Simplicity 5901597 Operator'S Manual Download

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3. Before removing the tank cap (C), make sure that the

area around the tank cap and fill neck of the tank is free

of dust, dirt, and other debris. Remove the tank caps.

4. Add oil up to the "FULL COLD" mark.
5. Re-install the tank cap.
6. After adding oil to the tanks, it may be necessary to purge

air from the hydraulic system. If the unit is not driving

properly perform the

Purging the Air from the Hydraulic

System

procedure.

Transmission Oil Filter Change

Change Interval:

Every 400 Hours or Yearly (Initial hydraulic

oil and filter change after first 100 hours of operation).

Filter Part Number:

5104385X1

Note:

Removing the oil filter from the transaxle will drain the

oil tank. Have a suitable container ready to catch any spilled

oil. The manufacturer recommends that this be a dealer-only

service item.
1. Locate the hydraulic oil filter on the side of the transaxle.
2. Remove the oil filter cover (A, Figure 31) from the

transaxle to drain the oil. Remove the O-ring (B) from the

cover and discard the O-ring.

3. After the oil has drained from the transaxle, remove the

oil filter (C) from the transaxle housing.

4. Install a new filter and a new O-ring onto the filter cover

and install the filter cover. Torque the filter cover to

480-580 in-lbs (54.2 - 65.5 Nm).

5. Remove the top oil fill vent port (D) and fill the transaxle

with new 20W50 motor oil through the expansion tank

until the oil reaches the oil fill vent port.

6. Install the top oil fill vent port plug and continue filling

the system with oil until the fill line is reached in the

expansion tank.

7. Repeat this process for the other side of the machine.
8. Perform the

Purging the Air from the Hydraulic System

procedure.

Purging the Air from the Hydraulic

System

Due to the effects air has on efficiency in hydraulic drive

systems, it is critical that it be purged from the system.

These purge procedures should be implemented any time a

hydraulic system has been opened to facilitate maintenance

or any additional oil has been added to the system.
The resulting symptoms of air in the hydraulic system may be:

• Noisy operation.
• Lack of power or drive after short term operation.
• High operation temperature and excessive expansion of

oil.

Before starting, make sure the transaxles/transmissions are

at the proper oil levels. If it is not, fill to the specifications

outlined in the

Check / Fill Transmission Oil Level

procedure.

Purging Air from the Hydraulic System:

1. Chock the front wheels to prevent the machine from

rolling. Raise the rear of the machine so that the vehicle’s

rear tires do not contact the ground. Position jack stands

under the rear bumper of the machine to secure it.

Summary of Contents for 5901597

Page 1: ...N o t f o r R e p r o d u c t i o n ...

Page 2: ...nd Filter Engines with Remote Oil Tank 25 Changing the Engine Oil and Filter All Other Models 26 Disposing of Used Engine Oil 27 Engine Maintenance 27 Electronic Fuel Injection EFI System EFI Models 27 Inspect Muffler and Spark Arrester 27 Fuse Location and Identification 27 Check Fill Transmission Oil Level 27 Transmission Oil Filter Change 28 Purging the Air from the Hydraulic System 28 Checking...

Page 3: ...e covered by this manual 5901597 and 5901748 The product identification tag A Figure 1 can be found in the location shown 1 Product Identification Tag Decal Product Model Number Product Serial Number Engine Model Type Number Engine Code Serial Number Date of Purchase Purchase Location When contacting your authorized dealer for replacement parts service or information you MUST have these numbers Re...

Page 4: ...ent investment Be sure to completely read the Safety Rules and Information found on the following pages Also completely read the Operation section Children Tragic accidents can occur with children Do not allow them anywhere near the area of operation Children are often attracted to the unit and mowing activity Never assume that children will remain where you last saw them If there is a risk that c...

Page 5: ...ly if the system does not pass all the safety interlock system tests found in this manual Roll Bar Use Keep the roll bar in the raised position and fasten the seat belt There is no roll over protection when the roll bar is down Do not jump off if the mower tips it is safer to be secured by the seat belt with the roll bar raised Lower the roll bar only when necessary such as to temporarily clear a ...

Page 6: ...ngle meter or angle gauge Dial type C or digital type D work others may not Follow user instructions with the angle finder tool 3 Put the two feet long straight edge along the steepest part of the lawn slope Put the board up and down the slope 4 Put the smartphone or angle finder tool on the straight edge and read the angle in degrees This is the slope of your lawn Note A paper gauge slope identif...

Page 7: ...or setting or overspeed the engine Stop on level ground lower implements disengage drives engage parking brake shut off engine before leaving the operator s position for any reason including emptying the grass catchers or unclogging the chute Stop equipment and inspect blades after striking objects or abnormal vibration occurs Make necessary repairs before resuming operations Keep hands and feet a...

