Alamo Bush Hog HDC-3 Series Operator'S Manual Download Page 98

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TECHNICAL DATA

HDC-3 ZT 05/19

Technical Data Section 9-4

50076065

ENGINE ADAPTOR HARNESS for KOHLER ENGINES

1 2 3
4 5 6

8 9

BATTERY (+) RED 14 GA.

GROUND/SOLENOID BLACK 14 GA.

STARTER/SOLENOID PURPLE 14 GA.

CONNECTOR

FEMALE 9 POSITION

OIL SENDER

GRAY/BLACK 18 GA.

CONNECTOR

MALE 6 POSITION

ALT OUTPUT

RED 14 GA.

MAGNETO TO GROUND

RED/BLACK 18 GA.

FUEL SOLENOID

BROWN 18 GA.

TECHNICAL

Summary of Contents for Bush Hog HDC-3 Series

Page 1: ...HDC 3 SERIES ZERO TURN MOWERS MODELS HDC2361FS3 HDC2561KP3 Published 05 19 Manual Number 50080652 2019 Alamo Group Inc ...

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Page 3: ... Exceeding 15 De grees is unsafe and can cause upset or loss of traction resulting in serious injury or death q w E q Fold along the dashed line to measure the slope being checked w 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 ...

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Page 5: ...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 ...

Page 6: ...t 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 the...

Page 7: ...ROPS to be rocked forward to align the Pin Out Holes Retractable seat belt functions property 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 li...

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Page 9: ...ZARDS 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 ...

Page 10: ...moving 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 Ter...

Page 11: ...ss or Failed Safety Interlock Switch Detection 6 14 Service Alerts 6 14 Alarms 6 14 Console Diagnostic Codes 6 15 SPARK ARRESTOR MAINTENANCE 6 16 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 with FUSE LOCATIONS 9 1 MAIN WIRING HARNESS SCHEMATIC 9 2 ENGINE ADAPTOR HAR...

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Page 13: ...SAFETY SECTION 1 ...

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Page 15: ...SAFETY SAFETY HDC 3 ZT 05 19 Safety Section 1 1 2019 Alamo Group Inc ...

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Page 31: ...SAFETY SAFETY 2019 Alamo Group Inc HDC 3 ZT 05 19 Safety Section 1 17 ...

Page 32: ...SAFETY HDC 3 ZT 05 19 Safety Section 1 18 SAFETY 2019 Alamo Group Inc ...

Page 33: ...2 Danger Decal Rotating Blades 2 D641 1 Warning Decal Pinch Point Hazard 3 D916 1 Danger Decal Do Not Mow without Discharge Chute in Place 4 D917 1 Danger Decal Thrown Object Hazard 5 D918 2 Warning Decal Keep Shields In Place 6 50077946 1 Installation Decal Mower Belt 7 D943 1 Not A Step Decal Under Shield Under Shield q u r e w y t t w q ...

Page 34: ...Ÿ 1R IXPHV PLHQWUDV UHSRVWDV FRPEXVWLEOH D951 Q1 q 1 ITEM PART NO QTY DESCRIPTION 1 D859 1 Warning Use Genuine Bush Hog Parts 2 D919 1 Warning Crushing Hazard 3 D920 1 Instruction Maintain ROPS English 4 D921 1 Warning Hot Surface 5 D922 1 Instruction Maintain ROPS Spanish 6 D923 1 Warning Crushing Hazard 7 D924 1 Caution Hearing Protection 8 D925 1 Caution Avoid Equipment Fires Spanish 9 D926 1 D...

Page 35: ...SAFETY SAFETY 2019 Alamo Group Inc HDC 3 ZT 05 19 Safety Section 1 21 Safety Decal Pictorials ...

Page 36: ...HDC 3 ZT 05 19 Safety Section 1 22 Safety Decal Pictorials SAFETY SAFETY 2019 Alamo Group Inc ...

Page 37: ...SAFETY SAFETY 2019 Alamo Group Inc Safety Decal Pictorials HDC 3 ZT 05 19 Safety Section 1 23 ...

Page 38: ...SAFETY SAFETY 2019 Alamo Group Inc HDC 3 ZT 05 19 Safety Section 1 24 ...

Page 39: ...INTRODUCTION SECTION 2 ...

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Page 41: ...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...

Page 42: ... Zero Turn has a 8 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 ava...

Page 43: ...ons 87 Octane Unleaded Gasoline TRANSAXLES 2 Hydro Gear ZT 3400 Hydrostats TIRES Front 13 x 6 5 6 Rear 23 x 10 5 12 Turf Tires Standard 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 10 mph Forward 0 4 mph Reverse DECK SPECIFICATIONS CUTTING WIDTHS 61 OVERALL WIDTH CH...

