Operating Machine

· Inspect machine before you operate. Be sure hardware is tight. Repair or replace damaged, badly worn, or missing parts. Be sure guards and shields are in good condition and fastened in place. Make any necessary adjustments before you operate.

· Clear work area of objects that might be thrown. Keep people and pets out of the work area. Stop machine if anyone enters the area.

· If you hit an object, stop the machine and inspect it. Make repairs before you operate. Keep machine and attachments properly maintained and in good working order.

· DO NOT leave machine unattended when it is running.

· Only operate during daylight or with good artificial light.

· Be careful of traffic when operating near or crossing roadways.

· Do not wear radio or music headphones while operating the machine. Safe operation requires your full attention.

Park Safely

· Stop machine on a level surface, not on a slope.

· Disengage PTO.

· Lower attachments to the ground.

· Engage and lock park brake.

· STOP engine.

· Remove key.

· Before you leave the operator's location, wait for engine and all moving parts to STOP.

Rotating Blades are Dangerous - Protect Children and Prevent Accidents

PROTECT CHILDREN:

MIF

· Never assume that children will remain where you last saw them. Children are attracted to mowing activity, stay alert to the presence of children.

· Keep children in the house when you are operating the machine.

· Turn machine off if a child enters the mowing area.

· Use extra care when you come to blind corners, shrubs, trees, or other objects that may block your vision.

· DO NOT let children or an untrained person operate the machine.

· DO NOT carry or let children ride on machine or any attachment. DO NOT tow children in a cart or trailer.

HELP PREVENT SERIOUS OR FATAL ACCIDENTS:

· Be alert at all times, drive forward carefully. People especially children can move quickly into the mowing area before you know it.

· Back carefully. Shut off PTO and look behind the machine carefully, especially for children, before you back up.

· DO NOT mow in reverse unless it is absolutely necessary.

· Shut off PTO when you are not mowing.

· DO NOT operate machine if you are under the influence of drugs or alcohol.

Operate Sulky Safely

M73408

· Use sulky ONLY on EVEN terrain for mowing mostly in a straight line.

· Be careful when you drive sulky and mower through a dip. Handlebars may hit you, ESPECIALLY when you make a turn.

· DO NOT use sulky on steep slopes.

Avoid Tipping

· DO NOT drive where machine could slip or tip.

· Stay alert for holes and other hidden hazards in the terrain.

· Keep away from drop-offs.

· Slow down before you make a sharp turn or operate on a slope.

· Mow across a hill-not up and down. Be careful when you change direction on a slope.

· DO NOT stop when going up hill or down hill. If machine stops going up hill, STOP PTO and back down slowly.

· DO NOT mow wet grass. Reduced traction could cause sliding.

Operator Training Required

· Study operation section of this manual before operating the machine.

· Operate machine in an open, unobstructed area under the direction of an experienced operator.

· Learn the use of all controls.

· Operator experience is required to learn the moving, stopping, turning and other operating characteristics of the machine.

Keep Riders Off

M73404

· Only allow the operator on the sulky. Keep riders off sulky and mower.

· Riders on the machine may be struck by foreignobjects or thrown off the machine causing serious injury.

· Riders obstruct the operator's view resulting in the machine being operated in an unsafe manner.

Using Operator Presence

M92094A

The operator presence system is designed to protect the operator. The operator presence bail (A) can be operated by either the left or right hand.

To operate the PTO, the operator presence bail (A) must be held down against the handlebars by the operator.

If the operator releases the operator presence bail (A) while mowing; the engine will automatically stop.

Using Steering Control Levers

M92094A

The steering control levers (A & B) are used to steer the unit. When each steering control lever is sqeezed or partially squeezed, the transmission on the side the steering control lever is engaged will slow down. The left and right hand sides work independently from each other.

Left steering control lever (A) controls left drive wheel. Pull lever up to turn LEFT.

Right steering control lever (B) controls right wheel. Pull lever up to turn RIGHT.

Using Neutral Locks

The neutral locks (A) are designed to hold a transmission in neutral and give the operator the opportunity to perform a different control function.

M92094A

NOTE: Left and right neutral locks work independently from each other.

