale.

Limited Lifetime Deck Weldment Warranty (Original Purchaser).

Engine Warranty is through the engine manufacturer.

The obligation of Bush Hog under these warranties are limited to repair or replacement of defective parts.

Replacement or repair parts installed in the equipment covered by this limited warranty are warranted for ninety (90) days from the date of purchase of such part or the expiration of the applicable new equipment warranty period, whichever comes later.

Warranted parts shall be provided at no cost to the user through an Authorized Bush Hog Dealer during regular hours of operation. Bush Hog reserves the right to inspect any equipment or parts which are claimed to have been defective in material or workmanship.

DISCLAIMER OF IMPLIED WARRANTIES & CONSEQUENTIAL DAMAGES

Bush Hog’s obligation under this limited warranty, to the extent allowed by law, is in lieu of all warranties, implied or expressed,

INCLUDING IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE and any liability for incidental and consequential damages with respect to the sale or use of the items warranted. Such incidental and consequential damages shall include but not be limited to: transportation charges other than normal freight charges; cost of installation other than cost approved by Bush Hog; duty; taxes; charges for normal service or adjustment; loss of crops or any other loss of income; rental of substitute equipment, expenses due to loss, damage, detention or delay in the delivery of equipment or parts resulting from acts beyond the control of Bush Hog.

THIS LIMITED WARRANTY SHALL NOT APPLY:

1. To vendor items which carry their own warranties, such as engines, tires, and tubes.

2. If the unit has been subjected to misapplication, abuse, misuse, negligence, fire or other accident.

3. If parts not made or supplied by Bush Hog have been used in connection with the unit, if, in the sole judgement of Bush

Hog such use affects its performance, stability or reliability.

4. If the unit has been altered or repaired outside of an authorized Bush Hog dealership in a manner which, in the sole judgement of Bush Hog, affects its performance, stability or reliability.

5. To normal maintenance service and normal replacement items such as hydrostatic oil, worn blades, or to normal deterioration of such things as belts and exterior finish due to use or exposure.

6. To expendable or wear items such as belts, springs and any other items that in the company’s sole judgement is a wear item.

NO EMPLOYEE OR REPRESENTATIVE OF BUSH HOG IS AUTHORIZED TO CHANGE THIS LIMITED WARRANTY IN

ANY WAY OR GRANT ANY OTHER WARRANTY UNLESS SUCH CHANGE IS MADE IN WRITING AND SIGNED BY

BUSH HOG’S SERVICE MANAGER, 2501 GRIFFIN AVE., SELMA, ALABAMA 36703.

Record the model number, serial number and date

purchased. This information will be helpful to your

dealer if parts or service are required.

MODEL NUMBER

SERIAL NUMBER

DATE OF RETAIL SALE

Make Certain that the retailing dealer has registered your warranty information with

Bush Hog at time of purchase.

DEALER PREPARATION CHECK LIST

For NEW ZERO TURN RIDING MOWER

BEFORE DELIVERING MACHINE - The following check list should be completed.

Use the Operator's Manual as a guide. Engine has been serviced.

 Ground Cable connected to Battery Negative Pole.

 Zero Turn Start Code communicated to Owner.

 Low oil pressure light checked for operation.

 Operator interlock switches checked for operation.

 Assembly completed.

 All fittings lubricated.

 Hydraulic Reservoirs filled to Cold Fill Line with oil.

 All shields in place and in good condition.

 Roll-over Protective Structure is installed and retractable seat belt functions properly.

 All fasteners torqued to specifications given in Torque Chart.

 All decals in place and readable. (See decal page.)

 Overall condition good (i.e. paint, welds)

 Parking brake checked and adjusted, if necessary.

 Steering checked and adjusted, if necessary.

 Check tire pressure.

 Warranty information has been registered on line with Bush Hog.

 Operator's manual has been delivered to owner and he has been instructed on the safe and proper use of the Zero Turn Mower.

Dealer's Signature ____________________________________

Purchaser's Signature ____

___________________________________

THIS CHECKLIST TO REMAIN IN OWNER'S MANUAL

It is the responsibility of the dealer to complete the procedures listed above before delivery of this Zero Turn Mower to the customer.

HDE SERIES ZERO TURN MOWER

TABLE OF CONTENT

SAFETY (SECTION 1)

General Safety Instructions and Practices ............................................................................1-1

Important Safety Considerations and Precautions ..............................................................1-2

Safety Instructions and Recommendations ..........................................................................1-2

OPERATOR SAFETY ................................................................................................................1-3

MOWER OPERATION SAFETY................................................................................................1-3

Ground Speed When Mowing ..................................................................................................................................1-3

ACCIDENT PATTERNS TO AVOID...........................................................................................1-4

Contact With The Rotating Blades............................................................................................................................1-4

Mower Thrown Objects.............................................................................................................................................1-4

Grass Discharge Chute ............................................................................................................................................1-4

Over Turning .............................................................................................................................................................1-4

Mower Running Over Victim .....................................................................................................................................1-4

Child Safety ..............................................................................................................................................................1-4

Fuel and Grass Fires ................................................................................................................................................1-4

MOWER BLADE CONTACT HAZARDS...................................................................................1-5

THROWN OBJECT SAFETY ....................................................................................................1-6

USE ROPS & SEATBELTS FOR OPERATING ON SLOPES SAFETY ...........................1-7 / 1-8

RUN OVER HAZARDS..............................................................................................................1-9

CHILD SAFETY .......................................................................................................................1-10

FUEL & FIRE SAFETY..................................................................................................1-11 / 1-12

MAINTENANCE SERVICE AND STORAGE SAFETY .................................................1-13 / 1/14

HIGH PRESSURE OIL LEAK HAZARD .................................................................................1-15

BATTERY SERVICE PRECAUTIONS.....................................................................................1-16

DRIVING AND TRANSPORTING ON PUBLIC ROADS.........................................................1-17

PARTS INFORMATION ...........................................................................................................1-18

SAFETY DECAL LOCATIONS (MOWER DECK)...................................................................1-19

SAFETY DECAL LOCATIONS (POWER UNIT) .....................................................................1-20

SAFETY DECAL PICTORIALS.....................................................................................1-21 / 1/23

FEDERAL LAWS and REGULATIONS ..................................................................................1-24

INTRODUCTION (SECTION 2)

INTRODUCTION ...............................................................................................................2-1 / 2-2

SPECIFICATIONS .....................................................................................................................2-3

CONTROLS (SECTION 3)

CONTROL LOCATIONS...........................................................................................................................................3-1

CONTROL PANEL....................................................................................................................................................3-2

IGNITION SWITCH ..................................................................................................................................................3-3

PERSONALIZING YOUR KEY CODE .....................................................................................................................3-3

CHOKE and THROTTLE ..........................................................................................................................................3-3

STEERING CONTROL LEVERS .............................................................................................................................3-4

PARKING BRAKE.....................................................................................................................................................3-4

PTO SWITCH ...........................................................................................................................................................3-5

CUTTING HEIGHT CONTROLS ..............................................................................................................................3-5

FUEL TANK and FILLER NECK ...............................................................................................................................3-5

SEAT ADJUSTMENT CONTROLS ..........................................................................................................................3-6

TRANSAXLE BYPASS CONTROLS ........................................................................................................................3-6

OPERATION (SECTION 4)

TRAINING

...............................................................................................................4-1

BEFORE STARTING ..................................................................................................................4-1

Starting the Engine ....................................................................................................................................................4-1

Shutting Down the Engine .........................................................................................................................................4-1

STEERING ..................................................................................................................................4-2

To Move Forward or Backwards ................................................................................................................................4-2

To Turn Left ................................................................................................................................................................4-2

To Turn Right..............................................................................................................................................................4-2

To Perform a Zero Turn..............................................................................................................................................4-2

OPERATING THE MOWER........................................................................................................4-2

ROPS and SEAT BELTS............................................................................................................4-3

MOWING ON SLOPES and HILLS ............................................................................................4-3

MOWING NEAR WATER, DITCHES, and EMBANKMENTS ....................................................4-4

MOWING TIPS............................................................................................................................4-4

AFTER MOWING is COMPLETED ............................................................................................4-4

MOVING THE MACHINE MANUALLY.......................................................................................4-5

WEAK or DISCHARGED BATTERY ..........................................................................................4-5

Jumper Cable Usage .................................................................................................................................................4-5

Starting Engine ..........................................................................................................................................................4-5

Removing Jumper Cables..........................................................................................................................................4-5

TRANSPORTING (SECTION 5)

TRANSPORTING THE MACHINE .............................................................................................5-1

Preparing to Transport ...............................................................................................................................................5-1

Loading the Machine..................................................................................................................................................5-1

Tie Down Points .........................................................................................................................................................5-1

Unloading the Machine ..............................................................................................................................................5-2

MAINTENANCE (SECTION 6)

RECOMMENDED REGULAR MAINTENANCE SCHEDULE ....................................................6-1

LUBRICATION............................................................................................................................6-2

Lubrication Points on Power Unit...............................................................................................................................6-2

Lubrication Points on Mower Deck ............................................................................................................................6-2

ENGINE MAINTENANCE...................................................................................................6-2 / 6-3

SERVICING the BATTERY.........................................................................................................6-4

Keep Battery Terminal Clean - Cleaning Battery Terminals .......................................................................................6-4

Replacing the Battery.................................................................................................................................................6-4

SAFETY SYSTEM ......................................................................................................................6-5

PARKING BRAKE ......................................................................................................................6-5

Parking Brake Adjustment..........................................................................................................................................6-5

TIRE PRESSURE .......................................................................................................................6-5

CASTER WHEELS .....................................................................................................................6-6

ANTI SCALP ROLLERS.............................................................................................................6-6

MOWER DECK V-BELT .............................................................................................................6-7

Mower Deck Belt Removal.........................................................................................................................................6-7

Mower Deck Belt Installation......................................................................................................................................6-7

Adjusting the Mower Deck Belt ..................................................................................................................................6-7