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Page 45: ...CONTROLS SECTION 3 ...

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Page 47: ...TROL LOCATIONS 1 Transaxle Bypass Linkage 2 Fuel Cap 3 Steering Control Levers 4 Parking Brake Lever 5 Deck Lift Pedal 6 Seat Adjusting Lever 7 Deck Height Adjusting Knob 8 Start Stop Button 9 Mower PTO Switch 10 USB Charging Socket 11 Choke 12 Engine Throttle Control 13 Tracking Adjusting Control 14 Deck Transport Lock ...

Page 48: ...rs 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 Alerts Operator when Engine oil is low o Fuel Level Indicator LED Alerts Operator when Fuel is low 1 PTO Switch Engages Disengages Mower Blades 1 LCD Display Indicates Hours Service Alerts Engi...

Page 49: ...g 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 IGNITION SWITCH CHOKE The Choke provides a richer fuel mixture to the engine to assist on cold starts Pull the choke up to en...

Page 50: ...e 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 WARNING Speed Tracking Adjusting The Speed Tracking Adjustment Screws located on the panels under the seat arm rest on each side allow the operator to adjust the forward speed of each Steering Control Lever so the ...

Page 51: ...wer near an open flame Clean away any spilled fuel after re fueling and before re starting the Zero Turn Mower Check the gas fill cap often for damage to gasket If dam aged replace the fill cap The engine is designed to operate on 87 Octane un leaded gasoline Damage to the engine may occur if E85 Alcohol based fuel or Methanol fuel is used The Cutting Height is controlled by the Height Control Kno...

Page 52: ...urn Mower can be moved Refer to Moving the Zero Turn by Hand in the Opera tion Section NOTE The Tansaxle Bypass Linkages must be disen gaged in order for the Zero Turn Mower to move forward or backward under its engine power 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 ...

Page 53: ...rn Mower into operation NOTE If the Parking Brake is not set in the Park po sition 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 op erating position will stop the engine and could do possible damage to the Hy...

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Page 55: ...OPERATION SECTION 4 ...

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Page 57: ...ll 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 ...

Page 58: ...e 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 Operating the Mower The Mowing Height is controlled by the Foot Control Pedal and a Height Adjusting Knob Mowing Height is adjustable from 1 1 2 to 5 in 1 4 in crements NO...

Page 59: ...n Slopes Safety To avoid tipover drive across slopes not up and down If ma chine 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 start ing up or down hills 2 Avoid stopping or changing speed on hills 3 If you must stop place the steering levers in the neu tral lock position and e...

Page 60: ... After Mowing is Completed After the Zero Turn Mower is shut down and the engine has cooled use compressed air to clean the top sur faces of the Zero Turn Mower deck and frame If com pressed 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 Zer...

Page 61: ...ng The minimum capacity battery for this Zero Turn Mower is a 12 Volt 350 cranking amp Lawn and Garden Lead acid Batteries generate explo sive 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 shor...

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Page 63: ...TRANSPORTING SECTION 5 ...

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Page 65: ...The ramp should be 4 times longer than the height of the trailer to prevent angles above 15 degrees WARNING CAUTION Trailer Height 4 Times Trailer Height 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 compo nents may hang up on the transition from the ramp to the trailer bed When loading the Zero Tur...

Page 66: ... 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 traile...

Page 67: ...MAINTENANCE SECTION 6 ...

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Page 69: ...ate the deck lift pivots Every 100 hours 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 Check And Clean Spark Arrestor Every 200 hours Change the engine oil filter Every 250 hours Replace the primary...

Page 70: ...t points every 50 hours and more frequently in dusty or sandy conditions 4 2 shots grease at 50 hours to the Pump Idler Pivot 1 2 3 Lubrication Points on the Zero Turn Mower Deck 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 Spin dles 2 2 shots of grease eve...

Page 71: ...el 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 t...

Page 72: ...emove the bat tery 3 Rinse the battery with plain water and dry CAUTION BATTERY TERMINALS HOLD DOWN STRAP 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 se verely d...

Page 73: ...gine stops if the Steering Levers are moved from the Neutral Lock position with the Park ing 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 Steeri...

Page 74: ... the Flange Bearing must be positioned so it is beneath the grease fitting in the hub tube when installed Axle Bolt Hub Axle Nut Axle Sleeve Flange Bearing Flange Bearing Grease Fitting Roller Bearing Roller Bearing 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...

