Husqvarna BZ7234TD/968999264 manual

Please read the operator’ s manual carefull y and make sur e y ou understand the instructions befor e using the machine. English Operat or's manual BZ6127TD/968999262 BZ7234TD/968999264[...]

2 ©2005 Husqvarna All righs reserved. Beatrice, NE Printed U.S.A.[...]

3 Contents ......................................................... 3 Introduction .................................................... 4 Congratulations ........................................... 4 General ........................................................ 4 Driving and Transport on Public Roads ...... 4 Operating .........................[...]

4 INTRODUCTION Introduction Congratulations Thank you for purchasing a Husqvarna ride-on mower. This machine is built for the greatest efficiency and rapid mowing of large areas. Conveniant controls and a hydrostatic transmission regulated by steering levers also contribute to the machine’s performance. This manual is a valuable document. Followi[...]

5 INTRODUCTION Good Service Husqvarna’s products are sold only in specialized retail stores with complete service. This ensures that you as a customer receive only the best support and service. Before the product is delivered, the machine has, for example, been inspected and adjusted by your retailer, see the certificate in the Service Journal in[...]

6 SYMBOLS AND DECALS Symbols and Decals These symbols are found on the machine and in the operator’s manual. Study them carefully so that you know what they mean. Used in this publication to notify the reader of a risk of personal injury , particularly if the reader should neglect to follow instructions given in the manual. IMPORTANT INFORMATION [...]

7 SAFETY INSTRUCTIONS Safety Instructions These instructions are for your safety. Read them carefully. General Use • Read all instructions in this operator’s manual and on the machine before starting it. Ensure that you understand them and then abide by them. • Learn how to use the machine and its con- trols safely and learn how to stop quick[...]

8 SAFETY INSTRUCTIONS • Be careful when rounding fixed objects, so that the blades do not hit them. Never drive over foreign objects. • Only use the machine in daylight or in other well-lit conditions. Keep the machine a safe distance from holes or other irregularities in the ground. Pay attention to other possible risks. • Never use the mach[...]

9 SAFETY INSTRUCTIONS 6003-004 Mow up and down, not side-to-side. Driving on Slopes Driving on slopes is one of the operations where the risk is greatest that the driver will lose control or the machine will tip over, which can result in serious injury or death. All slopes require extra caution. If you cannot reverse up a slope or if feel unsure, d[...]

10 SAFETY INSTRUCTIONS Children: • Serious accidents may occur if you fail to be on guard for children in the vicinity of the ma- chine. Children are often attracted to the ma- chine and mowing work. Never assume that children will stay put where you last saw them. • Keep children away from the mowing area and under close supervision by another[...]

11 SAFETY INSTRUCTIONS • Allow the engine to cool before refueling. Do not smoke. Do not fill fuel in the vicinity of sparks or open flames. • If leaks arise in the fuel system, the engine must not be started until the problem has been resolved. • Store the machine and fuel in such a way that there is no risk of leaking fuel or fuel vapor lea[...]

12 SAFETY INSTRUCTIONS • Never use the machine indoors or in spaces lacking proper ventilation. The exhaust fumes contain carbon monoxide, and odorless, poi- sonous, and lethal gas. • Stop and inspect the equipment if you run over or into anything. If necessary, make repairs before starting. • Never make adjustments with the engine run- ning.[...]

13 WARNING! This structure’s capability may be imparired by structural damage if overturned, or al- teration occurs. If any of these conditions take place, the total structure MUST be re- placed. DO NOT use ROPS as a lifting, attaching or anchoring point. DO NOT exceed Max GVW: 3553; ROPS mass 72 lbs./32 kg. Read machine operator’s manual befor[...]

14 SETUP AND ADJUSTMENTS Setup Uncrate machine. WARNING! No settings or adjustments are to be made unless: Engine is stopped, key has been removed, park brake is on and bat- tery cable removed from battery. Seat Assembly 1. Remove inner seat latch pin `E’ ring and slide pin out to left releasing latch, spring and washer. 2. Rotate latch so hook w[...]

15 ROPS Assembly (Roll Over Protection System) ROPS Assembly Components 1 - Top Loop 1 - Left Side Post 1 - Right Side Post 1 - Hardware Bag 2 - 1/2” Latch Pins w/lanyard 2 - 1/2C x 3 1/4” Cap screws 2 - 1/2C Centerlock nuts 4 - 5/8C X 3” Cap screws 4 - 5/8C Centerlock nuts 8 - 5/8 Washer, flat 2 - Knobs (all hardware Grade 5). 1. Remove roll[...]