1. Pull up steering control levers (B) to a neutral position. Push and engage each neutral lock (A) forward with thumbs.

M92101

· Neutral lock released into an operational position (C).

M92102

· Neutral lock pushed forward and locked in a set park brake position (D).

2. Release neutral locks:

· Pull up steering control levers and neutral locks will automatically release.

If the neutral locks cannot be engaged, or If the neutral locks are engaged and the drive wheels begin to creep, an adjustment will be necessary. (See Adjusting Neutral Position in the Service-Transmission section.)

Using the Speed Control Lever

M92103

The functions of the Speed Selector Lever (A) are:

· Controls forward speed and reverse motion.

· Operates as a park brake position when pulled completely back to the "Z" position.


IMPORTANT: Avoid damage! Help prevent damage to the transmission. Lever engagements and releases should be gradual and performed smoothly.

Forward:

· Move throttle lever to the "r" position.

· Hold down operator presence bail.

· Move speed control lever forward to a desirable walking speed.

· Speed range is approximately 0-8.1 km/h (0-6 mph).

· To stop forward travel, return speed control lever to the "Z" position or squeeze both steering control levers up to a neutral position.

· The transmission neutral position is adjustable. If adjustment is required, see Adjusting Neutral Position in the Service-Transmission section.

Reverse:

· Move speed control lever forward just beyond 25 mm (1 in.) from the "Z" position.

· Pull up both steering control levers to engage reverse motion.

· Reverse speed is approximately 0-1.6 km/h (0-1 mph).

· To stop reverse motion, slowly release steering control levers and return speed control lever to the "Z" position.

· The transmission neutral position and short reverse rods are adjustable. If adjustment is required, see Adjusting Neutral Position in the Service-Transmission section or Adjust Short Reverse Rods in the Service-Miscellaneous section.

The transmissions control machine forward and reverse motion. If any drivetrain slippage is suspected, check drive belt tension. (See Adjusting Transmission Drive Belt Tension in the Service-Transmission section.)

Using Tracking Adjustment Knob

NOTE: The tracking control knob should NOT be used to steer the machine.

Right and left transmission speeds will vary with travel speed and RPM variations.

M92103

The tracking adjustment knob (A) will allow the machine to maintain a straight line direction of travel.

Adjust Tracking

NOTE: To improve straight line tracking, drive wheel pressures must be equal. See Checking Tire Pressure in the Service-Miscellaneous section.

Tracking adjustment is done on-the-go at a preferred travel speed.

1. Slowly move the speed control lever forward to a desired mowing speed.

2. Turn tracking adjustment knob (A) in the direction the machine needs to move.

· Tracking knob adjustments should be done in 1/4 turn or less increments.

· If the machine moves to the left, turn the tracking adjustment knob to the right. Adjust direction of travel by pulling up the right steering control lever.

· If machine moves to the right, turn the tracking adjustment knob to the left. Adjust direction of travel by pulling up the left steering control lever.

3. Continue the adjustment process until the machine travels in a desirable straight line direction.

Using the Choke

M92103

Pull knob (A) up to CHOKE engine

Push knob (A) down to OPEN choke.

Using the Throttle Lever

M92103

Push lever (A) all the way forward to FAST position. Use this position when you mow.

Pull lever (A) to rear to SLOW position. Do not run engine at SLOW idle any longer than necessary.

Using the Hour Meter

NOTE: If machine is equipped with an electric start, the hour meter will continue to run with the key switch left on.

The hour meter (A) shows number of hours the machine has run.

M92092

The service interval chart gives necessary service intervals.

Use the hour meter and service interval chart to determine when machine will need service.

(See Service Interval Chart section.)

Using the PTO Switch

NOTE: Prior to engaging the PTO, the operator presence lever must be engaged. See Using Operator Presence Lever in this section.

M92103

Engage PTO:

· Move throttle lever (B) to the 1/2 to 3/4 FAST position.

· Pull knob (A) up.

· Move throttle lever (B) forward to the FAST (r) position for mowing.

Disengage PTO:

· Push knob (A) DOWN.