Page 8: ...even with the blade s off They may fall off and be seriously injured or interfere with safe unit operation Children who have been given rides in the past may suddenly appear in the mowing area for another ride and be run over or backed over by the machine Never allow children to operate the unit Use extra care when approaching blind corners shrubs trees or other objects that may obscure vision Emi...

Page 9: ... for major service and repair requirements Never attempt to make major repairs on this unit unless you have been properly trained Improper service procedures can result in hazardous operation equipment damage and voiding of manufacturer s warranty WARNING Units with hydraulic pumps hoses or motors Hydraulic fluid escaping under pressure may have sufficient force to penetrate skin and cause serious...

Page 10: ... and operator in excess of the maximum weight specified on the ROLL BAR label 6 Any modifications that have been made such as unauthorized welds and holes 7 Any permanent deformation or twisting of the ROLL BAR structure 8 That the ROLL BAR label is still in place and is readable 9 That the ROLL BAR on product warning labels are still on the ROLL BAR and are readable If there is any doubt as to th...

Page 11: ...Part No 5106563 Decal Main Safety B Part No 5061245 Decal Pinch Point Qty 2 Models w 61 Decks Qty 1 Models w 52 Decks C Part No 7101665 Decal Danger D Part No 5103184 Decal Warning E Part No 51004082 Decal Warning FLDG RL BR G Part No 5100405 Decal Warning ROPS F Part No 5104083 Decal Caution FLDG RL BR H Part No 5100683 Decal Warning ROPS Removed ...

Page 12: ...your safety do not attempt to bypass safety switches and never tamper with safety devices Check their operation regularly Operational SAFETY Checks Test 1 Engine SHOULD NOT crank if PTO switch is engaged OR Parking brake is not engaged Test 2 Engine SHOULD crank if PTO switch is not engaged AND Parking brake is engaged Test 3 Engine should SHUT OFF if Operator rises off seat with PTO engaged OR Op...

Page 13: ...r instructions on using these controls 6 Cutting Height Adjustment Pin Deck Lift Lock Lever Parking Brake Pull the parking brake lever up and back to engage the parking brake Move the lever fully forward and down to disengage the parking brake Note To start the unit the parking brake must be engaged Engaging the parking brake locks the ground speed control levers in the NEUTRAL position The parkin...

Page 14: ...he left rear drive wheel and the right lever controls the right rear drive wheel 8 Callout Icon Description A FORWARD B NEUTRAL C REVERSE D N A NEUTRAL LOCKOUT POSITION The parking brake must be disengaged before attempting to move the ground speed control levers from the NEUTRAL position Moving a lever forward A from the NEUTRAL position B increases the FORWARD speed of the associated wheel and p...

Page 15: ...re driving the unit or pushing it by hand See Pushing the Unit by Hand for operational information Seat Latch The seat latch A Figure 9 secures the seat plate to the frame of the unit 9 To raise the seat plate release the latch by moving the seat latch towards the front of the unit and then raise the seat plate The seat latch is spring loaded When the seat plate is lowered back into place the seat...

Page 16: ...rs when recording PTO hours To stop recording PTO hours push the PTO switch down to disengage the PTO clutch To stop recording engine hours engage the parking brake The hour meter has a self contained power source so that the recorded hours are always visible even when the engine is OFF Malfunction Indicator Lamp M I L The malfunction indicator lamp detects problems with the engine If the malfunct...

Page 17: ...over shut off key switch immediately and consult engine operator s manual Warm up the engine by running it for at least a minute before engaging the PTO switch or driving the rider 4 After warming the engine always operate the unit at FULL throttle when mowing In the event of an emergency the engine can be stopped by simply turning the ignition switch to STOP Use this method only in emergency situ...

Page 18: ...lance adjusted see the Speed Balancing Adjustment in the Adjustments section near the back of this manual Reverse Travel Practice 13 LOOK DOWN BEHIND then gradually move both ground speed control levers evenly BACK from neutral Slow down and repeat NOTE Practice backing up for several minutes before attempting to do so near objects The rider turns sharply in reverse as well as forward and backing ...

Page 19: ...to the 1 2 throttle position Note It is best practice to engage the PTO with the throttle set at the minimum throttle position necessary to engage the deck drive system without stalling the engine 5 Engage the PTO by pulling up on the PTO switch 6 Move the throttle to the FAST position and begin mowing 7 When finished reduce throttle speed so that the engine idles and push the PTO switch down to s...

Page 20: ...ften provide these ideal mowing conditions Avoid mowing after rain or even heavy dew and never mulch when the grass is wet moist grass does not mulch well and clumps beneath the mower deck Mowing Patterns Always start mowing on a smooth level area The size and type of area to be mowed will determine the best mowing pattern to use Obstructions such as trees fences and buildings and conditions such ...