16 Lift Lever Deck Height Adjusment Plates FIG - 3 Cutting Height Stop the mower and disengage the blades. Raise the deck height lever to the transport posi- tion. Remove the height adjustment pin and place it in the desired cutting height hole. Lower the lift lever down onto pin. NOTE: Anti-scalp rollers must be in the proper position for maximum [...]

17 Mower Deck Leveling Position machine on a flat surface. Preferably level concrete. Check the tire pressure in all four tires. Inflation should be 15 psi. Place 2x4’s on edge under the cutting deck from front to rear and lower the deck down onto 2x4’s. Adjust the four lower chain bolts to the center slots on the deck. FIG - 4 NOTE: Make sure [...]

18 CONTROLS Presentation This operator’s manual describes the Husqvarna Lever-Steered Rider Mower. The mower is fitted with a liquid cooled, 3 cylinder Daihatsu diesel engine (27 HP) or Daihatsu Turbo diesel engine (34 HP). Transmission from the engine is made via two belt-driven hydraulic pumps, which in turn drive a hydraulic motor for each dri[...]

19 Throttle Control The throttle control regulates the engine speed. In order to increase or decrease the engine speed, the control is moved forward or backward respectively. Avoid idling the engine for long periods. Use full throttle when mowing. Ignition The ignition key is placed in the front console and is used to start the machine. Hour Meter [...]

20 CONTROLS Engaging the mower deck BAM-2 Engaging the Mower Deck In order to engage the mower deck, pull the knob out; the mower deck is disengaged when the knob is depressed. Deck should be engaged at mid throttle and disengaged at idle speed to prolong clutch life. Parking brake not activated BAM-4 Seat Adjustment Lever & Suspension Adjustme[...]

21 CONTROLS Motion control levers BAM-6 Motion control lever pattern (right side) FORWARD NEUTRAL NEUTRAL SLOT NEUTRAL LOCK FRONT OF MOWER REVERSE Motion Control Levers The machine’s speed and direction are continuously variable using the two motion control levers. The motion control levers can be moved forward or backward from a neutral position[...]

22 If the steering controls are in uneven positions when standing still, they can be adjusted using the adjustment screws, not the link system, for the controls CONTROLS Hydraulic lift switch BAM-2 Adjusting screws ADJUSTINGSCREWS Hydraulic Lift Switch Used to raise and lower the mower deck hydraulically. Only used on units with power deck lifts. P[...]

23 CONTROLS WARNING! Diesel fuel is highly flammable. Observe caution and fill the tanks outdoors (see the safety rules). Fuel tanks BAM-8 Fuel shut-off BAM-9 Fuses BAM-10 Refueling The machine has two fuel tanks, one on each side just behind the seat. The tanks hold 11.4 gallons, 5.7 gallons each. The engine is run on clean, fresh, diesel fuel wit[...]

24 CONTROLS Hydraulic switch BAM-2 The mower deck’s lifting leer and foot pedal BAM-11 Manual Lifting Lever with Foot Assist for the Mower Deck The lifting lever is used to place the mower deck in the transport position or one of the 17 different cutting height positions. The cutting height is set by placing a pin in the hole for the desired cutt[...]

25 Relays BAM-12 CONTROLS Relays The relays and glow plug timer are located in a holder to the right side of the seat. Mulch kit attachment 8011-566 Accessories For mulching, there is a Mulch Kit attachment available. This is mounted underneath the mower deck and comprised of baffles and mulch blades. GLOW PLUG TIMER GLOW PLUG RELAY RUN RELAY START[...]

26 Running Before Starting • Read the sections Safety Instructions and Presentation before starting the machine. • Perform the daily maintenance before starting (see Maintenance Schedule in the Maintenance section). • Check that there is sufficient fuel in the fuel tanks. • Adjust the seat to the desired position. The following conditions m[...]

27 5. Move the steering controls outward to the locked (outer) neutral position. 6. Move the throttle to the middle position. OPERATION Set the throttle BAM - 2 Steering controls in the outward, locked neutral position STEERINGPOSITIONS[...]

28 OPERATION Open the fuel switch BAM-9 Wait till the glow plug light goes out or dam- age could result to the engine. IMPORTANT INFORMATION Start position 9. When the engine starts, immediately release the ignition key back to the run position. To prolong starter life, use short starting cycles, not to exceed 30 secs./min. Ex- tended cranking can [...]

