Page 3 - INTRODUCTION; Introduction; Using Your Operator’s Manual; Special Messages; Product Identification; Record Identification Numbers
All information, illustrations and specifications in this manual are based on the latest information at the time of publication. The right is reserved to make changes at any time without notice. COPYRIGHT© 2007 Auburn Consolidated Industries Inc. All rights reserved COPYRIGHT© 2006 WARNING: The Engi...
Page 4 - SAFETY LABELS; Safety Labels; Understanding The Machine Safety Labels
Safety Labels - 2 SAFETY LABELS MODEL NUMBER (POWER UNIT) (A): __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ SERIAL NUMBER (POWER UNIT) (A): __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ ENGINE MODEL NUMBER(B): __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ ENGINE SERIAL NUMBER (B): __...
Page 5 - DANGER
Safety Labels - 3 SAFETY LABELS DANGER Do not mow without discharge chute or entire grass catcher in place. DANGER To avoid injury from rotating blades and thrown objects, stay clear of deck edge and keep others away. Do not mow without discharge chute or entire grass catcher in place. DANGER • Ciga...
Page 6 - WARNING
Safety Labels - 4 SAFETY LABELS WARNING To avoid injury from rotating belts, keep all shields and guards in place. WARNING Hot surface CAUTION • Operator training required • Read operator’s manual • Keep shields in place • Never carry riders • Keep people a safe distance away • Maintain all safety d...
Page 7 - SAFETY; Safety
Safety - 5 SAFETY Emission Control System Certification Label NOTE: Tampering with emission controls and components by unauthorized personnel may result in severe fines or penalties. Emission controls and components can only be adjusted by EPA and/or CARB authorized service centers. Contact your Gre...
Page 8 - Using a Spark Arrestor; Rotating Blades are Dangerous
Safety - 6 SAFETY • Be aware of the mower discharge direction and do not point it at anyone. • Do not operate the machine while under the influence of alcohol or drugs. • Use care when loading or unloading the machine into or off of a trailer or truck. • Use care when approaching blind corners, shru...
Page 9 - Protect Children; Use Seat Belt Properly; Keep ROPS Installed Properly
Safety - 7 SAFETY Protect Children • Death or serious injury can occur when young children associate having fun with a lawn mowing machine simply because someone has given them a ride on a machine. • Children are attracted to lawn mowing machines and mowing activities. They don’t understand the dang...
Page 11 - Prevent Fires; Tire Safety
Safety - 9 SAFETY • Shut off fuel while storing or transporting. Do not store fuel near flames or drain indoors. • Park machine on level ground. Never allow untrained personnel to service machine. Understand service procedure before doing work. • Use jack stands or lock service latches to support co...
Page 12 - OPERATING; Handling Waste Product and Chemicals; Operating; Daily Operating Checklist
Operating - 10 OPERATING • Never remove the fuel tank cap or add fuel with the engine running. Allow engine to cool before refueling. • Never add fuel to or drain fuel from the machine indoors. Move machine outdoors and provide adequate ventilation. • Clean up spilled fuel immediately. If fuel is sp...
Page 13 - Operator Station Controls; Miscellaneous Controls; Raising and Lowering Operator Seat
Operating - 11 OPERATING • Be careful not to spill fuel on machine. Fuel may damage surface. Wipe up spilled fuel immediately. • Prolonged exposure to sunlight will damage the hood surface. Operator Station Controls A- Motion Control Levers B- Park Brake Lever C- Seat Adjustment Lever D- Hourmeter E...
Page 14 - Adjusting Seat; Using Seat Belt
Operating - 12 OPERATING Adjusting Seat Front-to-Back Adjustment 1.Park machine safely. (See Parking Safely in the SAFETY section.) 2.Sit on the operator seat. 3.To adjust the seat front to back, push and hold the seat adjustment lever (A) away from the seat. 4.Slide forward or backward to desired p...
Page 15 - Adjusting Mower Deck Cutting Height
Operating - 13 OPERATING 4.Push ROPS into upright position. 5.Install drilled pin (B) into holes on left and right side of ROPS, and secure in place with spring pins (A). 6.Check the ROPS bolt torque if the ROPS is loose. Lowering ROPS 1.Park machine safely. (See Parking Safely in the SAFETY section...
Page 16 - Testing Safety Systems; Testing PTO Switch; Testing Park Brake Switch
Operating - 14 OPERATING NOTE: The rear anti-scalp wheels are located under the rear of the mower deck. 4.Adjust anti-scalp wheel (A) to one of two positions (B). • Remove screw (C), nut and washer. • Adjust wheel up or down so it is approximately 6-13 mm (1/4-1/2 in.) above mowing surface. 5.Instal...