Page 21: ...unt is cut Do not use the mower as a mulching mower during the first two or three mowings in the spring The long grass blades quick growth and often wetter conditions are more suitable for broadcasting side discharging or grass bagging operation Engine Speed Ground Speed for Mulching Use full engine throttle matched with a slow ground speed so that clippings will be finely cut Ground speed while m...

Page 22: ...t when the roll bar is down Raise the roll bar as soon as clearance permits Do NOT jump off if mower tips To lower the roll bar 1 Pull the hair pin clips A Figure 22 out of the retainer pins B 22 2 Push or pull the top of the roll bar C forward against the spring clips D and remove the retainer pins B 3 Lower the roll bar and reinstall the retainer pins and hair pin clips to secure the roll bar in...

Page 23: ...he spark plug opening is protected from foreign objects with a suitable cover If the unit can t be stored on a reasonable level surface chock the wheels Clean all grass and dirt from the mower Long Term Storage Longer Than 30 Days Before you store your unit for the off season read the Maintenance and Storage instructions in the Safety Rules section then perform the following steps Drain crankcase ...

Page 24: ...st 3 minutes before refueling Do not allow open flame smoking or matches in the area Avoid over filling and wipe up any spills To add fuel 1 Remove the fuel cap A Figure 24 24 2 Fill the fuel tank to the bottom of the filler neck This will allow for fuel expansion Note Do not overfill Refer to your engine owner s manual for specific fuel recommendations 3 Install and hand tighten the fuel cap 4 If...

Page 25: ...ortant Always make sure that the mower is parked on a flat level surface when checking the engine oil level 1 Park the machine on a flat level surface Engage the parking brake and disengage the PTO Allow the engine to run until it is warm This will warm the oil so it will drain better Turn the ignition switch to OFF remove the ignition key and wait for all moving parts to stop before leaving the o...

Page 26: ...the lip C of the tank housing so that the dipstick is fully installed into the tank This action requires moderate force 28 12 Remove the engine oil dipstick and check the oil level Maximum oil level is the FULL line G Figure 26 on the dipstick If the oil level is at or below the ADD 1 QT line H add more oil 13 Re install the dipstick 14 Install a new engine oil filter by lowering it into the engin...

Page 27: ...ontrol Unit ECU A Malfunction Indicator Lamp M I L will illuminate if problems or faults are detected Servicing by an authorized dealer is necessary CAUTION Do not disconnect or reconnect ECU wiring harness connector or any individual components with the ignition switch in the ON position This can send a damaging voltage spike through the ECU Unplug harness from ECU before performing any welding o...

Page 28: ...er cover Torque the filter cover to 480 580 in lbs 54 2 65 5 Nm 5 Remove the top oil fill vent port D and fill the transaxle with new 20W50 motor oil through the expansion tank until the oil reaches the oil fill vent port 6 Install the top oil fill vent port plug and continue filling the system with oil until the fill line is reached in the expansion tank 7 Repeat this process for the other side o...

Page 29: ...erate at normal noise levels and move smoothly forward and reverse at normal speeds then the transaxles transmissions are considered purged Checking Tire Pressures Tire pressure should be checked periodically and maintained at the levels shown in the Specifications chart Note that these pressures may differ slightly from the Max Inflation stamped on the side wall of the tires The pressures shown p...

Page 30: ...indle Inspecting the Mower Blades DANGER Thrown objects hazard Avoid injury a worn or damaged mower blade can break and a piece of the blade could be thrown into the operator s area or bystander s area resulting in serious personal injury or death Inspect the mower blade every 25 hours or at least once per year If the mower blade hits a solid object stop the engine immediately and inspect the mowe...

Page 31: ...ould have a maximum of 1 64 0 40 mm cutting edge B or less Balancing the Mower Blades CAUTION Thrown objects hazard An unbalanced mower blade can create excessive vibration and damage the unit or cause mower blade failure resulting in thrown debris Be sure blade is balanced before installing 1 Clean the mower blade to remove any dried grass or other debris 2 Clamp a nail in a bench vise hang the m...

Page 32: ...forwards backwards seat adjustment lever A Figure 43 position the seat as desired and release the lever to lock the seat in position Seat Adjustment Knob Suspension Ride Comfort The seat adjustment knob B adjusts the suspension of the seat ride comfort Turn the adjustment knob until the display scale has a reading that matches the weight of the operator Lumbar Adjustment Lever Turn the lumbar adju...

Page 33: ...the mower s cutting height The cutting height is adjustable between 1 1 2 3 8 cm and 5 12 7 cm in 1 4 0 64 cm increments Note Make sure that the pin is inserted into the holes in both upper and lower plates of the pin box B 46 To set the cutting height at 1 1 2 3 37 cm 1 While sitting in the operator s seat press the deck lift foot pedal C forward until it locks into the 5 12 7 cm position 2 Remov...

