Assembly

c CAUTION: Avoid injury!

· Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode.

· Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer.

· Do not charge a frozen battery; it may explode. Warm battery to 16 degrees C (60 degrees F).

TS204

Charge the battery for a minimum of 30 minutes at 5-10 amps. If your battery charger has a Deep Cycle or Maintenance Free setting, use this setting to charge the battery. Failure to charge the battery before use will reduce battery performance and life.

Installing Front Roller (2500M)

NOTE: Roller brackets are offset. For standard use, the bracket should be installed to the roller with the offset to the rear of the base cutting unit to allow close proximity of front roller to rear roller.

Install the roller bracket with the larger holes and adjustment slot on the left side of the cutting unit, in the direction of travel.

The roller bearing spindle shaft has holes drilled in each end. Do not tighten set screws near the holes.

M97007

Picture Note: Photo shows left roller bracket being installed.

1. Install roller brackets (A) onto each bearing spindle shaft end.

· Install set screws (B) and lock nuts (C) loosely. DO NOT tighten.

M96838D

2. Select Height of Cut (HOC) adjustment range.

· Alignment of roller bracket (A) and cutting unit frame (D) adjustment holes will determine HOC adjustment range.

· Refer to chart for desired setting.


Height of Cut (2-Inch Front Roller)		Roller Bracket Hole	Cutting Unit Frame Hole
mm	in.	Roller Bracket Hole	Cutting Unit Frame Hole
0-9.5	0-3/8	Top (E)	Top (G)
6.4-16	1/4-5/8	Bottom (F)	Bottom (I)
12.7-22.0	1/2-7/8	Top (E)	Middle (H)


Height of Cut (3-Inch Front Roller)		Roller Bracket Hole	Cutting Unit Frame Hole
mm	in.	Roller Bracket Hole	Cutting Unit Frame Hole
12.7 - 22	1/2 - 7/8	Top (E)	Top (G)
19 - 28.5	3/4 - 1-1/8	Bottom (F)	Bottom (I)
25.4 - 32	1 - 1-1/4	Top (E)	Middle (H)

M97008

3. Install front roller and roller bracket assembly.

· Slide assembly roller brackets (A) into cutting unit frame slots.

· Align selected HOC adjustment holes.

NOTE: Install carriage bolts from the inside.

· Fasten bottom of left roller bracket to frame using one M8 x 20 carriage bolt and one M8 flange nut (E).

NOTE: Install serrated washer with cupped side facing cutting unit frame.

· Fasten top of left roller bracket to frame using one M8 x 40 carriage bolt, one serrated washer (F), one eccentric adjuster (G) and one M8 lock nut (H).

· Fasten right roller bracket to frame using two M8 x 20 carriage bolts and two M8 flange nuts (I).

· Tighten roller bracket attaching hardware.

NOTE: Make sure the roller bracket set screw locations are not aligned with the holes in each bearing spindle shaft end. Set screws must engage the bearing spindle shaft at each end.

M97009

· Center front roller. Tighten set screws (B) and jam nuts (C) on both roller brackets.

4. Adjust height of cut.

Install Front Roller (22 ESP)

1. Remove cap plugs from ends of roller shaft.

M56206

2. Insert grease fittings (A) in both ends.

M56206A

3. Thread set screw (B) half way into adjuster.

4. Thread jam nut (C) onto set screw.


IMPORTANT: Avoid damage! One end of the roller shaft has flats on it. The height adjuster with the set screw also has flats in the roller shaft mounting hole. The two must be on the motor end of the reel.

NOTE: It may be necessary to loosen the height adjuster towers (D) in order to insert the roller.

5. Install and center roller between right and left height adjusters.

Install Counterweights


IMPORTANT: Avoid damage! Counterweights are installed on the end of cutting units opposite of the motors. The reel motors go on the outside of the front, outer and rear cutting units, and on the left side of the front, center unit.

1. 22 ESP: Install counterweights on end of cutting unit opposite the motor.

Install The Cutting Units


IMPORTANT: Avoid damage! Install rollers and set units to the desired height of cut (HOC) before installing cutting units.

M57577B

1. 22 ESP: Install bolt through the lower hole on yoke and through welded bushing (J) at rear of cutting unit side. Do for both sides of units.