PUMP BELT INSTALLATION .....................................................................................................6-9

CUTTING BLADE MAINTENANCE ...........................................................................................6-9

Blade Removal...........................................................................................................................................................6-9

Inspect Blades ...........................................................................................................................................................6-9

Sharpening Blades...................................................................................................................................................6-10

Installing Blades.......................................................................................................................................................6-10

ADJUSTING the MOWER DECK.............................................................................................6-10

Leveling the Deck ....................................................................................................................................................6-10

TRANSAXLE MAINTENANCE .................................................................................................6-11

Fluid and Filter Change Procedure ..........................................................................................................................6-11

Purging Procedures .................................................................................................................................................6-12

CONSOLE MAINTENANCE ...........................................................................................6-13- 6-15

General Care ...........................................................................................................................................................6-14

Bypass or Failed Safety Interlock Switch Detection.................................................................................................6-14

Service Alerts ...........................................................................................................................................................6-14

Alarms......................................................................................................................................................................6-14

Console Diagnostic Codes.......................................................................................................................................6-15

STORAGE (SECTION 7)

WINTER STORAGE ...................................................................................................................7-1

Preparing the Machine for Storage ............................................................................................................................7-1

New Season Preparation ...........................................................................................................................................7-1

TROUBLE SHOOTING (SECTION 8) .....................................................................8-1

TECHNICAL DATA (SECTION 9)

MAIN WIRING HARNESS .........................................................................................................................................9-1

MAIN WIRING HARNESS SCHEMATIC ...................................................................................................................9-2

ENGINE ADAPTOR HARNESS for BRIGGS & STRATTON ENGINE ......................................................................9-3

ENGINE ADAPTOR HARNESS for KAWASAKI ENGINES.......................................................................................9-4

ENGINE ADAPTOR HARNESS for KOHLER ENGINES ..........................................................................................9-5

TORQUE SPECIFICATIONS .....................................................................................................................................9-6

SERVICE and MAINTENANCE RECORDS ..............................................................................................................9-7

SAFETY

SECTION 1

SAFETY

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Safety Section 1-1

SAFETY

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Safety Section 1-17

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Safety Section 1-18

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Under

Shield t

SAFETY

Safety Decal Location Mower Deck

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Under

Shield q r u q

ITEM PART NO.

QTY.

DESCRIPTION

6

7

4

5

1

2

3

D914

D646

D916

D917

D918

50077946

D943

2

2

1

1

2

1

1

Danger Decal - Rotating Blades

Warning Decal - Shield Missing Decal

Danger Decal - Do Not Mow without Discharge Chute in Place

Danger Decal - Thrown Object Hazard

Warning Decal - Keep Shields In Place

Installation Decal, Mower Belt

Not a Step Decal

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Safety Section 1-19

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SAFETY

Safety Decal Location Power Unit

t y u

1@ i

1#

1) q o

1!

ITEM

7

8

5

6

3

4

1

2

9

10

11

12

13

PART NO.

D859

D919

D920

D921

D922

D923

D924

D925

D926

D927

D928

D929

D931

QTY.

1

1

1

1

1

1

1

1

1

1

1

1

1

DESCRIPTION

Warning - Use Genuine Bush Hog Parts

Warning - Crushing Hazard

Instruction - Maintain ROPS (English)

Warning - Hot Surface

Instruction - Maintain ROPS (Spanish)

Warning - Crushing Hazard

Caution - Hearing Protection

Caution - Avoid Equipment Fires (Spanish)

Danger - Avoid Injury to Children

Caution - Help Avoid Bodily Injury (Spanish)

Caution - Help Avoid Bodily Injury (English)

Danger - Avoid Tip-Over

Caution - Avoid Equipment Fires (English)

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Safety Section 1-20

SAFETY

Safety Decal Pictorials

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Safety Section 1-24

INTRODUCTION

SECTION 2

INTRODUCTION

We are pleased to have you as a Bush Hog customer. Your Bush Hog Zero Turn Riding Mower has been carefully designed with care and built with quality materials by skilled workers to give maximum service with minimum down time. This manual is provided to give you the necessary operating and maintenance instructions for keeping your Zero Turn Mower in top operating condition. Careful use and timely service saves extensive repairs and costly down time losses.

Please read this manual thoroughly. Understand what each control is for and how to use it. No shielding is 100% effective in preventing thrown objects. The possibility of injury and property damage from this hazard can be substantially reduced by selecting proper shielding, maintaining the Zero Turn Mower and shielding in good operational condition, inspecting the area for foreign debris before mowing, and operating the Zero Turn Mower at a minimum cutting height, Keep unprotected persons at a minimum distance of 300 feet from the Zero Turn Mower at all times during operation. Safety is of primary importance to the owner/operator and to the manufacturer.

Observe all safety precaution decals on the Zero Turn Mower and noted throughout the manual for safe operation of Zero Turn Mowers. If any assistance or additional information is needed, contact your authorized Bush Hog dealer. The owner/operator/dealer should know and understand the Safety Messages before assembly and be aware of the hazards of operating this Zero

Turn Mower during assembly, use, and maintenance. The Safety Alert Symbol combined with a Signal Word, as seen below, is intended to warn the owner/operator of impending hazards and the degree of possible injury faced when operating this Zero Turn Mower.

!

DANGER

Indicates an imminently hazardous situation that, if not avoided, WILL result in DEATH OR VERY SERIOUS INJURY.

!

WARNING

Indicates an imminently hazardous situation that, if not avoided, COULD result in DEATH OR SERIOUS INJURY.

!

CAUTION

Indicates an imminently hazardous situation that, if not avoided, MAY result in MINOR INJURY.

IMPORTANT!

Identifies special instructions or procedures that, if not strictly observed, could result in damage to, or destruction of the Zero Turn Mower, attachments or the environment.

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Introduction Section 2-1

INTRODUCTION

The Bush Hog Zero Turn is intended for use on lawns and other frequently maintained areas where a smooth, even cut is desired and superior maneuverability is needed. The Power Unit consists of a Briggs & Stratton,

Kawasaki, or Kohler twin cylinder engine. The engine has a pressurized oil lubrication system with spin-on type filter, fused electronic ignition, electric start and the Zero Turn has a 9 gallon fuel system.

Two hydrostatic transaxles are used for propelling and steering. The

Transaxles are belt driven by the engine output shaft. One lever for each drive controls both speed and direction. This independent control of each drive wheel coupled with continuously variable speed selection gives the Zero Turn mower exceptional maneuverability.

The Zero Turn Mower Deck is available in 49”, 55” or 61” cutting widths. The Zero Turn Mower has three cutting blades, driven by an electromagnetic clutch through a single v-belt.

Front, rear, left and right are determined by the normal direction of travel, the same as driving an automobile.

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INTRODUCTION

SPECIFICATIONS

HDE Series Zero Turn Mower

MODEL ENGINE CUTTING WIDTH

HDE2049PS.........................................20 HP Briggs and Stratton Pro Series ....................................... 49” Deck

HDE2049KT .........................................20 HP Kohler 7000 Series ......................................................... 49” Deck

HDE2555PS.........................................25 HP Briggs and Stratton Pro Series ........................................55” Deck

HDE2255FS .........................................22 HP Kawasaki FS651 ..............................................................55” Deck

HDE2561CT.........................................25 HP Briggs and Stratton Commercial Turf ...............................61” Deck

HDE2561KP.........................................25 HP Kohler 7000 Series+ PRO Filtration.................................61” Deck

HDE2361FS .........................................23 HP Kawasaki FS691 ..............................................................61” Deck

HDE2461FS .........................................24 HP Kawasaki FS730V............................................................61” Deck

CONTROLS......................................... Electronic Control Module with Keyless Start, System Monitoring and

Soft Start PTO Engage

PTO......................................................Electromagnetic Clutch rated at 175 FT/LBS

FUEL CAPACITY.................................9 Gallons (87 Octane Unleaded Gasoline)

TRANSAXLES.....................................(2) Hydro-Gear ZT3100 Hydrostats

TIRES ..................................................Front - 13 x 6.5 - 6

Rear - 23 x 10.5 - 12 (Selection of Turf Tire or Bar Tire)

TREAD WIDTH ....................................50”

HEIGHT to TOP OF SEAT BACK .......47” Non Suspension Seat / 51” Full Suspension Seat

STEERING...........................................Dampened Twin Lever, Adjustable Fore, Aft and Vertical

SPEED .................................................Infinitely Variable 0-8 mph Forward, 0-4 mph Reverse

DECK SPECIFICATIONS

CUTTING WIDTHS ..............................49” .......................55” .......................61”

OVERALL WIDTH (CHUTE DOWN) ...63” .......................69” .......................75”

BLADES (Standard) ...........................(3) 17” Uplift.........(3) 19” Uplift .........(3) 21” Uplift

CUTTING HEIGHTS ............................1-1/2” to 5” Adjustable in 1/4” Increments

DECK CONSTRUCTION .....................7 Gauge reinforced steel

SAFETY

Integrated Operator Presence Controls

2-7/8” Round Tube ROPS

Seat Belts

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CONTROLS

SECTION 3

CONTROLS

CONTROL LOCATIONS

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Under Engine

1!

1) o i u y t

1.

Transaxle Bypass Linkage

2.

Fuel Cap

3.

Steering Control Levers

4.

Parking Brake Lever

5.

Deck Lift Pedal

6.

Deck Height Adjust Pin

7.

Seat Adjusting Lever

8.

Start/Stop Button

9.

Mower PTO Switch

10. Engine Throttle Control

11. Choke

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Controls Section 3-1 w e r

CONTROLS

CONSOLE

1!

r t y u

1) e

ITEM DESCRIPTION

q

FUNCTION

w i o

q

Engine Start/Stop Button

w

Key Code Buttons

Powers Engine ON / Powers Engine OFF.

Powers up Console by entering Key Code and enables specific functions

e

OK to Start Indicator Light

r

PTO Indicator LED as starting /stopping engine, engaging PTO.

