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Yazoo/Kees 966509601, Operator'S Manual

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Yazoo/Kees 966509601 Operator'S Manual Download Page 56

56

TeChNICal DaTa

ZELKH6125/966509601

Engine

Manufacturer

Kohler

Type

Courage Pro

Power

25 hp* 

Lubrication

Pressure with oil filter

oil capacity excluding filter

1.6 qt / 1.5 liter

oil capacity including filter

1.7 qt / 1.9 liter

Engine oil (See viscosity diagram)

10W30, 5W30 SG, SH, SJ

Fuel

Min 87 octane unleaded (Max 
ethyl alcohol 10%, Max MTBE 15%)

Fuel tanks capacity

5.2 gallons / 19.7 liters

Spark plugs / gap

Champion RCY12YC  

.030" / 0.75 mm

Cooling

Air cooled

Air filter

Standard

Alternator

12v

Starter

Electric

Transmission

Transmission

Hydrostatic pump

Speed and direction controls

Dual levers, foam gripped

Speed forward

8 mph / 12.9 km/h

Speed reverse

4 mph / 6.45 km/h

Brakes

Mechanical parking brake

Front caster tires, smooth tread

13 x 5.0-6, 4 ply 

Rear tires, turf pneumatic

23 x 10.5-12

Tire pressures

15 PSI / 103 kPa / 1 bar

*The power rating of the engines indicated is the 
average net power output (at specified rpm) of a typical 
production engine for the engine model measured 
to SAE standard J1349/ISO1585. Mass production 
engines may differ from this value. Actual power output 
for the engine installed in the final machine will depend 
on the operating speed, environmental conditions and 
other variables.

Summary of Contents for 966509601

Page 1: ...Operator Manual ZELKH6125 966509601 Please read the operator s manual carefully and make sure you understand the instructions before using the machine ...

Page 2: ... information contained in these instructions Use only original parts for repairs The use of other parts voids the warranty Do not modify or install non standard equipment to the unit without consent from the manufacturer Modifications to the unit may cause unsafe operations or damage the unit When this product is worn out and no longer used it should be returned to the reseller or other party for ...

Page 3: ...er Cables 31 Running 32 Operating on Hills 33 Stopping the Engine 34 Mowing Tips 35 Manual Transport 36 Pump Release Valves 36 MAINTENANCE 37 Maintenance Schedule 37 Battery 39 Safety System 40 Fuel Filter 40 Tire Pressures 40 Parking Brake 41 Deck Belt 42 Pump Belt 43 Replacing pump belt 43 Belt removal 43 Belt installation 43 V belts 43 Cutting Blades 44 Adjusting the Mower Deck 45 Leveling Deck...

Page 4: ...nd mind and body and must not be under the influence of any mind altering substance WARNING Engine exhaust some of its constituents and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State ...

Page 5: ...ing equipment and ensure that the machine is well anchored DO NOT operate this machine on public roadways Towing If machine is equipped with a tow hitch use extreme caution when towing Never allow children or others in or on the towed equipment Make wide turns to avoid jack knifing Travel slowly and allow extra distance to stop Do not tow on sloped ground The weight of the towed equipment may caus...

Page 6: ...y issues etc please consult the following professional Manufacturing Number The machine s manufacturing number can be found on the printed plate affixed to the right side in the engine compartment Stated on the plate from the top are The machine s type designation I D The manufacturer s type number Model The machine s serial number Serial no Please have the type designation and serial number avail...

Page 7: ...es Do not touch parts marking Only for keep away from the European market discharge deck Battery acid is corrosive explosive and flammable Do not stand here Noise emissions to the surroundings in accordance with the European Union s directive The machine s emission is stated in the chapter TECHNICAL DATA and on the decals Only machines for European market Use protective glasses Use protective glov...

Page 8: ...m no greater Manual performing any the machine than 10 maintenance or repair work Whole body Severing of fingers Do not open or Careful backing up Careful going exposure to and toes remove safety watch for other forward watch for thrown objects shields while people other people engine is running Moving sharp blades under cover ...

