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Alamo Bush Hog HDE-4 Series, Operator'S Manual

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Alamo Bush Hog HDE-4 Series Operator'S Manual Download Page 34

SAFETY

SAFETY

© 2020 Alamo Group Inc.

ZTR  04/20

Safety Section 1-21

Safety Decal Location Power Unit

ITEM

PART NO.

QTY.

DESCRIPTION

1

D1028

1

Decal, Warning - Hot Surface

2

D1015

1

Decal, Warning - Towing

3

D1021

1

Decal, Warning - Operators Manual

4

D859

1

Decal, Warning - Genuine Bush Hog Parts

5

D1033

1

Decal, Warning - Avoid Injury

6

D1014

1

Decal, Warning - Tip Over

7

D1018

1

Decal, Warning - Equip. Fires

8

D1020

1

Decal, Warning - Hearing

9

D1030

1

Decal, Warning - Hazard (Spanish)

10

D1029

1

Decal, Warning - Crushing Hazard

11

50079856

2

Decal, Tracking

12

D922

1

Decal, Instruction - Maintain ROPS (Spanish)

13

D920

1

Decal, Instruction - Maintain ROPS (English)

Summary of Contents for Bush Hog HDE-4 Series

Page 1: ...HDE 4 SERIES ZERO TURN MOWERS MODELS HDE2049KT4 HDE2249FS4 HDE2255FS4 HDE2555KP4 HDE2261FS4 HDE2561KP4 Published 04 20 Manual Number 50081705 2020 Alamo Group Inc ...

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Page 3: ...e Exceeding 15 De grees is unsafe and can cause upset or loss of traction resulting in death or serious injury q w 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: ... 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 WARRANT...

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: ...RUN OVER HAZARDS 1 10 CHILD SAFETY 1 11 FUEL FIRE SAFETY 1 12 1 13 MAINTENANCE SERVICE AND STORAGE SAFETY 1 14 1 15 HIGH PRESSURE OIL LEAK HAZARD 1 16 BATTERY SERVICE PRECAUTIONS 1 17 DRIVING AND TRANSPORTING ON PUBLIC ROADS 1 18 PARTS INFORMATION 1 19 SAFETY DECAL LOCATIONS MOWER DECK 1 20 SAFETY DECAL LOCATIONS POWER UNIT 1 21 SAFETY DECAL PICTORIALS 1 22 1 24 FEDERAL LAWS and REGULATIONS 1 25 I...

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: ... 6 14 Bypass 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 9 1 MAIN WIRING HARNESS SCHEMATIC 9 2 ENGINE ADAPTOR HARNESS for K...

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Page 33: ...DESCRIPTION 1 D1032 2 Decal Warning Keep Shields In Place 2 D1016 2 Decal Warning Pinch Points 3 D1022 1 Decal Warning Thrown Objects Hazard 4 D1024 1 Decal Warning Do Not Mow Without Discharge Chute 5 D1026 1 Decal Notice Not A Step 6 D1025 2 Decal Warning Rotating Blades 7 50077946 1 Decal Belt Installation Guide ...

Page 34: ...ning Operators Manual 4 D859 1 Decal Warning Genuine Bush Hog Parts 5 D1033 1 Decal Warning Avoid Injury 6 D1014 1 Decal Warning Tip Over 7 D1018 1 Decal Warning Equip Fires 8 D1020 1 Decal Warning Hearing 9 D1030 1 Decal Warning Hazard Spanish 10 D1029 1 Decal Warning Crushing Hazard 11 50079856 2 Decal Tracking 12 D922 1 Decal Instruction Maintain ROPS Spanish 13 D920 1 Decal Instruction Maintai...

Page 35: ...SAFETY SAFETY 2020 Alamo Group Inc ZTR 04 20 Safety Section 1 22 Safety Decal Pictorials ...

Page 36: ...ZTR 04 20 Safety Section 1 23 Safety Decal Pictorials SAFETY SAFETY 2020 Alamo Group Inc ...

Page 37: ...SAFETY SAFETY 2020 Alamo Group Inc Safety Decal Pictorials ZTR 04 20 Safety Section 1 24 ...

Page 38: ...SAFETY SAFETY 2020 Alamo Group Inc ZTR 04 20 Safety Section 1 25 ...

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

Page 40: ......

Page 41: ...stance 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 deal...

Page 42: ...o 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 excep tional maneuverability The Zero Turn Mower Deck is availa...

Page 43: ...age PTO Electromagnetic Clutch rated at 200 FT LBS FUEL CAPACITY 8 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 ...

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

Page 46: ......

Page 47: ...s 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 12 Tracking Adjusting Control t y u i o 1 1 1 1 q w e r Under Engine Under Armrest Under Armrest ...

Page 48: ...e to start engine Red when unsafe r PTO Indicator LED 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 Alerts Operator when Engine oil is low o F...

Page 49: ...ring 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...

Page 50: ... 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 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 Zero...

Page 51: ... Brake Lever PTO Switch 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 t...