29 Running 1. Release the parking brake by moving the lever forward. 2. Move the motion control levers out of the neutral slot/lock position (N). Set the engine speed BAM - 2 WARNING! Never run the engine indoors, in enclosed or poorly ventilated spaces. Engine exhaust fumes contain poisonous carbon mon- oxide. OPERATION Released parking brake BAM-[...]

30 OPERATION Hydraulic switch BAM - 2 Cutting height selection (27.5 HP) 8011-561 Engaging the mower deck BAM - 2 WARNING! Make sure that no one is near the machine when engaging the mower deck. IMPORTANT INFORMATION The mower deck’s anti-scalp rollers should be evenly adjusted. See Maintenance section. 3. Select the cutting height by placing the[...]

31 disengaged before the motion control levers can be moved from the neutral slots or the engine will kill. By moving the levers an equal amount forward or back the machine will move in a straight line in that direction. Movement of either lever forward will cause the right or left wheel to rotate in a forward direction. To stop movement pull both [...]

32 OPERATION dense, the driving speed can be increased without noticeably depreciating the mowing result. • The finest lawns are obtained by mowing often. The mowing becomes more even and the grass clippings more evenly distributed over the mown area. The total time taken is not increased as a higher driving speed can be used without poorer mowin[...]

33 OPERATION Disengaging the mower deck BAM - 2 WARNING! Make no adjustments without: - the engine stopped, - the ignition key removed, - the parking brake activated. Raise the mower deck with the lifting lever on manual decks 8011-552 System relief valve on the hydraulic pump Stopping the Engine Allow the engine to idle a minute in order to attain[...]

34 MAINTENANCE Maintenance Maintenance Schedule The following is a list of maintenance procedures that must be performed on the machine. For those points not described in this manual, visit an authorized service workshop. An annual service carried out by an authorized service workshop is recommended in order to maintain your machine in the best pos[...]

35 Maintenance Daily maintenance Before After Weekly mainte- nance At least once each year Maintenance interval in hours 300 100 50 25 Lubricate the steering control shafts Lubricate the mower deck’s struts Lubricate the mower deck’s cutting height adjuster Check/adjust the cutting height Change inner (safety) air filter element Clean the air c[...]

36 Checking the Safety System The machine is equipped with a safety system that prevents starting or driving under the following conditions. The engine can only be started when: 1. The mower deck is disengaged. 2. The motion control levers are in the outer, locked neutral position. 3. The driver is sitting in the driver’s seat. 4. The parking bra[...]

37 Checking the Engine’s Cooling Air Intake Check that the engine’s cooling air intake is free from leaves, grass, and dirt. If the cooling air intake is clogged, engine cooling deteriorates, which can lead to engine damage. The radiator screen can be removed and cleaned . Checking and Adjusting the Throttle Cable Check that the engine responds[...]

38 Replacing the Air Filter If the engine seems weak or runs unevenly and the dust load indicator has turned red the air filter may be clogged. If run with a clogged air filter, disruption of operation can occur. Cleaning/replacing the air filter is carried out as follows Only do so when the dust indicator is red. MAINTENANCE Remove the air filter [...]

39 Replacing the Fuel Filter The fuel filter is located with the priming pump. Replace the fuel filter every 800 hours (once per season) or more regularly if it becomes clogged. Replace the filter as follows: Unscrew fuel filter from pump and replace. Every 50 hours check for water in the fuel filter. Empty if necessary. Refer to the engine manual.[...]

40 When refilling the system, it is important that all trapped air be purged. The following procedure will help to insure this: 1. Make sure the engine is level. Fill the overflow reservoir up to the MAX mark with coolant mixture. 2. Slowly fill the radiator to the bottom of the filler neck with coolant mixture. 3. With radiator cap off, start the [...]

41 contact between brake shoes and drum can be felt. Hold in this position. 4. Rotate clevis until clevis pin can just be inserted thru clevis and brake lever with pin resting against rear of the hole in brake lever. 5. Remove clevis pin and rotate clevis two (2) full turns toward rear to allow correct clearance between brake shoes and drum. 6. Tem[...]

42 NOTE: Keep top of battery clean and free of corrosion by washing with a solution of baking soda and water OR ammonia and water. Rinse with clean water. Batteries with heavy corrosion should be removed and cleaned with solution. Battery cable should be disconnected before using a “Fast Charger”. MAINTENANCE WARNING! If a leak is suspected, us[...]