Using the Key Switch

Start Engine:

M92103

1. Move speed control lever (A) to the "Z" position.

2. Make sure PTO knob (B) is pushed down (disengaged).

3. Turn key switch (C) to the "e" position.

4. Start engine:

· Manual Start Model: Engine is ready to start. Pull starter handle.

· Electric Start Model: Turn key switch to the "R" position to start engine.

Stop Engine:

· Turn key switch to the "STOP" position.

Using Recoil Starter Handle (HD45)

M92097

1. Pull starter handle (A) slowly until you feel resistance within the engine.

2. Pull starter handle fast and steady. Repeat until engine starts.

3. Let starter handle return slowly. Do not let handle snap back when engine starts.

Setting the Park Brake

M92094A

Picture Note: Speed control lever shown in park position.

· Pull speed control lever (A) to the "Z" position to stop forward movement.

Release Park Brake:

c CAUTION: Avoid injury! Help prevent personal injury. Machine will travel forward when the speed control lever is pushed forward.

M92094

Picture Note: Speed control lever shown released from the park position.

· Push speed control lever (A) forward.

Using Park Brake Lock/Speed Limiter

This dual function feature will allow the speed control lever to be locked in a park position and the operator the ability to limit forward travel speed.

Park Brake Lock

· Pull speed control lever to the park position.

M92110

Picture Note: Knob shown with speed control locked in the park position.

· Slide knob (A) completely forward and tighten.

Speed Limiter

· Move speed control lever to a desirable travel speed.

· Slide knob (A) to set position and tighten.

Using Free-Wheeling Levers


IMPORTANT: Avoid damage! To prevent transmission damage, NEVER tow the mower. Push mower by hand only.

When the mower needs to be moved without starting the engine, use the free-wheeling levers:

M92117

· Pull back and latch both free-wheeling control levers (A).

· Release park brake lock.

· Move speed control lever forward a minimum of 25 mm (1 in.).

· Push mower to desired location. Due to transmission gear reduction, machine will move slowly.

For normal mowing operation the free-wheeling levers (A) need to be unlatched and released forward.

M92107

Picture Note: Position (B) shows free-wheeling levers latched to the rear and engaged.

M92106

Picture Note: Position (C) shows free-wheeling levers released forward for operational mowing.

Using Fuel Shut-Off Valve

M92086

This unit is equipped with a 2-position fuel shut-off valve (A). Turn "Red" knob (B) clockwise or counterclockwise to open or close the fuel shut-off valve.

CLOSED (OFF) position (C):

M85247

· When performing any type of engine service.

· When transporting.

· During storage.

OPEN (ON) position (D):

· Fuel shut-off valve must be in the full OPEN (ON) position for proper fuel delivery to the engine.

Using the Fuel Gauge

M86337

The fuel tank (A) has a built in fuel gauge.

1. Remove fuel cap.

2. Look inside fuel tank. Fuel tank has molded-in steps showing the approximate amount of fuel left in the tank.

· 3/4 tank marker (B).

· 1/2 tank marker (C).

· 1/4 tank marker (D).

Starting the Engine

c CAUTION: Avoid injury! Engine exhaust fumes can cause sickness or death.

- If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension.

- If an exhaust pipe extension is not available, open the doors and get outside air into the area.

M92086

1. Check fuel shut-off valve (A):

· Valve must be in the full OPEN (ON) position. (See Using Fuel Shut-Off Valve in this section).

M92104

2. Move speed control lever (B) to the "Z" position.

3. PTO knob (C) must be in OFF (DOWN) position.

4. Position choke knob (D):

· Cold engine: Pull knob up to the CHOKE position.

· Warm/Hot engine: If necessary, pull up knob to CHOKE position.

5. Move throttle lever (E) to set engine speed:

· Cold engine: set throttle lever at 1/2 to 3/4 fast position.

· Warm / Hot engine: set throttle lever in the fast position.

6. Turn key (F) to "e" position.

M92097

7. Start engine:

· Recoil Start: Pull starter handle (G) slowly until you feel resistance within the engine. Pull starter handle fast and steady. Repeat until engine starts. Let starter handle return slowly. Do not let handle snap back when engine starts.

