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Inspection and Maintenance of the Roll Bar

Seat Belt

WARNING

Failure to properly inspect and maintain the seat belt can

cause serious injury or death.

• The seat belt like the ROLL BAR, needs to be

periodically inspected to verify that the integrity has not

been compromised through normal machine use, misuse,

age degradation, modifications, or a roll over. If the seat

belt does not pass all of the following tests, it should be

replaced.

• BEFORE EACH USE – Conduct the following

inspections/maintenance of the seat belt and retraction

mechanism:

1) Check for dirt or debris in the retraction mechanism. If

dirt or debris is found, it should be removed.
2) Check to make sure the retraction mechanism retracts

easily and completely.
3) Check for damage to any part of the seat belt (A,

Figure 3) such as nicks, cuts, loose stitching, or fraying.
4) Check that the buckle and latch (B) operate properly

and that the latch plate is not excessively worn,

deformed, or the buckle is damaged or cracked. The seat

belt should latch and release easily.

Safety Decals and Icons (North American

Models)

Read the safety decals before operating your unit. The

cautions and warnings are for your safety. Understand and

follow all safety decals to avoid a personal injury or damage

to the unit.

WARNING

If any safety decals become worn or damaged and

cannot be read, order replacement decals from your

local dealer.

* Quantity 1 on models with 52" mower decks; Quantity 2 on models

with 60" mower deck and models with 61" mower decks.

Part Number: 84008252 - Decal, Main Safety

Part Number: 84008200 - Decal, Warning, Hand in Belt

Part Number: 84007896 - Decal, Danger, Cut Hand/

Foot

Part Number: 84008198 - Decal, Warning, Pinch Point

Part Number: 5104082YP - Decal, Warning, Folding

Roll Bar

Part Number: 5104083YP - Decal, Caution, Folding

Roll Bar

Part Number: 5100405YP - Decal, Warning, Roll

Bar and Overhead Obstacles

Part Number: 84008199 - Decal, Warning, Roll Bar

Removed

Decal, Main Safety

Part Number: 84008252

Содержание 5901879

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

Страница 2: ...g the Fuel Filter 29 Check Engine Oil Level 29 Changing the Engine Oil and Filter 29 Clean the Engine Compartment Area with Pressurized Air and Water 30 Electronic Fuel Injection EFI System EFI Models 30 Engine Maintenance 30 Containing Spilled Fluids and Proper Disposal of Waste 30 Inspect Muffler and Spark Arrester 30 Fuse Location and Identification 31 Check Fill Transmission Oil Level 31 Trans...

Страница 3: ...973 5901974 5901997 5902001 5902002 5902003 5902017 5902018 5902019 5902020 5902022 5902023 5902024 5902038 5902072 5902073 5902074 5902075 5902076 5902083 5902084 5902085 The product identification tag A Figure 1 can be found in the location shown 1 Your unit may feature a serial tag that looks like either one of the following two options Record your product model number product serial number eng...

Страница 4: ...f lawn and garden equipment Our products are designed and manufactured to meet or exceed all industry standards for safety Do not operate this machine unless you have been trained Reading and understanding this operator s manual is a way to train yourself Power equipment is only as safe as the operator If it is misused or not properly maintained it can be dangerous Remember you are responsible for...

Страница 5: ...tcher or discharge guard deflector in place Also do not allow anyone in the area while the unit is running If someone does enter the area shut the unit off immediately until they leave Moving Parts This equipment has many moving parts that can injure you or someone else However if you stay in the operator zone stay seated in the seat and follow the safety rules in this operator s manual the unit i...

Страница 6: ...nce is critical to the safety and performance of your unit Keep the unit free of grass leaves and excess oil Be sure to perform the maintenance procedures listed in this manual especially periodically testing the safety system Enclosed Areas Only operate this unit outdoors and away from unventilated areas such as inside garages or enclosed trailers The engine emits poisonous carbon monoxide gas an...

Страница 7: ...or with good artificial light keeping away from holes and hidden hazards Be sure all drives are in neutral and parking brake is engaged before starting engine Only start engine from the operator s position Use seat belts if provided Be sure of your footing while using pedestrian controlled equipment especially when backing up Walk don t run Reduced footing could cause slipping Slow down and use ex...

