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