Glows Green when safe to start engine, Red when unsafe.

Glows Red to indicate PTO is engaged.

t

Steering Lever Indicator LED Glows Reds when Steering Levers are not in Neutral position during startup

y

Parking Brake LED Glows Red if Parking Brake not set during startup.

u

Operator Position Indicator Glows Red if Operator is not in seat.

i

Low Oil Indicator LED

o

Fuel Level Indicator LED

Alerts Operator when Engine oil is low.

Alerts Operator when Fuel is low.

1)

PTO Switch

1!

LCD Display

Engages /Disengages Mower Blades.

Indicates Hours, Service Alerts, Engine RPM, and Voltage.

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Controls Section 3-2

CONTROLS

IGNITION

SWITCH

Ignition Switch

The Ignition Switch is keyless and is the Red Button on the Console located on the right hand side of the Zero

Turn Mower. This controls starting and stopping the engine.

IMPORTANT!

A 4 digit code must be entered before the engine can be started.

This code will be supplied by the dealer at the time the purchaser takes ownership of the Zero Turn

Mower. A code is programmed at the factory for use until the owner changes it to his personal code.

It is recommended that the owner personalize the code as soon as possible after taking ownership of the Zero Turn Mower.

See Personalizing Your Key Code.

PERSONALIZING YOUR KEY CODE

1. Record your new Key Code (1-12 digits) for safe keeping. NOTE: Only a dealer service call can reset a for-

gotten code.

2. Engine must be stopped and console unlocked (using

the original code that comes with the Zero Turn

Mower) and the PTO Switch down (OFF).

3. Hold KEY CODE BUTTONS 1 & 2 simultaneously for three seconds until the display shows “CHNGE”

“CODE” followed by a blank screen.

4. Enter the new key code into the console. If more than

12 digits are used the display shows “FULL”

NOTE: The display always shows the 5 most recently entered digits.

5. After entering the new code, pull the PTO Switch up.

If the new code is unusable, the display will show

“BAD” “CODE”. If this occurs push the PTO switch down and return to step 1 and try a different code.

NOTE: If user does not enter a code and pulls the PTO switch up the display shows “EMPTY” “CODE”.

6. If the new code is usable, the console prompts the user to re-enter the code again by displaying: ENTER”

“CODE” “AGAIN”. Re-enter the code used in step 4, then push the PTO switch down

.

7. The console confirms that the two key codes entered in step 4 and 6 match. If they do match, the console saves the new unlock code and displays “SAVED”

“CODE” before returning to the previous display mode. If they do not match the console displays “NO”

“MATCH” and the user must return to step 1.

NOTE: If no input is received for 10 seconds the console displays”TIME” “OUT” before returning to the previous display mode, retaining the previous unlock code.

RECORD YOUR PERSONALIZED KEY CODE HERE

Choke and Throttle

CHOKE

THROTTLE

LEVER

CHOKE

The Choke provides a richer fuel mixture to the engine to assist on cold starts. Pull the choke up to engage and once the engine starts push down to disengage.

THROTTLE

The Throttle controls the engine speed and blade speed when blades are engaged. To increase the engine and blade speeds push the Throttle forward and to decrease the speeds push the throttle toward the back. For best mowing performance run the engine at full throttle and control your ground speed with the Steering levers.

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CONTROLS

Steering Control Levers

Moving the right hand lever forward and the left hand lever backward the Zero Turn Mower will achieve a zero turn to the left. Moving the left hand lever forward and the right hand lever backward achieves a zero turn to the right. These maneuvers should be done with extra

care at a slow speed when turning.

Parking Brake

Steering Control Levers control the direction and speed of the Zero Turn Mower in both forward and reverse travel. Turning is controlled by pushing one lever forward and pulling the opposite lever backward or to the neutral position.

Moving the levers forward equally will cause the Zero

Turn Mower to travel forward in a straight line. Moving the levers backward equally causes the Zero Turn

Mower to travel in reverse. The further the levers are

moved forward or backward increases the speed of travel in that direction.

!

WARNING

THE ZERO TURN MOWER WILL

T U R N V E RY R A P I D LY I F O N E

STEERING LEVER IS MOVED MUCH FURTHER

FORWARD THAN THE OTHER.

Parking Brake

Lever

The Parking Brake is located on the left side of the Zero

Turn Mower. To set the brake pull the lever up and push down to release. When engaging the brake the Zero Turn

Mower must be completely motionless. Always set the

Parking Brake before dismounting the Zero Turn Mower and always release the brake before putting the Zero

Turn Mower into operation.

NOTE: If the Parking Brake is not set in the Park position when starting, the engine will not start and the

Parking Brake LED will be lit on the console. Release the brake after the engine has started.

NOTE: Applying the parking brake while in forward or reverse travel and the Steering Levers in the operating position will stop the engine and could do possible damage to the Hydrostat Drives.

Moving the right hand lever forward and the left hand lever to the neutral position turns the Zero Turn Mower left. Moving the left hand lever forward and the right hand lever to the neutral position turns the Zero Turn Mower to the right.

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PTO Switch

CONTROLS

IMPORTANT: To maintain an even cutting height, all tires must have equal air pressure of 15 psi /103kPa / 1bar.

PTO

Switch

Fuel Tank and Filler Neck

The PTO Switch is located on the Console and is Yellow in color.

To engage the Zero Turn mower blades pull the PTO

Switch switch up and to disengage push the switch down.

NOTE: The PTO Switch should only be engaged when the engine is running and the steering levers are in the Neutral position. The Zero Turn Mower will not start if the PTO Switch is pulled up prior to starting the Zero Turn Mower. It must always be in the OFF

(Down) position to start.

Cutting Height Controls

Height

Adjusting

Pin

Foot

Control

Pedal

The Fuel Tank is located under the operators seat and the Filler Neck is located on the left hand side toward the rear of the seat. The Fuel Cap is tettered to the tank to avoid dropping when refueling the Zero Turn Mower.

!

WARNING!

Filler

Neck

&

Fuel

Cap

Gasoline is highly flammable. The engine and exhaust system become very hot during operation.

Allow engine and exhaust system to cool down before refueling the Zero Turn Mower.

Use CAUTION and only fill outdoors.

Fill to the bottom of the filler neck (DO NOT OVER FILL).

Do not fuel the Zero Turn Mower near an open flame.

Clean away any spilled fuel after re-fueling and before re-starting the Zero Turn Mower.

The Cutting Height is controlled by selecting the desired height and pushing the Foot Control Pedal all the way forward and placing the Height Adjusting Pin in the desired cutting height. Release the pressure on the foot control until it stops at the set cutting height.

Check the gas fill cap often for damage to gasket. If damaged replace the fill cap.

The engine is designed to operate on 87 Octane unleaded gasoline.

IMPORTANT: Always raise the Zero Turn

Mower Deck to the highest position and disengage blades when transporting.

Damage to the engine may occur if E85 Alcohol based fuel or Methanol fuel is used.

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CONTROLS

Seat Adjustment Controls

NON-SUSPENSION SEAT

2. The Backrest Angle Adjustment Knob.

3. Arm Rest Height adjustment (raise arm rest to access adjustment knobs).

4. Seat Slide allows 6” of fore and aft adjustment.

5. Lumbar Support Adjustment Knob.

The seat is shaped to increase air flow so that you stay more comfortable on hot days

Move Lever to left to adjust.

Transaxle Bypass Control

NON-SUSPENSION SEAT

The Non-Suspension Seat can be adjusted forward or backward to fit the operators need. The adjusting lever is located under the front right hand side of the seat. Move the lever to the left as seen from the driver in the seat to move the seat backward or forward.

FULL SUSPENSION SEAT

Transaxle Bypass Linkages

3

2

1

5

4

The Transaxle Bypass Linkages must be pulled out when pushing or pulling the Zero Turn Mower without engine power. The linkages are located at the rear of the

Zero Turn Mower under the engine plate. The linkages must be pulled out and locked in order to relieve hydraulic pressure so the Zero Turn Mower can be moved.

Refer to Moving the Zero Turn by Hand in the Operation Section.

NOTE: The Tansaxle Bypass Linkages must be disengaged in order for the Zero Turn Mower to move forward or backward under its engine power.

!

CAUTION

The Bypass Linkage is located close to the muffler. To prevent burn injury, turn the engine off and allow the engine and muffler to

cool down before handling the Bypass Linkage.

FULL SUSPENSION SEAT

1. The Weight Adjustment Knob lets you set a personalized suspension setting.

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OPERATION

SECTION 4

OPERATION

IMPORTANT!

Training

If you are unfamiliar with the operation of a Zero Turn Mower, READ the Safety Section and the Controls Section before

Operating.

Zero Turn Mowers are more maneuverable than conventional riding mowers because of the unique steering capabilities.

Before attempting to operate this Zero Turn Mower under it’s own power, the Operation Section should be reviewed entirely.

After reviewing the Operation Section, board the Zero

Turn Mower (Always from the left side or front only,

never from the right hand side). Begin slowly by practicing on a smooth, hard, level surface such as concrete or asphalt before moving to turf.

Choose an area where no people, vehicles or other obstacles are present.

Do not move the Steering Levers too aggressively to the most forward or rearward positions during your initial operation. Moving to turf before being completely comfortable with the maneuverability of this Zero Turn Mower could cause turf damage.

Before Starting

1.Read the Safety and Controls sections before starting the Zero Turn Mower.

2.Do a maintenance check before starting. See Maintenance Schedule in the Maintenance Section.

3.Check Fuel for a sufficient amount to perform the task at hand.

4.Adjust the Operators Seat to desired position (See Seat

Adjustment Controls).

5. Raise the Zero Turn mower deck to the transport position (highest cutting setting).

6.The following Control settings must be applied before the engine will start.

• PTO Control Switch must be down (Off position).

• Parking Brake must be set (Up position).

• Both Steering control Levers must be in the Neutral

Lock position.

• Operator must be in the seat.

Starting the Engine

1.