Page 17 - Testing Seat Switch; Testing the Park Brake; Using the Park Brake
Operating - 15 OPERATING Testing Seat Switch Procedure 1: 1.Sit on the operator seat with the motion control levers in the neutral detent position (standard levers) or neutral lock position (optional “over the lap” levers). 2.Unlock the park brake. 3.Push PTO knob down to disengage. 4.Turn key switc...
Page 18 - Using the Key Switch; Using the PTO
Operating - 16 OPERATING Using the Key Switch NOTE: Machine will only start if the following conditions exist: • Park brake is locked. • PTO is disengaged. • Motion control levers are in the neutral detent position (standard levers) or neutral lock position (optional “over the lap” levers). • To tur...
Page 19 - Using the Choke
Operating - 17 OPERATING Using the Choke Engage Choke: • Pull choke knob (A) out. Disengage Choke: • Push choke knob (A) in. Using the Motion Control Levers NOTE: Two types of control levers are available - standard “center steer” levers and optional “over the lap” levers. The operation of both styl...
Page 21 - Starting the Engine
Operating - 19 OPERATING Sharp Left Turn: • Push right control lever forward and pull left control lever rearward at the same time. Sharp Right Turn: • Push left control lever forward and pull right control lever rearward at the same time. Starting the Engine 1.Sit on the operator seat. 2.Lock the p...
Page 22 - Engaging Mower
Operating - 20 OPERATING Engaging Mower 1.Adjust mower deck to desired cutting height. 2.Start engine. 3.Move throttle lever to the 1/2 - 3/4 throttle position. 4.Unlock the park brake. 5.Move both motion control levers to the neutral position. NOTE: In cold weather or with a new machine, it may be ...
Page 23 - Service Intervals - 21; SERVICE INTERVALS; Service Intervals
Service Intervals - 21 SERVICE INTERVALS • Mow tall or wet grass twice. Cut grass at half desired height – then cut at desired height. • Travel slow when mowing tall, thick or wet grass. • Avoid damaging grass by slipping or skidding machine drive wheels. Practice smooth control lever movements. • W...
Page 24 - Service Lubrication - 22; SERVICE LUBRICATION; Service Lubrication; Grease; Spray Lubricant
Service Lubrication - 22 SERVICE LUBRICATION Service Lubrication Grease Use a general all-purpose grease with an NLGI grade No.2 rating. Wet or high speed conditions may require use of a special-use grease. Contact your Servicing dealer for information. Spray Lubricant Use a general-purpose petroleu...
Page 25 - SERVICE ENGINE; Service Engine; Engine Warranty Maintenance Statement
Service Engine - 23 SERVICE ENGINE 6.Grease traction drive belt tension arm pivot (G). 7.Grease mower deck drive belt tension arm (H). NOTE: Use spray lubricant to lubricate the following items: 8.Lubricate mower deck idler pulleys (K-M). 9.Lubricate hydraulic pump control arms (N). 10.Lubricate con...
Page 26 - Checking Engine Oil Level; Changing Engine Oil and Filter
Service Engine - 24 SERVICE ENGINE Checking Engine Oil Level NOTE: Check oil twice a day if you run engine over 4 hours in a day. Make sure engine is cool when checking engine oil level. 1.Park machine safely. (See Parking Safely in the SAFETY section.) 2.Allow engine to cool. 3.Remove dipstick (A)....
Page 28 - Service Transmission - 26; SERVICE TRANSMISSION; Service Transmission; Hydraulic Oil
Service Transmission - 26 SERVICE TRANSMISSION Service Transmission Hydraulic Oil Use only 5W-50 or 15W-50 all synthetic oil. Checking Hydraulic Oil Level 1.Park machine safely. (See Parking Safely in the SAFETY section.) 2.Unscrew and remove hydraulic reservoir cap/dipstick (A) from hydraulic oil r...
Page 29 - Service Transmission - 27; Cleaning Hydraulic Pump Cooling Fins; Checking and Adjusting Motion Control Linkages
Service Transmission - 27 SERVICE TRANSMISSION 11.Start engine. 12.Move throttle lever to 3/4-throttle position. 13.Unlock the park brake. 14.Run engine in full forward position for several minutes and then cycle motion control levers forward and rearward several times. Check for leaks around filter...
Page 30 - Service Transmission - 28
Service Transmission - 28 SERVICE TRANSMISSION Check Neutral Creep NOTE: Check and adjust motion control linkages with the machine parked on a hard, level surface. 1.Start engine. 2.Set throttle lever to full-throttle position. 3.Unlock the park brake. 4.If the rear drive wheels begin to creep, an a...
Page 31 - Service Transmission - 29
Service Transmission - 29 SERVICE TRANSMISSION NOTE: If the machine travels to the left, adjust the right speed drift screw (A). If the machine travels to the right, adjust the left speed drift screw (B). 3.Adjust the appropriate speed drift screw (A or B) as follows: a.Loosen jam nut (C or D). b.Ad...
Page 32 - Service Transmission - 30; Hydraulic System Hose Routing
Service Transmission - 30 SERVICE TRANSMISSION Hydraulic System Hose Routing A- Hydraulic Reservoir B- Oil Filter C- Right Hydraulic Pump D- Right Wheel Motor E - Left Wheel Motor F - Left Hydraulic Pump
Page 33 - SERVICE STEERING & BRAKES; Hydraulic System Schematic; Service Steering & Brakes
Service Steering & Brakes - 31 SERVICE STEERING & BRAKES Hydraulic System Schematic A- Control Input Shaft B- Pump Block C- Charge Pump D- Charge System Check Valve E - Right Hydraulic Pump F - Manual Bypass (Free-Wheel) Valve G- Right Wheel Motor H- Cooling Orifice I - Charge Relief Valve J...
Page 34 - Removing and Installing Front Caster Wheels; Servicing Front Caster Wheel Roller Bearings - Chariot; Adjusting Front Caster Spindle Bearing
Service Steering & Brakes - 32 SERVICE STEERING & BRAKES Removing and Installing Front Caster Wheels Removing 1.Park machine safely. (See Parking Safely in the SAFETY section.) 2.Lift front of machine with a safe lifting device. 3.Remove hex nut (A) and wheel bolt (B). 4.Remove wheel (C) fro...
Page 35 - Servicing Caster Spindle Bearings
Service Steering & Brakes - 33 SERVICE STEERING & BRAKES 3.Remove cotter pin (B). 4.Turn castle nut (C) 1/4 turn clockwise. 5.Install a new cotter pin. Do not loosen the castle nut to align cotter pin hole, tighten to align. 6.Replace dust cover. 7.Test machine to determine if shimmy is stil...
Page 36 - SERVICE MOWER; Adjusting Park Brake; Service Mower; Removing and Installing Mower Deck Foot Plate
Service Mower - 34 SERVICE MOWER • To mount in the high position, mount the levers to the top four holes in the mounting bracket. • To mount in the low position, mount the levers to the bottom four holes in the mounting bracket. Checking and Aligning Motion Control Levers - Optional Over the Lap Lev...
Page 37 - Removing and Installing Mower Deck Belt Shields; Leveling Mower Deck
Service Mower - 35 SERVICE MOWER Removing Foot Plate 1.Park machine safely. (See Parking Safely in the SAFETY section.) 2.Raise foot plate (A) using hole (B). 3.Remove and retain hardware (C) securing foot plate (A) on both sides of machine. 4.Remove foot plate. Installing Foot Plate 1.Install foot ...
Page 39 - Checking and Adjusting Cutting Height
Service Mower - 37 SERVICE MOWER Checking and Adjusting Cutting Height Checking Thrust Arm-to-Stop Rod Clearance (Transport Position) 1.Park machine safely. (See Parking Safely in the SAFETY section.) 2.Set mower deck to transport (fully raised) position. 3.Check clearance (A) from the top of the th...
Page 40 - Removing and Installing Mower Deck Drive Belt; Checking and Replacing Mower Blades
Service Mower - 38 SERVICE MOWER 4.Loosen jam nut (A). 5.Check the mower deck drive belt (B) tension. The belt should deflect a maximum of 13 mm (1/2 in.) when a force of 4.5 kg (10 lb) is applied to the center of the longest span. When properly adjusted, there would be approximately a 2 mm (1/16 in...
Page 41 - Sharpening Blades
Service Mower - 39 SERVICE MOWER NOTE: Only replace blades. Never straighten or weld them. Checking Mower Blades 1.Park machine safely. (See Parking Safely in the Safety Section). 2.Raise the mower deck to the transport position (also the 12.7 cm [5 in.] cutting height position). 3.Raise front of ma...