43 MAINTENANCE Place a 2 x 4 board between the foot plate and the center of the seat to engage the seat safety switch. Loosen the nuts (A & B) directly behind each ball joint on linkages (C). See illustration. Start the engine. The park brake must be engaged and the motion control levers in the neutral slots to start the engine. Run the engine [...]

44 Begin with either side and put the motion control lever into the neutral position. Adjust the motion control linkage by rotating the double nuts (D) in the proper direction until the wheel stops rotating. See illustration. Move the motion control lever forward then into the neutral position and place it into the neutral slot. The wheel must be s[...]

45 LUBRICATION Lubrication Lubrication Schedule Lubrication schedule 8011-620 General Remove the ignition key to prevent unintentional movements during lubrication. When lubricating with an oil can, it should be filled with engine oil. When lubricating with grease, unless otherwise stated, a lithium based grease or another chassis or ball bearing g[...]

46 Lubricating the Cables If possible, grease both ends of the cable and move the controls to end stop positions when lubricating. Refit the rubber covers on the cable after lubrication. Cables with sheaths will bind if they are not lubricated regularly. If a cable binds, it can disrupt operation. If a cable binds, remove the cable and hang it vert[...]

47 LUBRICATION IMPORTANT INFORMATION Used engine oil is a health hazard and numt not be disposed of on the ground or in nature; it should always be disposed of at a service center or approprite disposl location. A void skin contact; wash with sopa and water in case of spills. WARNING! Engine oil can be very hot if it is drained directly after stopp[...]

48 LUBRICATION The oil level should be between the markings on the dipstick. If the level is approaching the “ADD” mark, add the oil to the “FULL” mark on the dipstick. Never fill above the “FULL” mark. The oil is topped off through the dipstick hole. Use engine oil SAE 30 or SAE 10W-30 or, alternately, 10W/40, class CF - 4, CI - 4 (ove[...]

49 LUBRICATION 5. Front Wheel Mount Lubricate with a grease gun, one zerk for each wheel mount, use 10 pumps of the grease gun at the recommended service intervals. Use only good quality lithium based grease. Grease from well-known brand names (petrochemical companies, etc.) usually maintains a good quality. 6. Front Wheel Bearings Lubricate with a[...]

50 9. Steering Control Shafts Tip the driver’s seat. Lubricate with a grease gun, one zerk for each steering control shaft, until the grease is forced out. Use only good quality lithium based grease. Grease from well-known brand names (petrochemical companies, etc.) usually maintains a good quality. 10. Mower Deck Struts Lubricate with a grease g[...]

51 13. Changing the Oil Filter 1. Drain the engine oil in following the procedure in the section, Engine Oil/ Change Engine Oil. 2. Disassemble the oil filter. If necessary, use a filter remover. 3. Partially fill the new filter with oil. 4. Wipe new, clean engine oil onto the seal for the new filter. 5. Mount the filter by hand with + 3/4 turn. 6.[...]

52 TROUBLE SHOOTING GUIDE Trouble Shooting Guide Problem Cause The engine will not start. • The control for engaging the mower deck is not depressed. • The steering controls are not locked in the neutral position. • The driver is not sitting in the driver’s seat. • The parking brake is not activated. • The battery is dead. • Contamina[...]

53 TROUBLE SHOOTING GUIDE The engine overheats. • Clogged air intake or cooling fins. • Engine overloaded. • Poor ventilation around engine. • Defective engine speed regulator. • Soot in the combustion chamber. • Too little or no oil in the engine. • Water pump not working. • Coolant system clogged. • Coolant level low. Battery no[...]

54 TROUBLE SHOOTING GUIDE The machine vibrates. • The blades are loose. • The blades are incorrectly balanced. • The engine is loose. • Wheels loose.[...]

55 WARNING! Never store an engine with fuel in the tanks indoors or in poorly ventilated spaces where fuel va- por cancome in contact with open flames, sparks, or a pilot light such as in a boiler, hot water tank, clothes drier, etc. Handle the fuel with care. It is very flammable and careless use can cause serious personal injury and property dama[...]

56 TECHNICAL DATA Technical Data Measurements, Weights, Etc. Length 95 in. Width (lowered discharge chute) 74 in.(61" deck), 85 in. (72" deck) