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Tabl e of C ont ent s
Maintenance Instructions__________ 44
MAINTENANCE SCHEDULE CHART _______ 44
IMPORTANT TIPS
FOR CARE OF THE KOHLER ENGINE _____ 45
Fuel System _________________________ 45
Starting/Stopping _____________________ 45
Cooling System ______________________ 45
Air Cleaner System ___________________ 45
Oil _________________________________ 45
LUBRICATION _________________________ 46
Engine Oil ___________________________ 46
Engine Break-In Oil
___________________ 46
Checking Engine Crankcase Oil Level
____ 46
Changing Engine Crankcase Oil/Oil Filter
_46
Grease Fitting and Oil Point Lubrication __ 47
Mower Deck Gearbox Lubrication _______ 50
DSD52 or DSD62 Mower Deck Lubrication 50
Tractor PTO Gearbox Lubrication _______ 51
Checking Gearbox Oil Level
____________ 51
Changing Gearbox Oil
________________ 51
Gear Axle Lubrication _________________ 51
Hydrostatic Transmission Fluid _________ 52
Checking Hydrostatic
Transmission Fluid Level
______________ 52
Changing Hydrostatic Transmission Fluid
__ 52
CLEANING ____________________________ 53
Engine Air Cleaner System _____________ 53
Turbine Precleaner
___________________ 54
Donaldson Radialseal™
Air Cleaner (Primary)
_________________ 54
Kohler Air Cleaner (Secondary)
_________ 56
Foam Precleaner
__________________ 56
Paper Element
____________________ 56
Engine Cooling System________________ 57
Air Intake System
____________________ 57
Cylinder Head Cooling Fins
____________ 57
Grass Buildup in Mower Housing________ 58
Non-Tilting Decks
____________________ 58
Tilt-Up Decks
_______________________ 58
GHS Blower _________________________ 59
GHS Exhaust Screen __________________ 59
Hydrostatic Transmission Cooling Fins __ 60
CHECKING/SERVICING _________________ 60
Security of Air Filtration Components ____ 60
Battery______________________________ 60
Electrolyte Level
_____________________ 60
Cleaning the Terminals
________________ 61
Charging the Battery
__________________ 61
Tire Pressure ________________________ 61
Sharpen Mower Blades ________________ 61
Drive Belts __________________________ 62
Mower Deck Gearbox Oil Seals _________ 63
Spark Plugs _________________________ 63
Fuel Lines and Clamps ________________ 63
Engine Starter _______________________ 63
Blade Brake Action ___________________ 63
REPLACING/REPAIRING ________________ 63
Drive Belts __________________________ 63
Engine PTO Drive Belt
________________ 65
Jackshaft Drive Belt
__________________ 66
GHS Blower Drive Belt
________________ 67
Hydrostatic Ground Drive Belt
__________ 68
Fuel Filter ___________________________ 69
Blade Overload Shear Bolts ____________ 69
Mower Blades _______________________ 70
Mower Deck Gearbox Replacement______ 70
GHS Blower Assembly ________________ 71
GHS Blower Assembly Removal
________ 71
Blower Wheel Removal
_______________ 72
Blower Wheel Installation
______________ 72
GHS Blower Assembly Installation
_______ 72
ADJUSTMENTS________________________ 73
Safety Switches ______________________ 73
Seat Switch
________________________ 73
FSC Neutral-Park Switch
______________ 73
PTO Switch
_________________________ 73
Tail Wheel Bearing Preload_____________ 73
Blade Clutch (PTO) ___________________ 74
Clutch Engagement/Belt Tension
________ 74
Clutch Disengagement/Brake Action
_____ 75
Stop Block Eccentric Adjustment
________ 76
Clutch Idler Pulley Travel Adjustment
_____ 76
Blade Brake Band Adjustment
__________ 76
Transmission Control _________________ 77
Set Forward Travel Limit (Stop)
_________ 77
Steering Lever End Play Adjustment
_____ 78
Neutral Function Adjustment
___________ 78
Straight Ground Travel Adjustment
______ 79
Forward Speed Control Friction Lock ____ 79
Tilt-Up Deck Adjustable Stop ___________ 80
Carburetor __________________________ 80
Engine Idle Adjustment
_______________ 80
GHS “Full” Signal Horn
with Grass-Pak
®
Switch _______________ 81
Troubleshooting
(When Horn Fails to Operate)
__________ 81
Adjustment
(When Horn Sounds at the Wrong Time)
__ 82
ELECTRICAL SYSTEM __________________ 82
Circuit Breakers______________________ 82
Wiring Diagram ______________________ 83
Operator’s Notes___________________ 84
Warranty___________________________ 87