E34013

2. Install coupling (K) on reel shaft and install motor.

3. Repeat steps 1 through 4 on the other cutting units.

M57577B

Picture Note: 22 ESP

4. 22 ESP: Connect the chain to the front welded bushing (P) and to the rear hole (L) in the yoke.

Install Grasscatchers (22 ESP)

M86200

1. Attach the metal brace (A) with hex flange head nuts to the cutting unit yoke at (B).

NOTE: The Grasscatcher has two designs, the squared (full) basket used on the three front cutting units and the notched basket used on the back two cutting units.

M86202, M86201

Picture Note: Rear basket shown in top photo; front basket shown in bottom photo.

2. To place the basket on the yoke pull back the catcher lock (C) and place the hooked ends (D) of the basket over the top of the yokes.

Install Scraper Blade (22 ESP)

M78699

1. Fasten scraper blade to roller scraper with 3 M6 x 16 pan screws and nuts. Screw heads (A) must be installed to the inside of the scraper.

NOTE: There is a right and left hand spring and each spring has a long and short leg.

M85450

2. Insert short leg (B) of springs through slots in both ends of scraper.

3. Slide rod (C) through scraper and springs.

M47238

4. Place long leg of spring in groove (F) of height adjuster. Press down and push rod (D) into hole (E) of height adjuster.

5. Follow same procedure for other end of scraper.

M47239

6. Align hole in rod with slot in center of scraper and drive roll pin (G) in flush with top of scraper.

Install Optional ROPS

NOTE: If Light Weight Mower is to be used for low clearance operation and ROPS is not installed, remove seat belt from the seat base.

MX3461

1. Install ROPS (A) angle toward rear of tractor.

M75913

2. Put four flange head cap screws (B) through holes in ROPS.

3. Install spacers (C) and lock nuts (D) (bolt head to the front and spacers to the rear).

4. Tighten bolts to 136 N·m (100 lb-ft.).

Install Seat Belt

c CAUTION: Avoid injury! Use a seat belt ONLY when operating with a roll-over protective structure (ROPS) to minimize chance of injury from an accident such as an overturn.

Do not use a seat belt if operating without a ROPS. Do not install seat belt or remove from seat base if ROPS is not used.

M70248

1. Install belt mounting brackets (A) by putting hole (B) over bottom tab of rubber bumper (C).

2. Fasten brackets to suspension using four M8x16 bolts and nuts (D).

3. Tighten nuts.

NOTE: Install belt halves so white tags (E) face up.

M70249

4. Install belt halves to brackets by putting M10x30 bolts (F) in rear holes.

5. Install spacers (G) on bolts.

6. Install belt brackets (H) over spacers.

7. Install washer.

8. Install M10 lock nuts (I).

9. Tighten lock nuts.

Adjusting Tire Pressure

c CAUTION: Avoid injury! Explosive separation of a tire and rim parts can cause serious injury or death:

· Do not attempt to mount a tire without the proper equipment and experience to perform the job.

· Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion. Welding can structurally weaken or deform the wheel.

· When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of/ or over the tire assembly.

· Check tires for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.

NOTE: Tire pressure at shipment is 104 kPa (15 psi).

1. Adjust tire pressure to 83 kPa (12 psi) for best results in average use.


IMPORTANT: Avoid damage! Tire pressure should never be less than 62 kPa (9 psi) or greater than 104 kPa (15 psi). Tire pressure should be equal for all tires on mower.

A lower pressure may improve traction and performance depending on turf conditions or if transport areas have steep inclines.

Introduction

Product Identification

Safety

Operating Machine

Operating Cutting Units

Replacement Parts

Service Intervals

Service Lubrication

Service Engine

Service Transmission

Service Cutting Units

Service Electrical

Service Miscellaneous

Troubleshooting

Storage

Assembly

Specifications

Warranty

John Deere Quality Statement

Service Record

Assembly

Charge Battery

Installing Front Roller (2500M)

Install Front Roller (22 ESP)

Install Counterweights

Install The Cutting Units

Install Grasscatchers (22 ESP)

Install Scraper Blade (22 ESP)

Install Optional ROPS

Install Seat Belt

Adjusting Tire Pressure