Operator sitting in seat. NOTE; The Seat is

equipped with an operator presence switch and the unit will not start if operator is not sitting in the seat!

2. Raise the Zero Turn mower deck to the transport position (highest cutting setting).

3. The PTO Switch must be disengage.

4. Engage the Parking Brake.

5. Steering Levers in the Neutral Lock position.

6. Move Throttle Control to middle position.

7.

Pull Choke Up. (On cold starts)

8. Enter Console Un-Lock Code.

9. Press Start/Stop Button after the Green light is on.

If the engine fails to start after 5 seconds release the

Starter Button wait 10 seconds and retry.

10. When engine starts release Starter Button and push the Choke Knob down.

NOTE: When engine is running, engine RPM shows

in the LED Display. When engine is shut down total usage Hours displayed.

11. Allow the engine to run at a moderate speed for a short time before beginning to mow.

Shutting Down the Engine

IMPORTANT!

The Engine can be shut down at any time by simply pushing the

Start/Stop Button, however this should not be done with

Zero Turn mower deck engaged and forward or reverse travel in progress. This should be done only in as emergency procedures.

NOTE: The engine will shut down during operation if the operator leaves the seat.

Proper Shutdown is achieved as follows:

1. Disengage the Zero Turn Mower deck by pushing the

PTO Switch down.

2. Bring the engine down to idle speed.

2. Place the Steering Levers in the Neutral Lock position.

3. Set the Parking Brake.

4. Depress the Start/Stop switch.

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Operation Section 4-1

Steering

Direction of travel and speed are controlled by the Steering Control Levers. The right hand lever controls the right wheel and the left hand lever controls the left wheel.

!

CAUTION

All procedures listed below should be performed slowly and with caution until the operator is confident in their ability to operate this Zero Turn Mower SAFELY.

Begin with the operator sitting in the seat and adjust the seat so the operator feels comfortable with the steering controls and can easily raise and lower the deck with the

Foot Control Pedal.

Begin by bringing the engine to idle speed. Release the

Parking Brake. Move the Steering Levers inward from the Neutral Lock position to the Neutral position.

To Move Forward or Backwards

Pushing the Steering Lever forward equally causes the

Zero Turn Mower to travel forward in a straight line. The further forward the Levers are pushed the travel speed will increase.

Pulling the levers backward equally causes the Zero

Turn Mower to travel in reverse and speed increases the further back they are pulled.

To Turn Left

To negotiate a left hand turn while moving forward pull the left hand lever backward toward the neutral position slowing the left wheel causing the Zero Turn Mower to turn left.

To Turn Right

To negotiate a right hand turn while moving forward pull the right hand lever backward toward the neutral position slowing the right wheel causing the Zero Turn Mower to turn right.

To Perform a Zero Turn

Bring both Steering Levers to the neutral position until the Zero Turn Mower slows or stops.

Pushing the Left Lever slightly forward and pulling the

Right Lever slightly backward negotiates a Right Hand

Zero Turn.

Pushing the Right Lever slightly forward and pulling the

Left Lever slightly backward negotiates a Left Hand Zero

Turn.

OPERATION

Operating the Mower

The Mowing Height is controlled by the Foot Control

Pedal and a Height Adjusting Pin.

Mowing Height is adjustable from 1-1/2” to 5” in 1/4” increments.

NOTE: Mowing Height Adjustment should only be made

with the Zero Turn Mower deck blades disengaged.

To adjust the Mowing Height, place the right foot against the knurled shaft on the Foot Control Pedal and push forward. Place the Height Adjusting Pin in the desired cutting height hole. Release pressure on the Foot Control

Pedal.

Height

Adjusting

Pin

Foot Control

Pedal

When the mowing height has been established, start the

Zero Turn Mower, pull the PTO Switch up to engage the blades. Engine should be at full throttle when engaging

the blades.

!

WARNING

Mower.

When engaging the blades make sure no one is near to the Zero Turn

Be sure the area to be mowed has been cleared of all debris that could be thrown by the rotating blades causing injury to bystanders and damage to the Zero Turn

Mower.

Best mowing results are achieved when the engine is at full throttle and ground speed is controlled by the Steering Levers.

When mowing is completed, disengage the Zero Turn

Mower deck blades by pushing the PTO Switch down.

Raise the Zero Turn Mower by pushing the Foot Control

Pedal and place the Height Adjusting Pin in the 5” hole for transporting to the next location.

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OPERATION

ROPS and Seat Belts

ROPS

Seat

Belt

This Zero Turn Mower is equipped with a ROPS (Roll

Over Protective System) and Seat Belts for the Operator’s safety.

The ROPS should always be raised and locked and Seat

Belt used when the Zero Turn Mower is in use.

Ensure the seat is secured to the Zero Turn Mower.

!

DANGER

If the ROPS must be lowered for clearance, do not wear the seat belt. There is no protection from a rollover when the

ROPS is lowered. Raise the ROPS and lock in the up position as soon as clearance allows.

Mowing on Slope and Hills

!

DANGER

Operating this Zero Turn Mower on a Slope Exceeding 15 Degrees is unsafe and can cause upset or loss of traction resulting in serious injury or death.

Refer to the Slope Indicator page in the front of this manual to determine if a Slope or Hill is too DANGER-

OUS to operate this Zero Turn Mower on!

Refer to SAFETY SECTION: Using ROPS & Seat Belts

For Operating on Slopes Safety.

!

CAUTION

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

Mowing on wet grass can cause sliding and result in loss of control!

1. Reduce speed to slowest speed possible before starting up or down hills.

2. Avoid stopping or changing speed on hills.

3. If you must stop, place the steering levers in the neutral lock position and engage parking brake.

4. To Restart movement release the parking brake. Move the Steering Levers out of Neutral Lock position and push forward equally to regain forward motion.

5. Make turns slowly if operator must turn on a slope or hill.

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OPERATION

Mowing Near Water, Ditches, and

Embankments

!

DANGER

Operating this Zero Turn Mower near water where drop offs are present is unsafe. Wheels dropping over the edge can cause rollover or loss of traction resulting in serious injury or death by drowning.

Refer to SAFETY SECTION: Using ROPS & Seat Belts

For Operating on Slopes Safety.

!

CAUTION

●

Watch for ditches, holes, rocks, dips and rises that can change the operating angle. Keep away from drop offs and steep banks. Tall grass can hide these obstacles.

●

Use caution near drop offs, ditches, or embankments.

The Zero Turn Mower can suddenly turn over if a wheel goes over an edge of a ditch, drop off, embankment, or an edge caves in.

●

Mow a safe distance from water’s edge (Ponds or

Lakes). A Danger Zone of 10 feet should be observed.

Mowing Tips

!

CAUTION

Before mowing check the area to be mowed for debris that can be removed. Objects that are fixed and cannot be removed, flag the object so a collision does not occur.

●

Start by setting the Zero Turn Mower at the desired cutting height so desired result is attained. The average lawn should be cut to a height of 2-1/2’’ during cool seasons and 3” during hot months. For healthier, better looking lawns mow often after moderate growth has occurred.

●

Grass over 6” in height should be mowed twice. Make the first cut relatively high and then mow a second time at desired height.

●

Mowing results are best when the engine is a full throttle (blades spin faster) and the travel speed is low. If grass is low, travel speed can increase without affecting mowing results.

●

Avoid mowing when grass is damp or wet. The mowing results can be poor and cause the wet grass to clump under the deck and stick to the underside of the mowing deck, resulting in an uneven cut.

After Mowing is Completed

●

After the Zero Turn Mower is shut down and the engine has cooled, use compressed air to clean the top surfaces of the Zero Turn Mower deck and frame. If compressed air is not available a leaf blower can be used.

●

Avoid using water on top surfaces around engine and electrical components.

●

Raise the Zero Turn Mower deck to its highest position and hose the underside of the Zero Turn Mower deck to remove any build up of grass clippings.

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OPERATION

Moving Machine Manually Weak or Discharged Battery

NOTE: Do not push, pull, or tow this Zero Turn Mower without first releasing the hydraulic pressure in the Integrated Transaxles.

To release the hydraulic pressure from the Transaxles, pull the two Bypass Linkages out and down to lock them in position in the keyhole slot.

The linkages must be returned to the original position before the Zero Turn Mower is placed back in service, otherwise the Zero Turn Mower will not move.

The linkages are located at the rear of the Zero Turn

Mower under the engine plate.

Transaxle Bypass Linkages

!

CAUTION

The Bypass Linkage is located under the Zero Turn Mower close to the muffler. To prevent burn injury DO NOT attempt ac-

cess to the Bypass Linkages from the top. Turn the engine off and allow the engine and muffler to cool down and access the Bypass Linkages from the underside

below the muffler before handling the Bypass Linkage.

If the battery is weak and will not start the engine, it should be recharged using a battery charger.

Replace the battery if it will not hold a charge after recharging.

The minimum capacity battery for this Zero Turn Mower is a 12 Volt / 350 cranking amp Lawn and Garden.

!

CAUTION

Lead-acid Batteries generate explosive gases. Keep sparks, flames and smoking materials away from batteries. Always wear eye protection when Jump Starting batteries.

Jumper Cable Usage

1. Attach each end of the RED cable ends to the POSI-

TIVE (+) terminals on each battery. Care should be taken not to short against the Zero Turn Mowers frame.

2. Connect one end of the BLACK (-) to the Fully charged battery.

3. Connect the other end of the BLACK (-) cable to a good CHASSIS GROUND on the Zero Turn Mowers frame.

Starting the Engine

4.

Operator sitting in seat. NOTE; The Seat is equipped

with an operator presence switch and will not start if operator is not sitting in the seat!

5. Raise the Zero Turn Mower deck to the transport position (highest cutting setting).

6. Disengage the PTO Switch.

7. Engage the Parking Brake.

8. Steering Levers in the Neutral Lock position.

9. Move Throttle Control to middle position.

10. Pull Choke Up. (On cold starts)

11. Enter Console Un-Lock Code.

12. Press Start/Stop Button.

Removing Jumper Cables

13. Disconnect the BLACK cable from the chassis ground first then from the Zero Turn Mowers battery.

14. Remove the RED cable from the Zero Turn Mowers battery and then the jumper battery.

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TRANSPORTING

SECTION 5

TRANSPORTING

Transporting the Zero Turn Mower

Transport Zero Turn Mower on a heavy duty trailer that is adequate to handle the size and weight of the Zero

Turn Mower. Be sure the trailer has all the necessary brakes, lighting and reflective markings required by law.

!

WARNING

Never drive this Zero Turn Mower on public streets or roadways.

Driving this Zero Turn Mower on streets or roadways without proper lighting, turn signals, reflective markings or a Slow Moving Vehicle Placard can lead to serious injury or death by collision with other vehicles.

Loading the Zero Turn Mower at a steeper angle than

15 degrees can cause possible tip over or loss of traction resulting in injury or death. Mower components may hang up on the transition from the ramp to the trailer bed.

BACK ZERO TURN MOWER UP

RAMP ONTO TRAILER

Preparing to Transport

1. Connect the trailer to the towing vehicle. Connect all trailer safety chains and lighting harness to tow vehicle.

2. Connect trailer brakes if applicable.

When loading the Zero Turn Mower on a trailer, back the

Zero Turn Mower up the ramp and center the weight of the Zero Turn Mower over the trailer axles.

After the Zero Turn Mower is loaded on the trailer shut the engine off and apply the parking brake

.

Loading the Zero Turn Mower

!

CAUTION

Extreme CAUTION should be used when loading and unloading the Zero Turn Mower. Avoid sudden acceleration and deceleration while driving on the ramp and trailer bed. This could cause loss of control and tipover.

!

DANGER

Do not use narrow individual ramps on each side to load this

Zero Turn Mower.

Only use a full width ramp that is wider than the Zero

Turn Mowers width.

Tie Down Points

IMPORTANT!

Do not rely strictly on the parking brake to transport on a trailer! Use of the tie down points are required for safe transport.

FRONT TIE

DOWN POINT

LOCATIONS

4 Times

Trailer

Height

REAR TIE DOWN POINT

LOCATIONS

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t

The ramp should be 4 times longer than the height of the trailer to prevent angles above

15 degrees.

Four (4) tie down points are located on the Zero Turn

Mower for safe transport. Two located on the front and two at the rear. Use tie down straps, chains or ropes to secure the Zero Turn Mower to the trailer at the four tie down locations.

Sudden stops or acceleration can cause the Zero Turn

Mower to skid in the bed of the trailer possibly over turning the Zero Turn Mower or ejecting the Zero Turn Mower from the trailer causing injury or death to by standers and damage to surrounding vehicles.

Transporting Section 5-1

TRANSPORTING

Unloading the Zero Turn Mower

!

CAUTION

Extreme CAUTION should be used when loading and unloading the Zero Turn Mower. Avoid sudden acceleration and deceleration while driving on the ramp and trailer bed. This could cause loss of control and tip-over.

1. Park the trailer on a level surface, then lower the ramp. NOTE: If unloading must be done on a slope,

position the trailer so the ramp extends up the slope not exceeding a 15 degree angle.

2. Release the tie down straps.

3. Board the Zero Turn Mower, start the engine.

4. Release the park brake and slowly drive forward off the trailer.

DRIVE ZERO TURN MOWER

FORWARD DOWN THE RAMP

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Transporting Section 5-2

MAINTENANCE

SECTION 6

MAINTENANCE

Recommended Regular Maintenance Schedule

Maintenance Service Maintenance Procedure

Interval

After the first 8 hours

After the first 50 hours

Before each use or daily

Every 25 hours

Every 50 hours

Every 100 hours

Every 200 hours

Every 250 hours

Every 400 hours

Every 500 hours

Monthly

Yearly

Before placing in storage

• Change the engine oil and oil filter.

• Check the torque on the wheel lug nuts.

• Change the hydraulic system filter and oil.

• Check the safety system.

• Check the engine oil level.

• Check the seat belt.

• Check the rollover protection system (ROPS) knobs.

• Clean the engine screen.

• Inspect the blades.

• Clean the Zero Turn Mower deck.

• Check the hydraulic oil level in the expansion tank.

• Grease the Zero Turn Mower deck idler arm.

• Grease Blade Spindles. (5 Shots)

• Grease Idler Pivot Point.

• Inspect the mower belt and hydrostat drive belt for cracks and wear.

• Lubricate the deck lift pivots.

• Change the engine oil (more often in dirty or dusty conditions).

• Check, clean and gap the spark plug.

• Check and clean engine cooling fins and shrouds.

• Grease the front caster pivots (more often in dirty or dusty conditions).

• Lubricate the caster wheel hubs.

• Change the engine oil filter.

• Replace the primary air filter (more often in dusty or sandy conditions).

• Check the safety air filter.

• Change the hydraulic system filter and oil.

• Replace the safety air filter.

• Replace the fuel filter (more often in dirty or dusty conditions).

• Adjust the caster pivot bearing.

• Check the electric clutch.

• Check the battery charge.

• Check the torque on the wheel lug nuts.

• Paint chipped surfaces.

• Check all maintenance procedures listed above before storage.

• Clean The Underside of the mowing deck.

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Maintenance Section 6-1

MAINTENANCE

Lubrication

Proper lubrication at specified intervals will increase the life of the Zero Turn Mower. Greasing more frequently where conditions are extremely dusty or sandy is recommended.

Lubrication Points on the Zero Turn Mower

Power Unit

The Zero Turn Mower Power Unit has 9 grease point locations, 4 on the left side and 4 on the right side (Left Side

Shown, corresponding points are on the Right Side) and

1 on the Pump Idler Pivot.

GREASE TYPE: No 2 Lithium or Molybdenum

1

2

3

Lubrication Points on the Zero Turn Mower

Deck

1

2

The Zero Turn Mower Deck has 4 grease points. 3 points on the Blade Spindles and 1 on the Idler pivot

.

GREASE TYPE: No 2 Lithium or Molybdenum

1. 5 shots of grease every 50 hours at the Blade Spindles.

2. 2 shots of grease every 50 hours in the Idler Pivot tube and more frequently in dusty or sandy conditions.

Engine Maintenance

4 Pump

Idler

Pivot

1. Grease the Front Caster Pivots every 100 hours and more frequently in dusty or sandy conditions.

2. Grease the Caster Wheels at the hubs (2 fittings on each hub) every 50 Hours and more frequently in dusty or sandy conditions.

3.Grease the Deck Lift Pivot points every 50 hours and more frequently in dusty or sandy conditions.

4. 2 shots grease at 50 hours to the Pump Idler Pivot.

The Bush Hog Series HDE Zero Turn Mowers are offered with 3 different engine manufactures. Briggs &

Stratton, Kawasaki and Kohler. Maintenance procedures vary from each manufacturer.

Operator / Maintenance manuals are available online as a free download from each engine manufacturer.

Bush Hog recommends following the Engine manufacturers maintenance schedules for each manufacturer’s engine model.

See links listed on next page for downloading the

Engine Manual for your Zero Turn Mower.

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MAINTENANCE

Mower Model ....Engine Series

Number

HDE2049PS ............Briggs and Stratton 40S877-0019

HDE2555PS ............Briggs and Stratton 44S977-0025

HDE2561CT ............Briggs and Stratton 44T977-0020

HDE2255FS.............Kawasaki FS651

HDE2361FS.............Kawasaki FS691

HDE2461FS.............Kawasaki FS730V

HDE2049KT.............Kohler KT715

HDE2561KP ............Kohler KT740

Locate your Mower Model Number and then go to the

Engine Manufacturer’s website and navigate to the manual needed. Follow links listed below, listing the engine series when prompted.

BRIGGS and STRATTON ENGINES: www.briggsandstratton.com

go to Support tab go to Download Manuals in drop down go to Riding Mowers enter the engine series number listed for your Zero

Turn Mower model above in the dropdown.

KAWASAKI ENGINES: www.kawaskienginesusa.com

go to Parts and Support tab go to Manuals in dropdown go to Series and choose FS Series choose either the FS651V Manual or FS691V

Manual from dropdown.

KOHLER ENGINES www.kohlerengines.com/manuals

go to Manuals and Maintenance go to Owners & Service Manuals enter engine model number under I know my model number (KT715 or KT740)

Under Manuals select Owners

Checking Engine Oil Level

NOTE: Check oil level when engine is cold.

Engine oil should be checked before each use or daily.

Follow the procedures for checking oil as instructed by the engine manufacturers manual which applies to your

Zero Turn Mower.

Changing the Engine Oil and Oil Filter

NOTE: It is recommended after the first 8 hours of usage the oil and filter be changed.

Follow the procedures for changing oil and oil filter as instructed by the engine manufacturers manual which applies to your Zero Turn Mower.

The engine manufacturers manual will provide the recommended service intervals, oils, amount required and filters required when changing oil.

Dispose of the used oil at a recycling center.

Servicing the Air Cleaner

Service Intervals:

Every 250 hours replace the primary Air Filter (more often in dusty or sandy conditions).

Check the Safety Filter every 250 hours and replace every 500 hours of usage.

Follow the procedures for changing air filter as instructed by the engine manufacturers manual which applies to your engine.

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Servicing the Battery

This Zero Turn Mower is equipped from the factory with a maintenance free battery that does not need servicing.

However, if the Zero Turn Mower is not being used for an extended period or placed in storage, disconnect the

Black (ground) cable from the battery. Periodic charging with automotive battery charger is recommended and will extend the battery life.

HOLD DOWN

STRAP

TERMINALS

BATTERY

!

CAUTION

Always wear eye protection when working with batteries!

The battery is located on the right hand side behind the seat.

!

WARNING

DO NOT short across battery terminals by allowing a wrench or any other metal object to come in contact with both terminals at the same time.

!

WARNING

DO NOT allow a wrench to come in contact with any part of the Zero

Turn Mowers frame when working with the POSITIVE (+) terminal of the battery.

• Keep Battery and Terminals Clean.

Cleaning battery and terminals

1. Disconnect the BLACK battery cable (ground) first and then the RED (Positive) battery cable.

2. Remove the nut and washer on the Hold Down Strap, then remove the Hold Down Strap. Remove the battery.

3. Rinse the battery with plain water and dry.

MAINTENANCE

4. Clean the terminals with a wire brush removing all corrosion and coat the terminals with a lite coat of battery terminal grease.

5. If corrosion is present on the cable ends clean the corrosion from them and place a lite coat of battery terminal grease to them. If the cable ends are severly damaged, replace the cables.

6. Re-install battery and cable in reverse order of removal.

Replacing the Battery

1. Disconnect the BLACK battery cable (ground) first and then the RED (Positive) battery cable.

2. Remove the nut and washer on the Hold Down Strap, then remove the Hold down Strap and remove the old battery.

3. Do Not install battery cables that show signs of cor-

rosion to a new battery. If corrosion is present on the cable ends, clean the corrosion from them and place a lite coat of battery terminal grease to them. If the cable ends are severly damaged, replace the cables.

4. Place the new battery in it’s proper location.

5. Re-install the Hold Down Strap and fasteners.

6. Attach the RED (positive) cable to the POSITIVE (+) terminal on the battery.

7. Attach the BLACK (ground) cable to the NEGATIVE

(-) terminal of the battery.

8. Check all connections to be sure they are tight. Do not over tighten.

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MAINTENANCE

Safety System

The Safety System of this Zero Turn Mower is designed to prevent starting or driving the Zero Turn Mower under the following conditions

.

The engine will only start when:

●

The Zero Turn Mower PTO Switch is in the down position (Blades disengaged).

●

Both Steering Levers are in the Neutral Lock Position.

●

The Parking Brake is on

.

●

Operator in seat.

Make periodic checks of the Safety System by attempting to start the engine when one of these conditions are not met.

If the engine starts when one of these conditions are not met, shut the Zero Turn Mower down and repair the safety system before using the Zero Turn Mower again.

Check to be sure the engine stops when the operator leaves the seat when the Parking brake is OFF.

Check to be sure the engine stops when the Zero Turn

Mower blades are engaged and the operator leaves the seat.

Check to be sure that engine stops if the Steering Levers are moved from the Neutral Lock position with the Parking Brake in the on position.

Parking Brake

The Zero Turn Mower must be standing still when

Parking Brake is applied.

The Parking Brake is designed to hold the Zero Turn

Mower in place when all forward or reverse motion has stopped.

NOTE: Applying the parking brake while in forward or reverse travel and the Steering Levers in the operating position will stop the engine and could do possible damage to the Hydrostat Drives.

Parking Brake Adjustment

Adjusting Nuts

Brake

Cable

The force on the brake handle to lock the brake in place should be 35 Lbs.

Adjust the brake tension by shortening or lengthening the

Brake Cable.

1. Raise the Zero Turn Mower and block up securely.

2. Remove drive wheels to gain access to the Brake

Cable and Adjusting Nuts.

3. Loosen the Adjusting Nuts to allow the Brake Cable to be moved up to remove slack in cable or down to slightly relieve tension on brake.

4. Tighten the Adjusting Nuts to maintain the adjustment.

5. Re-install drive wheels and torque lug nuts to 70 ft lbs.

Tire Pressure

All tire pressure should be at

15psi / 103kPa / 1 bar

HDE ZT 10/16

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MAINTENANCE

Caster Wheels

Roller

Bearing

Axle Nut

Grease

Fitting

Roller

Bearing

Axle Bolt

Flange

Bearing

Hub

Axle

Sleeve

Flange

Bearing

The Caster Wheels should be checked after every 200 hour of operation. Check that the wheels rotate freely on their axles. Check for excessive play on the Axle bolt and bearings.

If necessary remove the Caster Wheel from the yoke and disassemble the Wheel. Check the Axle Sleeve and

Roller Bearings for excessive wear and replace if needed.

To Disassemble:

1. Remove Axle Bolt and Nut.

2. Remove Wheel from yoke.

3. Remove Axle Sleeve.

4. Tap the Flange Bearings out of the hub.

5. Remove the Roller Bearings.

6. Clean Roller Bearings and Axle Sleeve removing old grease.

7. Clean the tube in the Hub of all old grease buildup.

To Reassemble:

1. Place the Roller Bearings into the Hub.

2. Re-insert the Flange Bearings into the Hub.

NOTE: The flat area on the Flange Bearing must be

positioned so it is beneath the grease fitting in the hub tube when installed.

3. Insert the Axle Sleeve through the Hub into the Flange

Bearings and Roller Bearings.

4. Put 10 shots of grease in both fittings on the Hub. Use

No 2 Lithium or Molybdenum grease.

5. Place the Wheel back in the yoke, insert the Axle Bolt, apply the Axle Nut and torque to 75 ft. lbs.

Anti-Scalp Rollers

Roller

Adjusting

Bolt

NOTE: All adjustments to Anti-scalp Rollers should be made with the Zero Turn Mower on a flat level surface.

Anti-scalp rollers should not be adjusted to support the

Zero Turn Mower deck. Supporting the Zero Turn Mower deck on the Anti-scalp rollers may damage the deck.

Adjust the Anti-scalp rollers so they are slightly off the ground when the deck is set at the desired cutting height.

There are 4 adjusting positions.

Check the rollers and adjusting bolt for wear often and replace when necessary.

HDE ZT 10/16

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MAINTENANCE

Mower Deck V-Belts

Mower deck V-Belts should be checked every 100 hours of usage and more often under heavy usage.

Inspect belts for severe cracking and large nicks.

NOTE: Belts will show small cracks under normal operation.

Mower Deck Belt Installation

To Clutch Pulley

Tension Rod

Outer Nut

Belt Tension

Idler Pulley

Mower Deck Belt Removal

Outer Nut

Tension Rod

Belt Tension

Idler Pulley

1. Park the Zero Turn Mower on a flat level surface and set the parking brake.

2. Lower the deck to its lowest cutting position.

3. Remove the foot plate and outer belt shields.

4. Let the tension off the Belt Tension Idler Pulley by backing off the outer nut on the Tension Rod until the belt has enough slack to be removed from the pulleys.

5. Remove the belt from the deck pulleys.

6. At the rear of the Zero Turn Mower remove the belt from the clutch pulley. Then remove the belt from under the Zero Turn Mower.

Inner Nut

BELT ROUTING DIAGRAM

For further reference, there is a Decal (Belt Installation Diagram) applied to the Deck.

1. Place the belt on the deck pulleys as illustrated above.

2. Route the belt to the clutch pulley and install.

3. Check to be sure there are no twist in the belt and the belt routing is correct.

4. Tighten the Outer Nut to apply tension to the Belt Tensioner Idler Pulley.

5. Before re-installing the foot plate the newly installed belt tension should be adjusted.

Adjusting the Mower Deck Belt

6. To adjust the belt tension, the spring should measure seven (7”) inches from the ends of loops, as shown in the illustration. This is achieved by turning the Adjusting Nuts on the Tension Rod against the Bracket.

5. When desired belt tension is achieved, tighten the two nuts against the bracket.

6. Re-Install the outer belt shields and foot plate.

Bracket

Tension Rod

7”

Spring Length

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Adjusting Nuts


MAINTENANCE

PUMP BELT

!

CAUTION

Servicing the Pump Belt will require the back end of the Zero

Turn Mower to be elevated to gain access to the belt area.

Parking Brake Set

Mower Deck Belt

Clutch Stop

Wheel Chocks

!

DANGER

Always set the Parking Brake and use wheel chocks on the front caster wheels before working under the Zero Turn

Mower.

Clutch

Automotive ramps will allow enough clearance to access the pump belts from the underside of th Zero Turn Mower.

If raising the Zero Turn Mower with a overhead hoist, raise the Zero Turn Mower and place jackstands under the Zero Turn Mower. Lower Zero Turn Mower down on the jackstands and chock the front wheels.

Pump Belt Removal

Pump Belt

Idler

Pulleys

1. Remove the foot plate to access the Mower Deck Belt.

2. The Mower Deck Belt must be removed from the

Clutch prior to working with the Pump Belt. Refer to

(Mower Deck Belt Removal) steps 4 and 6.

Tensioner

Adjusting

Nuts

3. Remove the Clutch Stop.

4. Release the tension on the Idler Pulleys by backing off the Tensioner Adjusting Nuts on the Tensioner Rod.

5. Remove the Pump Belt from the clutch pulley, idler pulleys and pump pulleys.

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Tensioner

Rod

Pump Pulley with

Cooling Fans

NOTE: The belt will need to be lifted over the cooling

fans attached to the top of pump pulleys.

MAINTENANCE

Pump Belt Installation

1.

Follow steps 1-4 of Pump Belt Removal.

2.

Place the belt over the Cooling Fans and into the pulley Groove.

3.

Place the belt on the Idler pulleys and pull the belt back to the clutch.

4.

Place the belt on the upper pulley above the Clutch.

5.

Check to be sure the belt is installed in all the pulley grooves and is not twisted.

6.

Tighten the belt using the Tensioner Adjusting Nuts on the Tensioner Rod. The Tensioner Rod end should be 2-5/16” from the frame obtain the proper

Belt tension. DO NOT OVER TIGHTEN!

Cutting Blade Maintenance

Best mowing results are achieved when blades are sharp and not damaged.

Replace blades that become bent or cracked while mowing.

!

WARNING

WHEN IT IS NECESSARY TO

RAISE THE DECK OR MOWER

FOR SERVICE OR MAINTENANCE, TO AVOID SERI-

OUS INJURY OR DEATH, STOP ENGINE, SET PARK-

ING BRAKE, SECURELY SUPPORT THE DECK OR

MOWER BEFORE WORKING UNDERNEATH.