Page 42 - Service Electrical - 40; SERVICE ELECTRICAL; Service Electrical; Service the Battery Safely
Service Electrical - 40 SERVICE ELECTRICAL 3.Remove nut (A), pulley (B) and spacer (C). 4.Remove retaining ring (D), spindle shaft (E), lower bearing (F) and spacer (G) from spindle housing (H). Discard bearing. 5.Remove and discard upper bearing (I). 6.Clean entire assembly. 7.Install a new lower b...
Page 43 - Service Electrical - 41; Cleaning Battery and Terminals; Using Booster Battery; Replacing Fuse; Burnishing the PTO Clutch
Service Electrical - 41 SERVICE ELECTRICAL Installing: 1.Install battery (H) using J-bolts (G), bracket (F), washers and nuts (E). 2.Connect the positive battery cable (D) first, then the negative cable (B). 3.Apply petroleum jelly or silicone spray to the terminals to prevent corrosion. 4.Slide cov...
Page 44 - Service Electrical - 42; Wiring Schematic
Service Electrical - 42 SERVICE ELECTRICAL Wiring Schematic
Page 45 - Service Miscellaneous - 43; SERVICE MISCELLANEOUS; Service Miscellaneous; Using Proper Fuel; Checking Tire Pressure; Removing and Installing Rear Drive Wheels
Service Miscellaneous - 43 SERVICE MISCELLANEOUS Service Miscellaneous Using Proper Fuel Use regular grade unleaded fuel with an octane rating of 87 octane or higher. Fuel blends containing up to 10% ethanol or up to 15% MTBE reformulated fuel are acceptable. Do not use fuel or additives containing ...
Page 46 - TROUBLESHOOTING; Cleaning and Repairing Plastic Surfaces; Troubleshooting; Using Troubleshooting Chart
Troubleshooting - 44 TROUBLESHOOTING 2.Slightly loosen five wheel nuts (A). 3.Lift machine with a safe lifting device. 4.Remove wheel nuts. 5.Remove wheel and tire assembly (B). Installing Rear Drive Wheels/Tightening Hardware: 1.Install new wheel and tire assembly. 2.Install and tighten wheel nuts ...
Page 47 - Engine
Troubleshooting - 45 TROUBLESHOOTING Engine Electrical System If Check Engine Will Not Start or Is Hard to Start Motion control levers not in the neutral detent (or neutral lock) position. Park brake lever unlocked. Key switch not in proper position. PTO engaged. Loose or corroded starter cable conn...
Page 48 - Machine
Troubleshooting - 46 TROUBLESHOOTING Machine Park Brake Steering Mower Deck PTO Clutch Does Not Engage Blown 20-amp fuse (main power circuit). Faulty PTO switch. Faulty PTO clutch. Loose PTO clutch connections. Starter Turns Slowly Loose or corroded battery or ground connections. Low battery power -...
Page 49 - STORAGE; Storage; Storing Safety; Removing Machine From Storage
Storage - 47 STORAGE Storage Storing Safety Preparing Machine for Storage 1.Repair any worn or damaged parts. Replace parts if necessary. Tighten loose hardware. 2.Repair scratched or chipped metal surfaces to prevent rust. 3.Remove grass and debris from machine. 4.Clean under the deck and remove gr...
Page 50 - ASSEMBLY; Assembly; Bag of Parts
Assembly - 48 ASSEMBLY Assembly Bag of Parts Prepare for Assembly • Remove machine from the shipping crate: • Remove box containing operator seat. • Cut plastic tie straps fastening the front wheels to the shipping crate. • Cut plastic tie straps holding the discharge chute up. • Cut plastic tie str...
Page 51 - SPECIFICATIONS; Specifications
Specifications - 49 SPECIFICATIONS NOTE: Using a tapered drift will aid in the alignment of mounting holes and ease installation of cap screws. 5.Lay ROPS on the ground, slide it up to the bumper and align the appropriate hole in the ROPS flange with the lower rear mounting holes in the machine fram...
Page 52 - Getting Quality Service - 50; GETTING QUALITY SERVICE; Getting Quality Service
Getting Quality Service - 50 GETTING QUALITY SERVICE Inflation Rear (Maximum) . . . . . . . . . . . . . . . . . . . . .69-97 kPa (10-14 psi) Wheel Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 N•m (75 lb-ft) Capacities Fuel Tank . . . . . . . . . . . . . . . . . . . . . . ...
Page 53 - Getting Quality Service - 51
Getting Quality Service - 51 GETTING QUALITY SERVICE
Page 54 - ENGINE AND RELATED COMPONENTS - B&S 23 HP VANGUARD
ENGINE AND RELATED COMPONENTS - B&S 23 HP VANGUARD - 52 ENGINE AND RELATED COMPONENTS - B&S 23 HP VANGUARD
Page 56 - ENGINE AND RELATED COMPONENTS - B&S 26 HP ELS
ENGINE AND RELATED COMPONENTS - B&S 26 HP ELS - 54 ENGINE AND RELATED COMPONENTS - B&S 26 HP ELS $
Page 58 - ENGINE AND RELATED COMPONENTS - KAWASAKI KAI/KOHLER
ENGINE AND RELATED COMPONENTS - Kawasaki Kai/Kohler - 56 $ '(7$,/$ .RKOHU(QJLQH '(7$,/$ .DZDVDNL.DL(QJLQH ENGINE AND RELATED COMPONENTS - KAWASAKI KAI/KOHLER
Page 60 - FUEL DELIVERY SYSTEM COMPONENTS
FUEL DELIVERY SYSTEM COMPONENTS - 58 FUEL DELIVERY SYSTEM COMPONENTS Ref. No. Part No. Description Qty. Remarks 1 181251 FILLER CAP 1 2 M88753 HOSE 1 3 R56101 CLIP 2 4 GDA10012 FUEL TANK 1 5 D18144 BUSHING 1 6 GDU10026 FUEL PICKUP 1 (INCLUDES M145626) 7 M63277 LOCK NUT 2 7.925 MM (5/16") 8 E5383...
Page 61 - OVER THE LAP CONTROL ASSEMBLY
OVER THE LAP CONTROL ASSEMBLY Ref. No. Part No. Description Qty. Remarks 1 TCU14989 TUBE 2 2 M131171 GRIP 2 3 GDU10047 STRAP 2 4 19M8320 SCREW 4 M10 X 45 5 14M7518 FLANGE NUT 4 M10 6 03M7195 BOLT 2 M10 X 45 7 M85516 LOCK NUT 2 M10 8 TCU13271 ARM 2 9 GDU10275 COVER 1 10 37M7059 SCREW 3 M5 X 12 KIT NU...
Page 62 - ELECTRICAL AND RELATED COMPONENTS - 60; ELECTRICAL AND RELATED COMPONENTS
ELECTRICAL AND RELATED COMPONENTS - 60 ELECTRICAL AND RELATED COMPONENTS
Page 64 - CONSOLE AND CONTROL ASSEMBLY - 62; CONSOLE AND CONTROL ASSEMBLY
CONSOLE AND CONTROL ASSEMBLY - 62 CONSOLE AND CONTROL ASSEMBLY
Page 66 - HYDROSTATIC DRIVE SYSTEM COMPONENTS - 64; HYDROSTATIC DRIVE SYSTEM COMPONENTS
HYDROSTATIC DRIVE SYSTEM COMPONENTS - 64 HYDROSTATIC DRIVE SYSTEM COMPONENTS
Page 68 - TRACTION DRIVE AND BRAKES - 66; TRACTION DRIVE AND BRAKES
TRACTION DRIVE AND BRAKES - 66 TRACTION DRIVE AND BRAKES
Page 69 - TRACTION DRIVE AND BRAKES - 67
TRACTION DRIVE AND BRAKES - 67 TRACTION DRIVE AND BRAKES Ref. No. Part No. Description Qty. Remarks 1 GDA10036 PIVOT 1 2 D25059 ARM 1 IDLER 3 D18076 BUSHING 2 4 959995 FITTING 1 5 D14104 SNAP RING 1 6 24H1441 WASHER 1 7 GDA10032 IDLER 1 8 03M7192 BOLT 3 M10 X 30 9 14M7518 FLANGE NUT 6 M10 10 19H1801...
Page 70 - HYDRAULIC SCHEMATIC - 68; HYDRAULIC SCHEMATIC
Page 72 - FRAME ASSEMBLY
Page 74 - FRONT CASTER ASSEMBLY - 72; FRONT CASTER ASSEMBLY
FRONT CASTER ASSEMBLY - 72 FRONT CASTER ASSEMBLY FRONT CASTER ASSEMBLY
Page 76 - ROPS
ROPS - 74 ROPS NOTES Ref. No. Part No. Description Qty. Remarks 1 200550 ROPS 1
Page 77 - NOTES
Page 78 - SPINDLE ASSEMBLY - 76; SPINDLE ASSEMBLY
Page 80 - DECK LIFT ASSEMBLY - 78; DECK LIFT ASSEMBLY
Page 86 - LABELS