· Electric Start: Turn key (F) to "R" position. Release key when engine starts.

M92104

8. With engine started:

· Push choke knob (D) to the OFF position.

· Move throttle lever (E) to the desired engine speed.

Stopping the Engine


IMPORTANT: Avoid damage! DO NOT stop engine when mower is on a slope of more than 10°. Oil may run through valve train into carburetor and muffler.

Follow steps below before you park, inspect or adjust this unit.

M92104

1. Move speed control lever (A) to the "Z" position.

2. Slowly move throttle lever (B) back to the SLOW (t) position.

3. Turn key (C) to "STOP" position.

4. Lock park brake.

M92086

5. Move fuel shut-off valve (D) to the CLOSED (OFF) position. (See Using Fuel Shut-Off Valve in this section.)

Adjusting Mower Deck Height

36-Inch Decks

The mower deck height adjustment consists of eight different cutting heights. The eight cutting heights range from 25-114 mm (1-4.5 in.) in 13 mm (1/2 inch) increments.

48/54-Inch Decks

The mower deck height adjustment consists of nine different cutting heights. The nine cutting heights range from 25-127mm (1-5 in.) in 13 mm (1/2 inch) increments.

The cutting height indicators (B) are labeled in the mower deck support frame.

NOTE: To maintain a level mower deck, both sides, front and rear of the deck must be adjusted equally.

To change the mower deck cutting height:

M92105

Picture Note: Top photo: 36-Inch Mower Deck

· Pull out spring-loaded pins (A).

M92087

Picture Note: Bottom Photo: 48/54-Inch Mower Deck

· Lift or lower mower deck using handle (C) to the desired mower deck height indicator (B).

· Release spring-loaded pins.

· Make sure spring-loaded pins are fully engaged into the mower deck support bracket holes.

Adjusting Oscillation Stops

c CAUTION: Avoid injury! Help prevent personal injury. Oscillation stops MUST be properly adjusted if an optional grass catcher is used. The weight of the grass catcher and grass clippings will cause the left side of the mower deck to raise up. This may expose the operator or bystanders to thrown objects or rotating blades.


IMPORTANT: Avoid damage! The two oscillation stop bolts (A) have been installed and adjusted to the proper setting at the factory. DO NOT remove the stop bolts. Removal of the bolts could result in damage to the mower deck drive belt system.

Normal Operating Adjustment:

1. Park mower on a level surface.

2. Stop engine.

M92140

3. Locate both adjustable oscillation bolts (A) mounted vertically on the front of the power deck.

NOTE: The distance between the bottom of each stop bolt head and the top of the mower deck A-frame can be reduced if less oscillation is desired.

4. Measure distance (B) between the bottom of each stop bolt head and the top of the mower deck A-frame. The recommended distance is 30 mm. This measurement would allow a maximum 6° mower deck oscillation.

5. If an adjustment is necessary:

· Loosen stop bolt jam nuts (C).

· Adjust stop bolt up or down to obtain the desired distance (B).

· Tighten jam nuts (C).

· Check adjustment.

Operating Adjustment with Grass Catcher Option:

Restricting left side mower deck oscillation is required when optional grass catcher is used.

M92139

· Loosen left side stop bolt jam nuts (C).

· Lower left side stop bolt (A) until it makes contact with top of mower deck A-frame.

· Tighten jam nuts (C).

Adjusting Mower Deck Front Bracket (36-Inch Decks)

M92108

The mower deck front bracket (A) is designed to comply with Domestic (United States) and CE (European) safety standards. This bracket is essentially an extension of the front of the mower deck weldment.

In most cases this bracket should not be changed.

Bracket in lower position:

· This position is for CE (European) safety standards.

Bracket in upper position:

· This position is for Domestic (United States) safety standards.

Daily Operating Checklist

Maintain desirable operational standards and help ensure the safety of the operator by routinely checking the following on a daily basis:

· Test safety systems.

· Check fuel level.

· Check engine oil level.

· Remove grass and debris from machine.