Page 9: ... unless absolutely necessary Always look down and behind before and while backing Never direct discharged material toward anyone Avoid discharging material against a wall or obstruction Material may ricochet back toward the operator Stop the blades when crossing gravel surfaces Do not operate machine without the entire grass catcher discharge guard or other safety devices in place and working Slow...

Page 10: ...hts or counterweights Anyone who operates this machine must first read and understand this Operation Manual Local laws may regulate the age of the user Keep machine free of grass leaves or other debris buildup which can touch the hot exhaust or engine parts and burn Do not allow the mower deck to plow leaves or other debris causing buildup to occur Clean any oil or fuel spillage before operating o...

Page 11: ...obstacles Choose a low ground speed so that you will not have to stop while on the slope Do not mow on wet grass Tires may lose traction Avoid starting stopping or turning on a slope If the tires lose traction disengage the blades and proceed slowly straight down the slope Keep movement on the slopes slow and gradual Do not make sudden changes in speed or direction which could cause machine to rol...

Page 12: ...esponsible adult other than the operator Be alert and turn machine off if a child enters the area Before and while backing look behind and down for small children Never carry children even with the blades shut off They may fall off and be seriously injured or interfere with safe machine operation Children who have been given rides in the past may suddenly appear in the mowing area for another ride...

Page 13: ...ground If this is not possible refuel such equipment with a portable container rather than from a gasoline dispenser nozzle Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete Do not use a nozzle lock open device If fuel is spilled on clothing change clothing immediately Never overfill fuel tank Replace gas cap and tighten securely D...

Page 14: ...egularly to be sure it works properly The machine must not be driven with defective or unmounted protective plates protective cowlings safety switches or other protective devices Do not change the settings of governors and avoid running the engine with overly high engine speeds If the engine runs too fast there is risk for damaging the machine components Be very careful when handling battery acid ...

Page 15: ...ary make repairs before starting Never make adjustments with the engine running The machine is tested and approved only with the equipment originally provided or recommended by the manufacturer Only use approved repair parts for the machine The blades are sharp and can cause cuts and gashes Wrap the blades or use protective gloves when handling them Check the parking brake s functionality regularl...

Page 16: ...iler to transport the machine Activate the parking brake turn off the fuel supply and fasten the machine with approved fastening devices such as bands chains or straps when transporting Do not operate this machine on public roadways Check and abide by local traffic regulations before transporting the machine on any road Do not tow this machine it may cause damage to the drive system Load the unit ...

Page 17: ...l levers 1 Left tracking bolt 2 Parking brake 3 Fuses 4 Fuel tank 5 The power rating of the engines indicated is the average net power output at specified rpm of a typical production engine for the engine model measured to SAE standard J1349 ISO1585 Mass production engines may differ from this value Actual power output for the engine installed in the final machine will depend on the operating spee...

Page 18: ... control towards the neutral position The rotation of the right wheel is reduced and the machine turns to the right Zero turn can be achieved by moving one control backward behind the neutral position and carefully moving the other steering control forward from its neutral position The rotation direction when zero turning is determined by which steering control is moved backward behind the neutral...

Page 19: ...perate unit by driving it at full throttle and 4 the full forward position on both motion control levers Gradually turn in the tracking bolt on the right hand side until the unit noticeably starts drifting right Drive forward at full throttle with both motion 5 control levers in the full forward position Gradually turn in the left tracking bolt until unit tracks straight Hour Meter The hour meter ...

Page 20: ...ngine Turn the key clockwise to start the engine 8066 011 Blade switch 8066 012 Ignition switch Parking Brake The parking brake is found on the left of the machine Pull the lever backward to activate the brake and forward to release it IMPORTANT INFORMATION The machine must stand absolutely still when applying the parking brake Always set the parking brake before dismounting Release the parking br...

Page 21: ...8066 013 Ignition switch accessory CONTROLS 21 8066 014 Ignition switch RUN position Release the key to the RUN position when the engine has started For using accessory turn the key counter clockwise ...

Page 22: ... mower deck s lifting lever 8066 014 Choke control Choke Control The choke control is used for cold starts to provide the engine with a richer fuel mixture For cold starts the control should be pulled out to its extent As the engine reaches operating temperature gradually push the choke in normal operating choke position Fuses Fuses are located on the right hand side of the machine They are access...

Page 23: ...n making adjustments the lever is moved to the left or upward depending on model 8066 006 Lengthways adjustment Fuel Shut Off Valve The fuel shut off valve is located at the left rear of the seat The valve is off when the handle tab is turned perpendicular to the fuel line 8065 010 Fuel shut off valve in the CLOSED position ...

Page 24: ...gine and the exhaust system become very hot during operation Risk for burns if touched Allow engine and exhaust system to cool at least two 2 minutes before refueling WARNING Fill to bottom of filler neck Do not overfill Wipe off any spilled oil or fuel Do not store spill or use gasoline near an open flame 8066 017 Gasoline fuel tanks Read the safety instructions before refueling The machine has o...

Page 25: ...must be in the seat start engine see Before Starting in the Operation section adjust engine speed to idle disengage parking brake do not engage blades at this time rotate control levers inward As long as the control levers have not been IMPORTANT INFORMATION When control levers are in the reverse position they return to neutral when released This may cause the mower to suddenly stop moved forward ...

Page 26: ... there is sufficient fuel in the fuel tank Adjust the seat to the desired position The following conditions must be fulfilled before the engine can be started The blade switch for engaging the mower 1 blades must be depressed The parking brake must be on 2 8065 018 Place controls in neutral position Both steering controls must be in the locked 3 outer neutral position 8058 044 Activate parking bra...

Page 27: ...te the parking brake 3 Disengage the mower blades by depressing the 4 blade switch Move the steering controls outward to the 5 locked outer neutral position 8066 012 Press the control for disengaging the mower deck 8066 018 Place controls in neutral position 8066 019 Set mower deck to the transport position ...

Page 28: ...lve 8 If the engine is cold the choke control should 7 be pulled outward to the choke position 8066 020 Set the choke control 8065 013 Fuel valve in the OPEN position Move the throttle to the middle position 6 8066 020 Set the throttle ...

Page 29: ...TART position When the engine starts immediately release the 10 ignition key back to the run position IMPORTANT INFORMATION Do not run the starter for more than 5 seconds each time If the engine does not start wait about 10 seconds before retrying 8066 022 Release ignition to the RUN position ...

Page 30: ...e choke control in gradually when the 11 engine has started WARNING Engine exhaust and certain vehicle components contain or emit chemicals considered to cause cancer birth defects or other reproductive system damage The engine exhaust contains carbon monoxide which is an odorless colorless poisonous gas Do not use the machine in enclosed spaces 8066 023 Set the engine speed 8066 022 Push choke in...

Page 31: ... the discharged battery away from the fuel tank and battery To remove cables reverse order Remove BLACK cable first from chassis and then from the fully charged battery Remove RED cable last from both batteries 8011 642 Jumper cable connection IMPORTANT INFORMATION The mower is equipped with a 12 volt negative grounded system The other vehicle must also be a 12 volt negative grounded system Do not...

Page 32: ...eck to set cutting height Make sure the work area is free from objects that could be thrown by the rotating blades Engage the mower deck by pulling out the 4 blade switch Move throttle control to full throttle 5 The machine s speed and direction are continuously variable using the two steering controls When both controls are in the neutral position the machine stands still By moving both controls ...

Page 33: ...to the outside of the unit and engage the parking brake To restart movement release the parking brake Pull the control levers back to the center of the mower and press forward to regain forward motion Make all turns slowly IMPORTANT INFORMATION Control levers return to neutral when released This may cause the mower to suddenly stop WARNING Do not drive up or down hills with slopes greater than 10 ...

Page 34: ...eck by depressing the blade switch 8066 024 Disengage the mower deck and move throttle to minimum Raise the mower deck by pressing the foot pedal forward to the transport position When the machine is standing still activate the parking brake by pulling the lever upward Turn the ignition key to the stop position Move the steering controls outward Remove key To prevent unauthorized use always remove...