Страница 8: ... See your authorized dealer for recommendations of available weights to improve stability Do NOT Avoid starting stopping or turning on a slope Do NOT make sudden changes in speed or direction which could cause the mower to rollover Do not mow down slope towards or near drop offs ditches or embankments The mower could suddenly turn over if a wheel is over the edge of a cliff or ditch or if an edge ...

Страница 9: ...cool before storing Shut off fuel while storing or transporting Do not store fuel near flames or drain indoors Keep all hardware especially blade attachment bolts tight and keep all parts in good working condition Replace all worn or damaged decals Never tamper with safety devices Check their proper operation regularly Disengage drives lower implement set parking brake stop engine and remove key o...

Страница 10: ...he machine weight rating of the roll bar Read and follow all of the instructions shown below regarding the inspection and maintenance of the roll bar structure and the seat belt Inspection of the Roll Bar Protective Structure WARNING Failure to properly inspect and maintain the ROLL BAR protective structure can cause serious injury or death A ROLL BAR like any other safety device needs to be perio...

Страница 11: ...atch B operate properly and that the latch plate is not excessively worn deformed or the buckle is damaged or cracked The seat belt should latch and release easily Safety Decals and Icons North American Models Read the safety decals before operating your unit The cautions and warnings are for your safety Understand and follow all safety decals to avoid a personal injury or damage to the unit WARNI...

Страница 12: ...n or others are near Keep bystanders away Do not carry riders especially children even with the blades off They may fall off or return for another ride when you are not expecting it Look down behind and to the side before changing directions and while backing DANGER Loss of control and roll over hazard Operating on slopes can be hazardous and cause loss of control and roll overs Do not operate on ...

Страница 13: ...otection when the roll bar is down Lower the roll bar only when necessary and never remove it Do not use seat belt when the roll bar is down Raise the roll bar as soon as clearance permits Do not jump off if mower tips Read and follow all operating instructions and warnings in the operator s manual Decal Caution Folding Roll Bar Part Number 5104083YP WARNING Roll Over Protective Structure To maint...

Страница 14: ...controls Do not operate this machine unless you are trained Warning Consult technical literature before performing technical repairs or maintenance When leaving the machine shutoff engine set the parking brake to the lock position and remove the ignition key Danger Amputation and dismemberment hazard To avoid injury from rotating blades and moving parts keep safety devices guards shields and switc...

Страница 15: ...sh and cut Keep hands away from deck lift rod 5061042 Decal Danger Danger Dismemberment This machine can crush and cut Keep hands away from belts and pulleys 5102456 Decal Fire Danger Fire Hazard Keep unit free of grass leaves and excess oil Do not add fuel while engine is hot or running Stop engine remove key and allow to cool for at least 3 minutes prior to adding fuel Do not add fuel indoors in...

Страница 16: ...ngage the parking brake 2 Stop the engine and remove the ignition key 3 Properly jack the machine and secure with jack stands before working under the machine Safety Interlock System This unit is equipped with safety interlock switches These safety systems are present for your safety do not attempt to bypass safety switches and never tamper with safety devices Check their operation regularly Opera...

Страница 17: ...edal A Figure 7 the cutting height adjustment pin B and the deck lift lock lever C are used together to control the cutting height of the mower deck See Cutting Height Adjustment for instructions on using these controls 7 Cutting Height Adjustment Storage Hole for Cutting Height Adjustment Pin Deck Lift Lock Lever Ground Speed Control Levers These levers control the ground speed and direction of t...

Страница 18: ...round speed control levers out of the NEUTRAL position DISENGAGE Releases the parking brake ENGAGE Locks the parking brake Suspension Seat Some models are equipped with a suspension seat This seat has several additional options See Figure 9 and the list below for the location of the seat s features and brief description of their function 9 A Seat Adjustment Lever Forwards Backwards The seat can be...