Page 52: ...cated on the left hand side toward the rear of the seat The Fuel Cap is tethered to the tank to avoid dropping when refueling the Zero Turn Mower Gasoline is highly flammable The en gine and exhaust system become very hot during operation Allow engine and exhaust system to cool down before re fueling the Zero Turn Mower Use CAUTION and only fill outdoors Fill to the bottom of the filler neck DO NO...

Page 53: ...tion 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 Transaxle Bypass Control Transaxle Bypass Linkages 2 The Backrest Angle Adjustment...

Page 54: ......

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

Page 56: ......

Page 57: ... 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 t...

Page 58: ... 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 Operating the Mower The Mowing Hei...

Page 59: ...ng on 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 a...

Page 60: ...neven 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 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 o...

Page 61: ...harging 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...

Page 62: ......

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

Page 64: ......

Page 65: ...Mowers width The ramp should be 4 times longer than the height of the trailer to prevent angles above 15 degrees 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 death or injury Mower compo nents may hang up on the transition from the ramp to the trailer bed When loading the Zero Turn M...

Page 66: ...ng 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 trai...

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

Page 68: ......

Page 69: ...e 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 a...

Page 70: ...t 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 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 grea...

Page 71: ...ge English 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 proced...

Page 72: ... Strap Remove the bat tery 3 Rinse the battery with plain water and dry 4 Clean the terminals with a wire brush removing all corrosion and coat the terminals with a lite coat of bat tery 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 damaged replace the cables BATTERY...

Page 73: ...ne 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 Steering...

Page 74: ...he 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 Axle Bolt Hub Axle N...

Page 75: ...foot plate MAINTENANCE MAINTENANCE ZTR 04 20 Maintenance Section 6 7 2020 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 the p...

Page 76: ...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 Clutch Stop 4 Release the tension on the Idler Pulleys by backing off the Tensioner Adjusting N...

Page 77: ...htening the Tensioner Ad justing 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 Cutting Blade Maintenance Best mowing results are achieved when blades are sharp and not da...

Page 78: ...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 Use The Following Steps to Level the Mow...

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

Page 80: ...e 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 afte...

Page 81: ... 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 Alerts Operator when Engine oil is low o Fuel Level Indicator LED Alerts Operator when Fuel is low 1 PTO Switch Engag...

Page 82: ...onsole 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 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 ...

Page 83: ...ns 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 c...

Page 84: ...uality 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 oper ating properly Replace screen if damaged 5 Re install the cleaned and inspected screen Installation 1 Insert the screen into the tailpipe on the muffler until the retaining ring is against the tip...

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

Page 86: ......

Page 87: ...uel 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 a...

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

Page 90: ......

Page 91: ... 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 PROBLEM CAUSE MACHINE VIBRATES Loose Blade or Blades Blades not balanced Engine mount bolts loose ENGINE OVERHEATS Clogged air intakes or cooling fins Engine overloaded Low Oil Contamination in fuel line Fo...

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

Page 94: ......

Page 95: ... To Fuel Sender Black Yellow To Battery Ground Black Fuse Red To Oil Pressure Gray Black To LH Neutral Switch Orange Green To Parking Brake Green Violet To Engine Connector To Electromagnetic Clutch Blue Black MAIN WIRING HARNESS ASSEMBLY To Adaptor Harness To Control Module Connector 15 AMP NOTE 15 AMP fuse located behind seat between the front of engine and fuel tank ...

Page 96: ...LACK 16GA BLACK 14GA VIOLET 18GA BLUE 14GA BLACK 14GA BLUE WHITE 18GA BROWN 18GA BLUE 14GA RED CLUTCH WIRE BLACK CLUTCH WIRE 2 WAY CONNECTOR DELPHI 2984883 CLUTCH PIN 7 RED BLACK 18GA PIN 1 RED 14GA BLUE WHITE 18GA RED 16GA ORANGE BLACK 18GA BLACK 16GA BLACK 16GA BLACK 14GA YELLOW GREEN 18GA MOLEX 39 01 2200 CONNECTOR 5 16 RING 14 16 GA BATTERY GROUND BLACK 14GA FEMALE BULLET 14 18 GA ENGINE OIL P...

Page 97: ... ADAPTOR HARNESS for KAWASAKI ENGINES 2 4 5 6 7 8 9 BROWN 18 GA FUEL SOLENOID RED BLACK 18 GA MAGNETO TO GROUND RED 12 GA VOLTAGE REGULATOR GRAY BLACK 18 GA OIL SENDER RED 14 GA BLACK 14 GA BATTERY GROUND SOLENOID PURPLE 14 GA STARTER SOLENOID CONNECTOR FEMALE 9 POSITION TECHNICAL ...

Page 98: ...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 ZTR 04 20 Technical Data Section 9 5 2020 Alamo Group Inc TECHNICAL ...

Page 100: ...TECHNICAL DATA ZTR 04 20 Technical Data Section 9 6 2020 Alamo Group Inc SERVICE and MAINTENANCE RECORDS Service or Maintenance Date Meter Performed Hours TECHNICAL ...

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Page 102: ...HDE 4 SERIES ZERO TURN MOWER P N 50081705 Printed in U S A ...

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