Page 35: ... The lawn becomes more even and the grass clippings more evenly distributed over the mown area The total time taken is not increased as a higher operating speed can be used without poor mowing results Avoid mowing wet lawns The mowing result is poorer because the wheels sink into the soft lawn clumps build and the grass clippings fasten under the cowling Hose the mower deck underside with water af...

Page 36: ...ease valves Pump Release Valves Pump release valves are located at the front and rear of the pump They are used to release the system so the machine may be moved by hand when not running Tilt seat forward to gain access to the pump The rear bypass valve sits directly opposite the front valve below the seat support It is not visible in the illustration Use a 17 mm open end wrench or socket and ratc...

Page 37: ...re screws nuts Clean under the mower deck Start the engine and blades listen for unusual sounds Check for damage Thoroughly clean around the engine Clean around belts belt pulleys Check the tire pressures Check battery connections Sharpen3 Replace mower blades Clean the engine s cooling air intake 2 Clean the air cleaner s pre filter 2 foam Clean the air cleaner s filter cartridge 2 paper filter C...

Page 38: ...etely stopped Disconnect the spark plug wire from all spark plugs and place the wire where it cannot come in contact with the plug MAINTENANCE Daily At least once each year Maintenance interval in hours Before After 50 250 500 Check adjust throttle cable Check the condition of belts belt pulleys Change the engine oil 1 Replace the engine oil filter Clean replace the spark plugs Replace the fuel fi...

Page 39: ...50 Amps 30 Amps 20 Amps 10 Amps 12 6V 100 FULL CHARGE 12 4V 75 20 min 35 min 48 min 90 min 12 2V 50 45 min 75 min 95 min 180 min 12 0V 25 65 min 115 min 145 min 280 min 11 8V 0 85 min 150 min 195 min 370 min Charging time depends on battery capacity condition age temperature and efficiency of charger Battery Removal Corrosion and dirt on the battery and terminals can cause the battery to leak powe...

Page 40: ...RTANT INFORMATION To be able to drive the driver must sit in the seat and release the parking brake before the steering controls can be moved into the neutral position otherwise the engine will stop 8065 021 Conditions for starting Fuel Filter Replace the line mounted fuel filter every 100 hours once per season or more often if it becomes clogged Move the hose clamps away from the filter Use 1 fla...

Page 41: ...onging to the parking brake Perform a standstill test and check that there is sufficient braking action IMPORTANT INFORMATION The machine must be standing still when applying the parking brake 8058 044 Parking brake WARNING Faulty adjustment results in reduced braking ability and can cause an accident ...

Page 42: ...lation NOTE For ease in installing the deck belt refer to the routing decal on the cutting deck Wrap the deck belt around the electric clutch 1 pulley that is located on the engine shaft Route the belt forward between and up onto the 2 deck Place belt around spring loaded idler pulley 3 Wrap the belt around the stationary idler pulley 4 and around the mandrel housings Push inward on the idler arm ...

Page 43: ...m the engine pulley and pump pulleys Belt installation Wrap the belt around the pulley 1 Route the belt around the inside of the idler 2 pulley Wrap the belt around the engine pulley 3 Reattach the spring on the pump idler arm 4 Reconnect clutch wire 5 Replace and secure clutch stop 6 Reinstall the deck belt see Deck Belt Removal 7 in this section of the manual V belts Check every 100 hours of ope...

Page 44: ...eplaced Balance the blades after sharpening Check the blade mounts Blade Replacement Remove blade bolt by turning counterclockwise 1 Install new or re sharpened blade with stamped 2 GRASS SIDE facing towards ground grass down or THIS SIDE UP facing deck and cutter housing Install and tighten blade bolt securely 3 Torque blade bolt to 90 ft lbs 122 Nm 4 8065 028 1 Blade 2 Blade bolt special 3 Cutte...