Blade Removal

Tensioner

Adjusting

Nuts

Blade Washer

Tensioner

Rod

2 5 /

16

”

Blade

7. When desired tightness is achieved lock the Tensioner Rod position by tightening the Tensioner Adjusting Nuts.

8.

Place the Mower Deck Belt back on the Clutch.

9.

IMPORTANT! Re-Install the Clutch Stop.

Damage to the Clutch will result if Zero Turn

Mower is engaged without Clutch Stop Installed.

10. Adjust the Mower Deck Tension (See Adjusting

Mower Deck Belt).

11. Re-install the foot plate.

1. Lift deck and secure in raised position.

2. Remove Blade Bolt, Cup Washer, Blade and

Blade Washer from shaft.

Cup Washer

Blade Bolt

Inspect Blades

Blades should be discarded when worn excessively.

HDE ZT 10/16

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MAINTENANCE

Sharpening Blades

!

WARNING

When sharpening blades wear gloves and eye protection.

1. Sharpen blade with a hand file, electric grinder or blade sharpener.

2. Grind blade at original bevel.

3. Check balance of blade by positioning the blade on a nail or blade balance pedestal.

4. Grind the blade on the end that is heavier until both sides balance.

Installing Blades

IMPORTANT!

When installing blades be sure they are installed with the cutting edge down and the uplift facing up.

Adjusting the Mower Deck

IMPORTANT!

Check tire pressure before adjusting Mower Deck (See - Tire Pres-

sure). Under inflated or over inflated tires will not allow you to properly adjust your Zero Turn Mower deck

.

Leveling the Deck

Use The Following Steps to Level the Mowing Deck

1. Park the Zero Turn Mower on a hard level surface, turn the Zero Turn Mower off and set the parking brake.

2. Rotate the outer blades so the blade tips align with the deck sides as shown above. NOTE: wear heavy

gloves when working with blades.

Discharge

Side

Outer

Blades

1. Place Cup Washer on the Blade Bolt (cup side up) so the concave side will be against the blade.

2. Place the Blade Bolt through the blade mounting hole from the blades cutting side (Grass Side).

3. Place the upper side of the blade to the Blade Washer

(Smooth Side).

4. Put the Blade Bolt in the hole of the Blade Washer and push through.

5. Install the assembly in the spindle housing and tighten the Blade Bolt to 75 ft lbs torque.

3. Depress the deck lift pedal to raise the mower deck.

Place the Deck Height Adjusting Pin in the 3” adjusting hole and release the pedal.

4. Measure from the blade tip to the ground level and retain this measurement. Repeat this process on the opposite side.

Height Adjusting

Pin placed in the

3” adjusting hole.

Level Reference

Surface

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MAINTENANCE

5. Adjustment is achieved by turning the Adjusting Nuts at the Rear Deck Hangers on each side of the deck until the blade tips are at the 3” position.

(Right Hand Side Shown, Fender not shown for clarity.)

Height Adjustment Pin placed in 3” setting.

Adjusting Nut

Eye Bolts

Level

Transaxle Maintenance

This Zero Turn Mower has two Transaxles. The

Transaxles have external filters for ease of maintenance.

To ensure fluid quality and longer life, changing the oil and filter after the initial 50 hours of Zero Turn Mower usage then every 400 hours thereafter is recommended.

NOTE: Recommended oil is 20W50 motor oil.

The Zero Turn Mower must be parked on a level surface, parking brake set and bypass lever on each transaxle applied.

Allow the Zero Turn Mower to cool down before proceeding to perform maintenance.

Fluid and Filter Change Procedure

1. Remove the three 1/4” filter guard screws and filter guard. Clean any loose debris from around the perimeter of the filter.

2. Place an oil drain pan (12” or more diameter and 8 qt.

6. After the blade tips are at the 3” position on both sides, place a level on the top of the deck, positioned front to rear.

7. At the Front Hangers, turn the Adjusting Nuts on each side to raise or lower the deck until the deck is level.

Do this procedure on both sides of the deck.

8. Once the deck is level on both sides, check the level of the deck side to side by placing the level on the front of the deck. Some minor adjustment may be necessary.

9. After the deck is level on both sides, re-check the blade tips for the 3” position. Some minor adjustment may be necessary.

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capacity is optimal) beneath the oil filter. Remove the oil filter from the transaxle.

3. After the oil has drained, wipe the filter base surface off and apply a film of new oil to the gasket of the new replacement filter (Hydro-Gear part number 52114).

4. Install the new filter by hand, turn 3/4 to one full turn after the filter gasket contacts the filter base surface.

5. Re-install the filter guard with three 1/4” screws. Torque screws to 65 in. lbs.(7.3 Nm) each.


MAINTENANCE

6. Repeat steps 1-5 on the opposite side transaxle drive.

7. Drain old oil filters of all free flowing oil prior to disposal.

Place used oil in appropriate containers and deliver to an approved recycling collection facility.

8. Remove the Top Port Plug from the left side and right side transaxles prior to filling with oil. This will allow the transaxles to vent during oil fill.

Top Port Plug

9. Remove the cap from the transaxle’s Oil Reservoir

Tank located on the vehicle frame.

Oil Reservoir Tanks

10. Fill with 20W50 motor oil until oil just appears at the bottom of each transaxle’s top port (approximately 2 qts.

per transaxle, 4 qts. total). Install the top port plug into each transaxle as the oil level reaches this port.

Note: The oil volume figure shown does not include what is in the Oil Reservoir Tank hose or the Oil Reservoir

Tank.

11. Install and torque the Top Port Plugs to 180 in. lbs.

(20.3 Nm).

12. Continue to fill the transaxles through the Oil Reservoir Tank until the “Full Cold” line is reached on the Hydro-

Gear Oil Reservoir Tank.

13. Re-install the Oil Reservoir Tank cap by hand. Be careful to not overtighten.

14. Proceed to Purging Procedures.

Purging Procedures

These purge procedures should be implemented any time a hydrostatic system has been opened to facilitate maintenance or the oil has been changed.

Due to the effects air has on efficiency in hydrostatic drive applications, it is critical that it is purged from the system.

Air creates inefficiency because its compression and expansion rate is higher than that of the oil approved for use in hydrostatic drive systems.

The resulting symptoms in hydrostatic systems may be:

1. Noisy operation.

2. Lack of power or drive after short term operation.

3. High operation temperature and excessive expansion of oil.

Before starting, make sure the transaxle is at the proper oil level. If it is not, fill to the specifications outlined in this manual. Refer to steps 10-12 under

Fluid and Filter Change Procedure

The following procedures are best performed with the vehicle drive wheels off the ground. Then repeated under normal operating conditions.

If this is not possible, then the procedure should be performed in an open area free of any objects or bystanders.

1. Disengage the brake if activated.

2. With the bypass valve open and the engine running, slowly move the directional control in both forward and reverse directions (5 or 6 times).

3. With the bypass valve closed and the engine running, slowly move the directional control in both forward and reverse directions (5 to 6 times). Check the oil level, and add oil as required after stopping the engine.

4. It may be necessary to repeat Steps 2 and 3 until all the air is completely purged from the system. When the transaxle operates at normal noise levels and moves smoothly forward and reverse at normal speeds, then the transaxle is considered purged.

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Console Maintenance

MAINTENANCE

1!

r t y u

1@

1$

1#

1%

1) e q w i o

ITEM DESCRIPTION FUNCTION q

Engine Start/Stop Button

w

Key Code Buttons

Powers Engine ON / Powers Engine OFF.

Powers up Console by entering Key Code and enables specific functions

e

OK to Start Indicator Light

r

PTO Indicator LED as starting /stopping engine, engaging PTO.

Glows Green when safe to start engine, Red when unsafe.

Glows Red to indicate PTO is engaged.

t

Steering Lever Indicator LED Glows Reds when Steering Levers are not in Neutral position during startup

y

Parking Brake LED Glows Red if Parking Brake not set during startup.

u

Operator Position Indicator Glows Red if Operator is not in seat.

i

Low Oil Indicator LED

o

Fuel Level Indicator LED

Alerts Operator when Engine oil is low.

Alerts Operator when Fuel is low.

1)

PTO Switch

1!

LCD Display

1@

Key Pad Button 1

1#

Key Pad Button 2

1$

Key Pad Button 3

1%

Key Pad Button 4

Engages /Disengages Mower Blades.

Indicates Hours, Service Alerts, Engine RPM, and Voltage.

Enter Functions

Enter Functions

Enter Functions

Enter Functions

HDE ZT 10/16

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MAINTENANCE

Console Maintenance

General Care

The Console is a completely sealed instrument designed to withstand exposure to outdoor environments. Pressure washing of the console face is acceptable when water spray pressure does not exceed 2000 psi while using a

30 degree or greater nozzle tip (fan spray) at a distance no closer than 12”. Oil, gasoline, chemicals and detergents spilled on the console should be wiped off immediately with a clean dry cloth.

Never use abrasive or corrosive cleaning products on the

console.

Bypassed or Failed Safety Interlock Switch

Detection

While monitoring the safety interlocks, the console identifies interlock switches that have failed, closed, or have been bypassed closed. When the console detects a failed or bypassed switch, it slowly flashes the corresponding indicator LED and flashes “SEAT”/”BRAKE”/”DRIVE”

“INTLK” “FAULT” on the LCD.

The console allows the equipment to continue operating normally for a short time after detecting a potentially faulty switch to allow the equipment to return to a service area, locking out engine operation after this time is exhausted.

To clear this error, replace or repair the faulty interlock switch and open the switch while the console is unlocked by entering your Key Code.

Service Alerts

Service alerts remind the operator to perform specific maintenance tasks based on equipment run time. While the console is unlocked by entering your Key Code, click key code button 1 (12) once to enter service alert display, and again as needed to select the desired alert to display.

The display returns to engine hour meter after 30 seconds of inactivity.

To Reset A Service Alert:

a. Begin with the console unlocked by entering your Key

Code. The console must be unlocked to reset a service alert.

b. Select the service alert to reset by clicking keypad button 1(12) until the LCD shows the desired service message.

c. Press and hold keypad button 1 (12) for 6 seconds.

d. Release the button when the LCD shows “00000”.