Страница 19: ...ansmissions so that the unit can be pushed by hand Both transmission release levers must be in the same position whether you are driving the unit or pushing it by hand See Pushing the Unit by Hand for operational information and control location Transmission Oil Fill Transmission oil is added through the hydraulic oil tanks It also serves as extra holding capacity for oil as the transmissions heat...

Страница 20: ...mode icon will display a E and the hour glass icon will not flash To begin recording engine hours start the unit s engine and release the parking brake The hour glass icon will flash To begin recording PTO hours pull the PTO switch up to engage the PTO clutch The unit s engine must be running The mode icon will display a P and the hour glass icon will flash While recording PTO hours the hour meter...

Страница 21: ...nd how a specific control functions or have not yet thoroughly read the FEATURES AND CONTROLS section do so now Do NOT attempt to operate the unit without first becoming familiar with the location and function of all controls 1 While sitting in the operator s seat engage the parking brake make sure the PTO switch is disengaged and the ground speed control levers are locked in the neutral position ...

Страница 22: ... control of the unit s forward reverse and turning movements will take some practice Before you begin mowing spend some time going through the maneuvers shown in this manual and become familiar with how the unit accelerates travels and steers Locate a smooth flat area of your lawn with plenty of room to maneuver Clear the area of objects people and animals before you begin Operate the unit at mid ...

Страница 23: ...o turn gradually move one ground speed control lever forward from neutral and the other lever back from neutral simultaneously Repeat several times Note Changing the amount each ground speed control lever is pulled forward or back changes the pivot point you turn on Advanced Driving Executing an End Of Row Zero Turn 18 Your zero turn riding mower s unique ability to turn in place allows you to tur...

Страница 24: ...oo short is often more damaging than allowing the grass to be slightly higher Letting grass grow a bit longer especially when it is hot and dry reduces heat build up preserves needed moisture and protects the grass from heat damage and other problems However allowing grass to grow too high can cause thin turf and additional problems Cutting off too much at one time shocks the plant s growth system...

Страница 25: ...Always operate the engine at full throttle when mowing If you hear the engine slowing down you are mowing too fast using a slower ground speed will improve the cutting efficiency of the blades and prevents many common cutting problems ALWAYS use an appropriate ground speed for the thickness and height of the grass you are cutting 3rd gear or slower for manual gear models If you hear the engine slo...

Страница 26: ... unit between the two rear wheels on the transmission cradle B There is one transmission release lever on each transmission The transmission release levers open and close the transmission bypass valves 23 3 To open the transmission bypass valve bypass position C move the transmission release lever up and pull it towards the rear of the unit When the second nut D has passed through the hole lower t...

Страница 27: ...fuel tank will still contain some fuel so never store the unit indoors or in any other area where fuel vapor could travel to any ignition source Fuel vapor is also toxic if inhaled so never store the unit in any structure used for human or animal habitation WARNING Never store the unit with fuel in the engine or fuel tank in a heated shelter or in an enclosed poorly ventilated enclosures Fuel fume...

Страница 28: ... manual for recommendations 5 See engine operator s manual and follow all instructions for preparing engine after storage 6 Check crankcase oil level and add proper oil if necessary If any condensation has developed during storage drain crankcase oil and refill 7 Inflate tires to proper pressure Check fluid levels 8 Start the engine and let it run slowly DO NOT run at high speed immediately after ...

Страница 29: ...d hand tighten the fuel cap 4 If your unit is equipped with two fuel tanks repeat this process to fill the other fuel tank NOTICE Refer to your engine operator s manual for specific fuel recommendations Replacing the Fuel Filter WARNING Fuel and its vapors are extremely flammable and explosive Fire or explosion can cause severe burns or death Do NOT remove the fuel filter when the engine is hot as...

Страница 30: ... pressure for cleaning purposes must be below 205 kPa 30 psi The maximum water pressure for cleaning purposes must be below 275 kPa 40 psi Electronic Fuel Injection EFI System EFI Models EFI is an electronically controlled fuel management system which is monitored by an Electronic Control Unit ECU A Malfunction Indicator Lamp M I L will illuminate if problems or faults are detected Servicing by an...