Page 75: ...ot plate MAINTENANCE MAINTENANCE HDC 3 ZT 05 19 Maintenance Section 6 7 2019 Alamo Group Inc 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 oper ation Mower Deck Belt Removal 1 Park the Zero Turn Mower on a flat level surface and set th...

Page 76: ...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 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 3 Remove the Clutc...

Page 77: ...on 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 T...

Page 78: ...lade 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 Adjusting the Mower Deck Check tire pressure before adjust ing 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 ...

Page 79: ...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 sur face parking brake set and bypass lever on each transaxle applied Allow the Zero Turn Mower to cool down before pro ceeding to perform maintenance Fluid ...

Page 80: ...ance 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 ex pansion 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 a...

Page 81: ...ral 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 Alerts Operator when Engine oil is low o Fuel Level Indicator LED Alerts Operator when Fuel is low 1 PTO Switch Engages Disengages Mower Blades 1 LCD Display Indicates Hours Service Alerts Engine RPM and Voltage...

Page 82: ...tering 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 sec onds of inactivity To Reset A S...

Page 83: ...s check wiring for shorts 17 Check battery condition and connections 18 Check battery condition and connections check starter and fuel solenoid and wiring for shorts 19 Check battery connections and connections check PTO and PTO wiring for shorts 20 Check battery connections check fuel solenoid and wiring for shorts 21 Check battery connections check headlight wiring for shorts 22 Check battery co...

Page 84: ...oot and carbon The amount of carbon collected will vary with fuel used air quality engine age and condition A soft metel brush may be required to fully clean the screen 4 Cartefully inspect the screen for any tears rips or any other damage which will prevent the screen from operating properly Replace screen if damaged 5 Re install the cleaned and inspected screen Installation 1 Insert the screen i...

Page 85: ...STORAGE SECTION 7 ...

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Page 87: ...er 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 WARNING 6 Lubricate all grease fittings joints and axles 7 Remove the battery Clean charge and s...

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Page 89: ...TROUBLE SHOOTING SECTION 8 ...

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Page 91: ...ged ventilation valve fuel cap Clogged Spark Arrestor ENGINE POWER IS WEAK Clogged Air Filter Fouled Spark Plugs Carburetor out of adjustment Air trapped in hydraulic system Clogged Spark Arrestor MACHINE VIBRATES Loose Blade or Blades Blades not balanced Engine mount bolts loose PROBLEM CAUSE ENGINE OVERHEATS Clogged air intakes or cooling fins Engine overloaded Low Oil Contamination in fuel line...

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Page 93: ...TECHNICAL DATA SECTION 9 ...

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Page 95: ...n Fuel Sender Black Yellow Battery Ground Black Fuse 30AMP Red Oil Pressure Gray Black L H Neutral Switch Orange Green Parking Brake Violet Green Engine Connector to Adaptor Harness Lights Red White Black Electromagnetic Clutch Black Blue MAIN WIRING HARNESS ASSEMBLY NOTE 15 AMP fuse located behind seat between the front of engine and fuel tank 1 AMP Fuse for Auxillary Power Source located in the ...

Page 96: ...TECHNICAL DATA TECHNICAL HDC 3 ZT 05 19 Technical Data Section 9 2 2019 Alamo Group Inc MAIN WIRING HARNESS SCHEMATIC ...

Page 97: ...TECHNICAL DATA HDC 3 ZT 05 19 Technical Data Section 9 3 2019 Alamo Group Inc 50077206 ENGINE ADAPTOR HARNESS for KAWASAKI ENGINES TECHNICAL ...

Page 98: ...ARNESS for KOHLER ENGINES 1 2 3 4 5 6 7 8 9 BATTERY RED 14 GA GROUND SOLENOID BLACK 14 GA STARTER SOLENOID PURPLE 14 GA CONNECTOR FEMALE 9 POSITION 1 2 3 4 5 6 OIL SENDER GRAY BLACK 18 GA CONNECTOR MALE 6 POSITION ALT OUTPUT RED 14 GA MAGNETO TO GROUND RED BLACK 18 GA FUEL SOLENOID BROWN 18 GA TECHNICAL ...

Page 99: ...TECHNICAL DATA HDC 3 ZT 05 19 Technical Data Section 9 5 2019 Alamo Group Inc TECHNICAL ...

Page 100: ...TECHNICAL DATA HDC 3 ZT 05 19 Technical Data Section 9 6 2019 Alamo Group Inc SERVICE and MAINTENANCE RECORDS Service or Maintenance Date Meter Performed Hours TECHNICAL ...

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Page 102: ...HDC 3 SERIES ZERO TURN MOWER P N 50080652 Printed in U S A ...

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