Page 34: ...h a removable floor pan which can be removed to provide better access to the mower deck 1 Loosen and remove the retaining hardware A Figure 48 that secures the floor pan to the frame of the unit 48 2 Tilt the back end of the floor pan up and then remove it from the unit 3 To re install the floor pan Reverse the removal procedure Neutral Adjustment The neutral system for this mower consists of two ...

Page 35: ...ard and release 5 Move the ground speed control levers out towards the NEUTRAL LOCKOUT position if the ground speed control lever aligns with the notch in the neutral lock plate adjustment is complete if the ground speed control lever stops it s return motion past the notch while standing at the rear of the machine re position the set collar so the neutral return spring is less compressed if the g...

Page 36: ...parking brake spring brackets D CAUTION Do not adjust the springs to be shorter than 2 3 8 6 03 cm when compressed This may damage the spring mechanism 7 Turn the adjustment nuts E to compress or release the spring 8 Engage the parking brake and re measure the springs Continue this process until the compressed length of the each spring measures 2 5 8 6 7 cm 9 Position the set collars 1 8 32 cm awa...

Page 37: ...ift rod 6 Remove blocks from under the mower deck 7 Remove the cutting height adjustment pin from in front of the deck lift pedal arm Lift mower deck and reinstall adjustment pin in desired mowing height Deck Leveling Adjustment Before adjusting the deck level the deck lift rod timing must be checked and or adjusted Determining if the Deck Leveling Needs to be Adjusted 1 Park the unit on a flat le...

Page 38: ...are achieved re tighten the jam nut 10 Repeat the process for the other side of the unit Deck Lift Assist Springs Some models are equipped with deck lift assist springs A Figure 58 that assist the operator in raising the mower deck with the deck lift pedal The deck lift assist springs are factory set to provide optimal lifting performance 58 Although it is fastened with a multi position anchor thi...

Page 39: ...uld equal 10 1 4 26 cm If not loosen the jam nut C on the eye bolt D and then turn the adjustment nut E until the measurement is achieved Tighten the jam nut 60 11 Re install the mower deck guards and the floor pan 12 Run the mower under no load condition for about five 5 minutes to break in the new belts Short Right Hand Deck Belt Replacement 61 Mower Deck NOTICE To avoid damaging belts do not pr...

Page 40: ...until the measurement is achieved Tighten the jam nut and the 3 8 nut that secures the rear idler pulley to the deck 13 Re install the long left hand deck belt See Long Left Hand Deck Belt Replacement for re installation instructions 14 Re install the mower deck guards and the floor pan 15 Run the mower under no load condition for about five 5 minutes to break in the new belts Transmission Drive B...

Page 41: ...the machine on a flat level surface Disengage the PTO stop the engine and engage the parking brake 2 Chock the front wheels to prevent the machine from rolling Raise the rear of the machine and secure with jack stands 3 Remove the rear drive tires WARNING Spring loaded components can kick back causing injury Use two hands when adjusting the shock springs This will prevent the wrench from slipping ...

Page 42: ...to allow it to continue to operating properly This troubleshooting guide lists the most common problems their causes and remedies Refer to Maintenance Procedures for instructions on how to perform most of these minor adjustments and service repairs yourself If you prefer all of these procedures can be performed for you by your local authorized dealer WARNING Remove ignition key prior to performing...

Page 43: ...rking Brake Adjustment Braking pads in transmissions worn See authorized dealer Problem Unit steers or handles poorly Cause Remedy Problem Unit steers or handles poorly Steering linkage is loose Check and tighten any loose connections Improper tire inflation See Checking Tire Pressures Troubleshooting the Mower Problem Mower will not raise Cause Remedy Lift linkage not properly attached or damaged...

Page 44: ...Cutting Uneven cutting is waviness or smooth troughs in the lawn surface Uneven cutting is usually caused by mower deck damage or misadjustment Cause Remedy Problem Uneven Cutting Deck is not leveled correctly Level the deck correctly Blades are dull or worn Sharpen or replace the blades Blades are damaged Replace the blades Deck is clogged with grass clippings Clean out the deck Deck shell is dam...

Page 45: ... Blades 90 days 90 days Engine See Engine Operator s Manual See Engine Operator s Manual Emissions related components are covered by the Emissions Warranty Statement In Australia Our goods come with guarantees that cannot be excluded under the Australian Consumer Law You are entitled to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or da...

Page 46: ... in material or workmanship Stale Fuel In order to function correctly this product requires fresh fuel that conforms to the criteria specified in the Operator s Manual Damage caused by stale fuel carburetor leaks clogged fuel tubes sticking valves etc is not covered by warranty Other Exclusions This warranty excludes damage due to accident abuse modifications alterations improper servicing freezin...

Page 47: ...N o t f o r R e p r o d u c t i o n Notes ...

Page 48: ...N o t f o r R e p r o d u c t i o n ...

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