Страница 31: ... FULL COLD mark B on the transmission oil tanks If the oil is below this level proceed to step 3 28 3 Before removing tank caps C make sure the area around the tank cap and fill neck of the tank is free of dust dirt or other debris Remove the tank caps 4 Add oil up to the FULL COLD full cold mark 5 Reinstall the tank caps 6 After adding oil to the tanks it may be necessary to purge air from the hy...

Страница 32: ... wheels to prevent the unit from rolling Raise the rear of the unit so that the unit s rear tires do not contact the ground Position jack stands under the rear bumper of the unit to secure it 2 Open the transaxle s bypass valves see Pushing the Unit by Hand for the location and function of the bypass valves start the engine release the parking brake and slowly move the unit s ground speed control ...

Страница 33: ...rval Front caster wheel axles A Figure 35 Every 25 hours Interval Front caster yoke axles Yearly 1 Remove the 1 4 28 bolt B Figure 35 screwed into the caster and install a 1 4 28 grease fitting 35 2 Grease the front caster 3 Remove the 1 4 28 grease fitting and reinstall the 1 4 28 bolt 4 Repeat the process for the other side of the unit Servicing the Mower Blades Removing the Mower Blades CAUTION...

Страница 34: ...spect the mower blades Never weld or straighten bent mower blades 3 Inspect the mower blade Figure 37 Discard the mower blade if it has any of the following conditions More than 5 12 7 mm of the mower blade metal has been removed from previous sharpening or wear A The air lifts are excessively eroded B and the notch C is 25 6 35 mm deep or greater The mower blade is broken or bent 37 4 If the cutt...

Страница 35: ...ON Laceration hazard Mower blades are sharp Always wear gloves when handling or working near mower blades 1 Install each mower blade with the air lifts C Figure 40 pointing up towards the mower deck as shown in Figure 40 and secure with the mower blade mounting bolt A and flat washer B 40 2 Wedge a wooden block D between the mower blade and the mower deck housing to keep the mower blade from turni...

Страница 36: ...tion You will need to adjust the control lever alignment as described above Speed Balancing Adjustment If the unit drifts to the right or left when the ground speed control levers are in the maximum forward position the top speed of each of these control levers can be balanced by turning the adjustment bolt s A Figure 43 Only adjust the speed of the wheel that is traveling faster 43 To Reduce the ...

Страница 37: ...ting height hole 3 Press the deck lift pedal forward and then push the lock lever towards the right to release the lock 4 Slowly release the deck lift foot pedal until it comes to rest against the cutting height adjustment pin To set the cutting height at 5 12 7 cm 1 While sitting in the operator s seat press the deck lift foot pedal forward until it locks into the 5 12 7 cm position 2 Place the c...

Страница 38: ...the linkage rod to adjust If the unit creeps forward turn the rod clockwise while standing at the rear of the unit facing forward If the unit creeps backward turn the rod counter clockwise while standing at the rear of the unit facing forward 3 Lock the jam nut against the ball joints when neutral is achieved Note This adjustment should not be performed while the unit is running It may take severa...

Страница 39: ...6 Position the neutral lockout bolts to the center of the notches of the neutral lockout plates 7 Re tighten the jam nuts Parking Brake Adjustment The parking brake mechanism consists of a two parking brake cables with a spring on both ends that routes from the transmission to the parking brake lever shaft The position of the parking brake cables and the compressed length of the lower springs loca...

Страница 40: ... until all hanger chains are slack 4 To adjust the inner lift rod A Figure 53 Loosen the jam nut B on the front ball joint C then remove the 1 2 hardware D fastening the ball joint to the lift pivot arm Turn the ball joint clockwise to shorten the distance between the rod pivots or counter clockwise to lengthen the distance between the rod pivots Reinstall the ball joint on the lift pivot arm and ...

Страница 41: ...ment 1 Set the mower deck to the 4 10 2 cm cutting height position 2 Measure from the front tips of the blades to the ground If the measurements between the front tips of the blades and the ground is greater than 4 1 4 10 8 cm or less than 3 3 4 9 5 cm the mounting hardware will be to be positioned into different holes If the measurements between the front tips of the blades and the ground falls b...