Page 45: ...ng procedure mower deck drive belt must be installed prior to leveling the deck Wear heavy gloves Turn each outer blade tip to 1 align the deck in a side to side manner Measure from the floor surface up to the bottom 2 of the blade tip on the discharge side of the mower deck Retain this measurement Move to the opposite side check that measurement is the same If adjustment is required loosen the lo...

Page 46: ... INFORMATION Adjust anti scalp rollers with the mower on a flat level surface IMPORTANT INFORMATION The anti scalp rollers must not be used for gauge wheels or the roller and deck may be damaged The anti scalp rollers can be set in three positions Upper position 1 to 2 25 to 63 mm grass Middle position 2 to 3 63 to 102 mm grass Lower position 3 to 4 102 to 127 mm grass 8061 008 Anti scalp rollers ...

Page 47: ...he deck with normal water pressure Do not use a high pressure washer or steam cleaner Avoid spraying engine and electrical components with water Do not rinse hot surfaces with cold water Let unit cool before washing Caster Wheels Check every 200 hours Check that wheels rotate freely Removal and Installation Remove nut and caster bolt Pull the wheel out of the fork Install in reverse order Tighten ...

Page 48: ...hen lubricating with grease unless otherwise stated use high grade molybdenum disulphide grease For daily use the machine should be lubricated twice weekly Wipe away excess grease after lubrication It is important to avoid getting lubricant on the belts or the drive surfaces on the belt pulleys Should this happen attempt to clean them with spirits If the belt continues to slip after cleaning it mu...

Page 49: ...ont Wheel Bearings Lubricate 3 4 strokes with a grease gun on each set of wheel bearings 8065 032 Lubricating front wheels 8065 064 Deck spindle Deck Spindles Lower the cutting deck completely If a grease gun without rubber hose is used the foot plate must be removed Lubricate with a grease gun 2 3 strokes per spindle IMPORTANT INFORMATION Use minimal lubrication and remove excess lubricant so tha...

Page 50: ... Procedures Due to the effects air has on efficiency in hydrostatic drive applications it is critical to purge the system These purge procedures should be implemented any time a hydrostatic system has been opened to facilitate maintenance or any additional oil has been added to the system Resulting symptoms in hydrostatic systems may be Noisy operation 1 Lack of power or drive after short term 2 o...

Page 51: ...y Poor contacts on the battery terminal cable connections Fuse blown Ignition system faulty Fault in the starter safety circuit See Safety System in the Maintenance Section Engine runs rough Faulty carburetor Choke control is pulled out with warm engine Clogged fuel filter or jet Clogged ventilation valve on the fuel cap Fuel tank nearly empty Fouled spark plug Spark plug is loose Rich fuel mixtur...

Page 52: ...transmission gears slack or has come off Air in hydraulic system Mower deck not engaging Drive belt for the mower deck has come loose Contact for the electromagnetic coupling has loosened The blade switch is faulty or has come loose from the cable contact The fuse has blown Hydraulic drive leaks oil Damaged seals housing or gaskets Air trapped in hydraulic system Uneven mowing results Unequal tire...

Page 53: ...uel tanks or add a fuel stabilizer Start 4 the engine and allow it to run until the carburetor is drained of fuel or the stabilizer has reached the carburetor Remove the spark plug and pour about a 5 tablespoon of engine oil into the cylinder Turn over the engine so that the oil is evenly distributed and then refit the spark plug Lubricate all grease zerks joints and axles 6 Remove the battery Cle...

Page 54: ...54 WIRING DIAGRAM ...

Page 55: ... 203 225 305 250 339 370 502 7 8 378 513 591 801 11 8 782 1060 1410 1912 Grade 5 Minimum commercial quality lower quality not recommended Metric Standard Hardware Grade Grade 8 8 Grade 10 9 Grade 12 9 ft lbs ft lbs Nm ft lbs Nm ft lbs Nm Shank Size Diameter in millimeters fine or coarse thread M4 1 5 2 2 2 3 2 7 3 6 M5 3 4 4 5 6 5 2 7 M6 5 2 7 7 5 10 8 2 11 M7 8 2 11 12 16 15 20 M8 13 5 18 18 8 25...

