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Table of Contents
Maintenance Instructions__________ 41
MAINTENACE SCHEDULE CHART ________ 41
IMPORTANT TIPS FOR CARE
OF THE KOHLER ENGINE _______________ 42
Fuel System _________________________ 42
Starting/Stopping_____________________ 42
Cooling System ______________________ 42
Air Cleaner System ___________________ 42
Oil _________________________________ 42
LUBRICATION _________________________ 43
Engine Oil ___________________________ 43
Engine Break-In Oil __________________ 43
Checking Engine Crankcase Oil Level ___ 43
Changing Engine Crankcase Oil/Oil Filter _43
Grease Fitting and Oil Point Lubrication __ 44
Mower Deck Gearbox Lubrication _______ 44
DSD52 Mower Deck Lubrication_________ 45
Tractor PTO Gearbox Lubrication _______ 46
Checking Gearbox Oil Level ___________ 46
Changing Gearbox Oil ________________ 46
Gear Axle Lubrication _________________ 46
Hydrostatic Transmission Fluid _________ 46
Checking Hydrostatic
Transmission Fluid Level ______________ 46
Changing Hydrostatic Transmission Fluid _47
CLEANING ____________________________ 50
Engine Air Cleaner System _____________ 50
Turbine Precleaner __________________ 50
Donaldson Radialseal™ Air Cleaner _____ 51
Engine Cooling System________________ 52
Air Intake System ___________________ 52
Cylinder Head Cooling Fins ____________ 53
Grass Buildup in Mower Housing________ 53
GHS Blower _________________________ 54
GHS Exhaust Screen __________________ 55
Hydrostatic Transmission Cooling Fins __ 55
CHECKING/SERVICING _________________ 55
Security of Air Filtration Components ____ 55
Battery______________________________ 55
Electrolyte Level ____________________ 55
Cleaning the Terminals _______________ 56
Charging the Battery _________________ 56
Tire Pressure ________________________ 56
Sharpen Mower Blades ________________ 56
Drive Belts __________________________ 57
Mower Deck Gearbox Oil Seals _________ 58
Spark Plugs _________________________ 58
Fuel Lines and Clamps ________________ 58
Engine Starter________________________ 58
Engine Valve Clearance________________ 58
Blade Brake Action ___________________ 58
REPLACING/REPAIRING ________________ 59
Drive Belts __________________________ 59
Engine PTO Drive Belt _______________ 61
Jackshaft Drive Belt _________________ 62
GHS Blower Drive Belt _______________ 63
Hydrostatic Ground Drive Belt _________ 64
Fuel Filter ___________________________ 65
Blade Overload Shear Bolts ____________ 65
PTO Shear Pin _______________________ 66
Mower Blades _______________________ 66
Mower Deck Gearbox Replacement______ 67
GHS Blower Assembly ________________ 68
GHS Blower Assembly Removal _______ 68
Blower Wheel Removal ______________ 68
Blower Wheel Installation _____________ 69
GHS Blower Assembly Installation ______ 69
ADJUSTMENTS________________________ 70
Safety Switches ______________________ 70
Steering Levers ______________________ 70
Blade Clutch (PTO) ___________________ 71
Clutch Engagement/Belt Tension _______ 71
Clutch Disengagement/Brake Action ____ 72
Stop Block Eccentric Adjustment _______ 73
Clutch Idler Pulley Travel Adjustment ___ 73
Blade Brake Band Adjustment _________ 73
Transmission Control _________________ 74
Set Forward Travel Limit (Stop) ________ 74
Steering Lever End Play Adjustment ____ 75
Neutral Function Adjustment __________ 75
Straight Ground Travel Adjustment _____ 76
Forward Speed Control Friction Lock ____ 76
Tilt-Up Deck Adjustable Stop ___________ 77
Carburetor __________________________ 77
Engine Idle Adjustment _______________ 77
GHS “Full” Signal Horn
with Grass-Pak® Switch _______________ 78
Troubleshooting
(When Horn Fails to Operate) __________ 78
ELECTRICAL SYSTEM __________________ 79
Circuit Breakers______________________ 79
Wiring Diagram - Model MC ____________ 80
Operator’s Notes___________________ 81
Warranty___________________________ 83