Страница 42: ... mower deck guards and floor pan to gain access to the mower deck drive belts WARNING Use extreme caution when rotating the idler arm with the breaker bar due to the increased tension in the spring as the idler arm is being rotated Injury may result if the breaker bar is prematurely released while the spring is under tension 3 Using a 1 2 breaker bar A Figure 58 place the square end in the opening...

Страница 43: ... E to the mower deck 6 Remove the old short right hand belt F from the front idler pulley G and the center spindle pulley H 7 Install the new short right hand belt onto the center spindle pulley and the front idler pulley 8 Re connect the idler arm spring Install the 3 8 washer and then the spacer onto the shaft of the 3 8 bolt Install the hook of the idler arm spring around the body of the spacer...

Страница 44: ...draulic tank mount plate G Rotate the pulley support plate away from the hydraulic tank mount so that the belt can be removed from the machine 8 Remove the old belt and replace with a new one H Figure 61 Make sure that the V side of the belt runs in the grooves of the front stationary idler pulley I both transmission pulleys J and the crankshaft pulley K Make sure that the flat side of the belt co...

Страница 45: ...ar mounted grass collection system is installed on the unit To Adjust the Spring Pre load This procedure details the process for adjusting the spring s pre load for the rear shocks To adjust the spring s pre load for the front shocks only steps 1 and 5 are required The shock s pre load adjustment consists of rotating the pre load adjuster A Figure 64 with a spanner wrench so that the adjuster ride...

Страница 46: ...t when the pressure is relieved 4 Remove the upper shock mounting hardware and pivot the shock to the next higher numbered position see Figure 65 65 5 Adjust the jack to align the shocks to the shock mounting holes 6 Install the upper shock mounting hardware and tighten securely 7 Remove the jack from under the transmission cradle 8 Remove the jack stands from underneath the unit Battery Maintenan...

Страница 47: ...tend the life of your equipment prolonged or constant use may eventually require that service be performed 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 procedur...

Страница 48: ...ed or worn Replace belt Problem Brake will not hold Cause Remedy Brake is incorrectly adjusted See Parking Brake Adjustment Braking pads in transmissions worn See authorized dealer Problem Unit steers or handles poorly Cause Remedy Steering linkage is loose Check and tighten any loose connections Improper tire inflation See Checking Tire Pressures Troubleshooting the Mower Problem Mower will not r...

Страница 49: ...use Remedy Deck is not leveled correctly Level the deck correctly Tires are not properly inflated Check and inflate the tires Blades are damaged Replace the blades Deck shell is damaged Repair or replace the deck Mower spindle is bent or loose Repair or replace the spindle Blades are installed incorrectly Reinstall the blades correctly Problem Uneven Cutting Uneven cutting is waviness or smooth tr...

Страница 50: ...Stratton Model 49X977 0003 G1 Electrical System 12 volt 16 amp alternator Battery 340 cca Fits models 5901973 5901879 5901933 5902017 5902020 5902038 5902072 5902076 5902085 in Serial Number Range 4002060045 and above Briggs Stratton 49X977 Make Briggs Stratton Model 49X977 0005 J1 Electrical System 12 volt 20 amp alternator Battery 340 cca Fits models 5902001 5902022 5902074 Kawasaki Fuel Injecte...

Страница 51: ...Belt Conventional Single Belt Deck Drive Systems 1 year 12 months or 100 hours whichever occurs first 90 days Mower Deck Drive Belt Two Belt Deck Drive Systems 3 years 36 months or 300 hours whichever occurs first Parts and labor in year one parts only in years two and three 90 days Attachments 1 year 90 days Engine See Engine Operator s Manual See Engine Operator s Manual Emissions related compon...

Страница 52: ...riginal or non equivalent parts is not covered by warranty Normal Wear and Tear Like all mechanical devices the unit is subject to wear even when properly maintained This warranty does not cover replacement or repairs when normal use has exhausted the life of a part or the equipment Except as noted in the warranty period maintenance and wear items such as filters belts cutting blades and brake pad...

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