Page 56: ...tric Transmission Transmission Hydrostatic pump Speed and direction controls Dual levers foam gripped Speed forward 8 mph 12 9 km h Speed reverse 4 mph 6 45 km h Brakes Mechanical parking brake Front caster tires smooth tread 13 x 5 0 6 4 ply Rear tires turf pneumatic 23 x 10 5 12 Tire pressures 15 PSI 103 kPa 1 bar The power rating of the engines indicated is the average net power output at speci...

Page 57: ...Rollers Yes Sprung Seat Standard Hinged Arm Rests Yes Hour Meter Yes Blade Engagement 200 ft lb Warner Deck Construction 11 gauge fabricated Productivity 4 9 acres h 19830 m2 h Dimension Weight 780 lbs 354 kg Base Machine Length 76 193 cm Base Machine Height 42 107 cm Base Machine Width 49 125 cm Overall Width Chute Up 63 157 cm Overall Width Chute Down 76 193 cm ...

Page 58: ...t the machine will fulfill the requirements This is also applicable to special requirements for any of the states California emission rules etc Do not remove any of these labels Certificates can also be supplied with the machine at delivery or written in the Engine manual Take care of them as they are valuable documents ...

Page 59: ...ety switch for the parking brake Safety switch for the mower deck Safety switch in the seat Safety switch in the steering controls Parking brake functionality and adjustment Driving forward Driving backward Engaging the blades 11 Check idle speed 12 Check engine high idle speed 13 Inform the customer about Need and advantages of following the service schedule Need and advantages of leaving the mac...

Page 60: ...il 2 Change the oil filter 3 Check hydraulic oil level 4 Inspect hydraulic hoses 5 Inspect hydraulic belt 6 Inspect hydraulic filter 7 Check neutral position 8 Check safety system 9 Check seat belt 10 Check fuel system for leaks 11 Inspect safety guards and shields 12 Check brake adjustment ...

Page 61: ...m mower 2 Check engine oil level 3 Check the tire pressures 4 Check underside of deck 5 Inspect deck pulleys 6 Check clean the engine s cooling air intake 7 Check safety system 8 Check seat belt 9 Check brake adjustment 10 Check fuel system for leaks 11 Inspect safety guards and shields ...

Page 62: ...Change the engine oil and filter 3 Check the tire pressures 4 Clean the air filter 5 Grease blade spindles 6 Inspect deck belt and blades 7 Check hydraulic oil level 8 Check safety system 9 Check seat belt 10 Check brake adjustment 11 Check fuel system for leaks 12 Inspect safety guards and shields ...

Page 63: ...l filter 11 Check engine RPM 12 Clean underside of deck 13 Check blade pitch 14 Grease blade spindles 15 Inspect spindle bearings 16 Inspect deck belt and blades 17 Inspect idler arm bearings 18 Inspect deck idler pulleys 19 Check hydraulic oil level 20 Inspect hydraulic filter 21 Inspect hydraulic drive belt 22 Inspect hydraulic hoses 23 Check neutral position 24 Inspect battery connections 25 Ch...

Page 64: ...ean underside of deck 13 Check blade pitch 14 Grease blade spindles 15 Inspect spindle bearings 16 Inspect deck belt and blades 17 Inspect idler arm bearings 18 Inspect deck idler pulleys 19 Change hydraulic oil 20 Change hydraulic filter 21 Replace hydraulic drive belt 21 Inspect hydraulic hoses 22 Check neutral position 23 Inspect battery connections 24 Load test battery 25 Clean electrical conn...

Page 65: ...air intake 2 Replace the air cleaner s pre filter foam 3 Replace the air filter s paper cartridge 4 Change the engine oil 5 Replace the engine oil filter 6 Check adjust the cutting height 7 Check adjust the parking brake 8 Clean Change the spark plugs 9 Inspect spark plug 10 Check the engine valve clearance ...

Page 66: ...66 SERVICE JOURNAL Action Date mtr reading stamp sign ...

Page 67: ......

Page 68: ...P N 115 264927R1 11 10 09 ...

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