Alarms

Low Oil Alarm - If the oil pressure switch closes for ten seconds while the engine is running, the console displays

“OIL” “PSI” on the LCD (11), flashes the low oil alarm

LED indicator, and shuts down the engine. The alarm is reset when the engine is restarted, or when the console goes to sleep.

The alarm may also be configured to lock out the PTO but leave the engine running. In this configuration, the alarm is immediately reset when the oil pressure switch opens.

Low Voltage Alarm - While the console is unlocked by entering your Key Code, and the system voltage is below

12.0 V for 90 seconds, the console displays “LOW

VOLTS” and the current system voltage. This alarm is reset when the system voltage rises above 12.0 V or when the console goes to sleep.

High Voltage Alarm - While the console is unlocked by entering your key code, and the system voltage is above

15.0 V for more than 2 seconds the console displays

“HIGH VOLTS” and the current system voltage. This alarm is reset when the system voltage drops below 15.0

V or when the console goes to sleep.

HDE ZT 10/16

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22

23

24

25

18

19

20

21

14

15

16

17

10

11

12

13

30

39

40

26

27

28

29

MAINTENANCE

Console Diagnostic Codes

When a fault is detected by the console it is displayed on the LCD (14) as a numeric code. Below is a chart of the error codes and potential sources

.

ERROR DESCRIPTION

CODE #

Check battery condition and connections, check starter solenoid wiring for shorts

Check battery condition and connections, check PTO and PTO wiring for shorts.

Check battery condition and connections, check fuel solenoid and fuel solenoid wiring for shorts.

Check headlight wiring for shorts.

Check battery condition and connections, check wiring for shorts.

Check battery condition and connections.

Check battery condition and connections, check starter and fuel solenoid connections for shorts


Check battery connections, check fuel solenoid and wiring for shorts.

Check battery connections.

Check battery condition and connections.

Check battery condition and connections, check all wiring for shorts.

Excessive system current.

Check battery condition and connections, check starter solenoid wiring for shorts.


Check PTO current.



Excessive system current,


Console internal fault.

Console internal fault, some or all power functions disabled.

Console internal fault.

HDE ZT 10/16

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STORAGE

SECTION 7

STORAGE

Winter Storage

At the end of the mowing season, or when it will not be in use for more than 30 days, the Zero Turn Mower should be readied for storage.

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 to the sticky residues that can occur during storage.

Add stabilizer to the fuel in the tank and 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 dryer, etc. Handle the fuel with care. Gasoline Fumes are very flammable and can cause serious personal injury and property damage. Drain the fuel into an approved container outdoors and store far away from open flame or sources of ignition. Never use gasoline for cleaning. Use a degreaser and warm water instead.

Preparing the Machine for storage:

1. Thoroughly clean the Zero Turn Mower, especially under the Zero Turn Mower deck. Touch up damage to the paint and spray a thin layer of oil on the underside of the Zero Turn Mower deck to avoid corrosion.

2. Inspect the Zero Turn Mower 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 spark plug and pour about a tablespoon of engine oil into the cylinder. Turn over the engine so that the oil is evenly distributed and then re-install the spark plugs.

6. Lubricate all grease fittings, joints, and axles.

7. Remove the battery. Clean, charge, and store the battery in a cool place, but protect it from direct cold or freezing.

8. Store the Zero Turn Mower in a clean, dry place and cover it for extra protection.

New Season Preparation

Before starting the mower following post season storage, the following service is required:

IMPORTANT!

Always check that fresh oil has been added to Zero Turn Mower. If oil is drained at season’s end and not replaced, engine damage will result.

1. Clean Zero Turn Mower, removing trash and dirt accumulation.

2. Check engine oil and hydraulic oil levels.

3. Fill fuel tank with fresh fuel. Run Zero Turn Mower at half speed for 5 minutes, checking operation of steering control lever. Stop engine and check for oil leaks, loose fittings.

4. Tighten any bolts that have loosened and make sure all hair pins, cotter pins and clevis pins are in place.

5. Check that all safety shields are in place and secure and review safety precautions listed in this manual.

6. Check Mower belt and drive belt for damage or severe cracking and replace if needed.

7. Check Mower blades for sharpness and damage. Replace or sharpen if needed.

8. Check and inflate tires to 15 psi / 1 bar / 103 kPa.

9. Install fully charged battery and attach the battery cables.

10. Check Safety system startup. Refer to Safety Sys-

tem in the Maintenance Section.

11. Refer to engine manual for more information.

IMPORTANT!

If Service Parts are required after New Season Preparation check is completed use only Genuine Bush Hog

Parts. The use of “Wiil Fit” parts may reduce Zero

Turn Mower performance, void warranty and pres-

ent a safety hazard.

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Storage Section 7-1

TROUBLE SHOOTING

SECTION 8

PROBLEM

CAUSE

ENGINE WILL NOT START

Battery Dead

PTO Switch Engaged

Steering Levers not in Neutral Lock Position

Parking Brake Not Set

Contamination in Carburetor or Fuel Line

Clogged Fuel Filter

Ignition System Faulty

STARTER DOES NOT TURN OVER

Dead Battery

Poor contact of the battery cable connection

Blown Fuse

Faulty Starter

Parking Brake not set.

Steering Levers not in the Neutral Lock position.

Clutch is engaged.

BATTERY NOT CHARGING

Poor contact of the battery cable connection

Charging Lead Disconnected

Faulty engine charging system

ENGINE RUNS ROUGH

Faulty Carburetor

Clogged Fuel Filter

Water in fuel

Fuel tank near empty

Rich Fuel mixture or fuel air mixture

Wrong type fuel

Clogged air filter

Fouled Spark Plug

Clogged ventilation valve fuel cap

ENGINE POWER IS WEAK

Clogged Air Filter

Fouled Spark Plugs

Carburetor out of adjustment

Air trapped in hydraulic system

MACHINE VIBRATES

Loose Blade or Blades

Blades not balanced

Engine mount bolts loose

TROUBLE SHOOTING

PROBLEM

CAUSE

ENGINE OVERHEATS

Clogged air intakes or cooling fins

Engine overloaded

Low Oil

Contamination in fuel line

Fouled Spark Plugs

MACHINE MOVES SLOW, UNEVEN, NOT AT ALL

Park Brake engaged

Bypass linkage engaged

Pump Belt for tranmissions loose or has come off

Air in hydraulic system

MOWER DECK NOT ENGAGING

Drive Belt has come off

Mower Belt tension needs adjusting

Faulty electromagnetic clutch

Connection to clutch is loose or off

Faulty PTO switch

Blown Fuse

TRANSAXLE LEAKING OIL

Damaged seals, housing or gaskets

Air trapped in hydraulic system

UNEVEN MOWING

Air pressure not equal in all tires

Bent blade or blades

Mower Deck not adjusted level

Blades are dull

Driving speed to fast

Grass too high

Grass build up under Zero Turn Mower deck

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Trouble Shooting Section 8-1

TECHNICAL DATA

SECTION 9

TECHNICAL DATA

MAIN WIRING HARNESS ASSEMBLY

To RH Neutral Switch

Brown

Orange

Blue/White

Green

To Seat Switch

Black

To Fuel Sender

Yellow

To Battery Ground

Black

NOTE: 15 AMP fuse located behind seat between the front of engine and fuel tank.

15 AMP

Fuse

Red

Green

Violet

Green

To LH Neutral Switch

Orange

To Parking Brake

To Oil Pressure

Gray/Black

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To Electromagnetic Clutch

Blue/Black

Technical Data Section 9-1

TECHNICAL DATA

BROWN 18GA.

DELPHI 2973872 (RH HANDLE)

VIOLET 18GA.

18-22 GA. (SEAT)

18-22 GA. (SEAT)

30 AMP FUSE HOLDER IN-LINE/SPLASH-PROOF

(ENGINE OIL PRESSURE)

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BLACK 14GA.

5/16 RING 14-16 GA. (BATTERY) GROUND (-)


TECHNICAL DATA

FUEL SOLENOID

MAGNETO TO GROUND

3

6

2

5

1

4

ALT OUTPUT

CONNECTOR

MALE 6 POSITION

OIL SENDER

BROWN 18 GA.

RED/BLACK 18 GA.

RED 14 GA.

CONNECTOR

FEMALE 9 POSITION

4

7

1 2 3

5 6

8 9

GRAY/BLACK 18 GA.

BATTERY (+) RED 14 GA.

GROUND/SOLENOID

STARTER/SOLENOID

BLACK 14 GA.

PURPLE 14 GA.

HDE ZT 10/16

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TECHNICAL DATA

ENGINE ADAPTOR HARNESS for KAWASAKI ENGINES

FUEL SOLENOID


VOLTAGE REGULATOR

OIL SENDER

BATTERY (+)

GROUND/SOLENOID

STARTER/SOLENOID

BROWN 18 GA.


RED 12 GA.


RED 14 GA.

BLACK 14 GA.

PURPLE 14 GA.

4

7

2

5

8

6

9

CONNECTOR


HDE ZT 10/16

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TECHNICAL DATA

ENGINE ADAPTOR HARNESS for KOHLER ENGINES

3

6

2

5

1

4

FUEL SOLENOID


ALT OUTPUT

CONNECTOR

MALE 6 POSITION

OIL SENDER

BROWN 18 GA.


RED 14 GA.

CONNECTOR


1 2 3

4 5 6

7 8 9


BATTERY (+) RED 14 GA.

GROUND/SOLENOID BLACK 14 GA.

STARTER/SOLENOID PURPLE 14 GA.

HDE ZT 10/16

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TECHNICAL DATA

HDE ZT 10/16

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TECHNICAL DATA

SERVICE and MAINTENANCE RECORDS

Service or Maintenance Date Meter

Performed Hours

HDE ZT 10/16

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Printed in U.S.A.

HDE SERIES

ZERO TURN MOWER

P/N 50077697

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