Avoid Damage To Plastic And Painted Surfaces

· Insect repellent spray may damage plastic and painted surfaces. Do not spray insect repellent near machine.

· Be careful not to spill fuel on machine. Fuel may damage surface. Wipe up spilled fuel immediately.

Transporting Machine

· Use a heavy-duty trailer to transport your machine.

· Drive machine forward onto a trailer.

· Move speed control lever to the "Z" position.

· Engage park brake lock.

· Fasten machine to trailer with heavy-duty straps, chains, or cables. Both front and rear straps must be directed down and outward from machine.

· Trailer must have signs and lights required by law.

Testing Safety System

NOTE: This unit is equipped with a Electronic Safety Interlock. Engine will not start unless the PTO switch is in the disengaged position and the speed control lever is in the PARK position.

Use the following checkout procedures to check for normal operation.

If there is a malfunction during one of these procedures, DO NOT operate machine. (See your John Deere dealer)

Perform these tests in a clear open area.

Keep bystanders away.

TEST 1

M92104

1. Push PTO switch (A) down to the DISENGAGED position.

2. Move speed control lever (B) into the "Z" position.

3. Attempt to start engine. Engine should start.

· If engine does not start, there is a problem. (See your John Deere dealer.)

Test 2

M92104

1. Pull PTO switch (A) up to the ENGAGED position.

2. Move speed control lever (B) to the "Z" position.

3. Try to start engine. Engine MUST NOT start.

· If engine starts, there is a problem with the safety interlock circuit. (See your John Deere dealer.)

TEST 3

1. Push PTO switch (A) down to the DISENGAGED position.

m92104

2. Move speed control lever (B) forward from the "Z" position.

3. Attempt to start engine. Engine MUST NOT start.

· If engine starts, there is a problem with the safety interlock circuit. (See your John Deere dealer.)

TEST 4

c CAUTION: Avoid injury! Before engaging mower PTO clear the area of bystanders, ESPECIALLY CHILDREN.

M92104

1. Move speed control lever (B) to the "Z" position.

2. Start engine and move throttle lever (C) to ONE-HALF speed position.

3. With operator presence lever (D) held down, pull PTO switch (A) up to the ENGAGED position. Mower deck will start up.

4. Release operator presence lever. Engine MUST stop.

· If engine does not stop, there is a problem with the safety interlock circuit. (See your John Deere dealer.)

TEST 5

1. Pull up steering control levers and engage neutral locks.

M92104

2. Move speed control lever (B) to the "Z" position.

3. Push PTO switch (A) down to the DISENGAGED position.

4. Start engine and move throttle lever (C) to ONE-HALF speed position.

5. With operator presence lever (D) held down, move the speed control lever (B) forward.

6. Release operator presence lever. Engine MUST stop.

· If engine does not stop, there is a problem with the safety interlock circuit. (See your John Deere dealer.)

TEST 6

M92107

1. Pull back and latch free-wheeling levers (E).

M92104

2. Move speed control lever (B) to the "Z" position.

3. Push and pull machine - rear wheels (drive wheels) should skid.

4. Parking brakes MUST prevent drive wheels from turning.

· If machine moves (drive wheels turn), the brakes need to be adjusted. (See Adjust Park Brake in the Service - Steering And Brakes section.)

5. Release free-wheeling levers.

Checking Mower Blade Stop Time

c CAUTION: Avoid injury! Before engaging mower PTO clear area of bystanders, ESPECIALLY CHILDREN.

1. Set park brake.

M92108

2. Remove belt shield (A).

M92104

3. Start engine and move throttle lever (B) to the 1/2 to 3/4 FAST (r) position.

NOTE: Mower deck will engage and operate. Observe the entire mower drive system rotating.

4. With operator presence levers (D) held down, pull PTO switch (C) up to the ENGAGED position.

5. Move throttle lever (B) forward to the FAST position.

6. Check the mower blade stop time:

· Push PTO switch (C) down to the DISENGAGED position and begin timing.

· Watch mower drive belt. Note time when belt stops to get blade stop time.

· If blade stop time is more than 5 seconds, adjust PTO clutch. (See Adjusting PTO Clutch in the Service - Electrical section.)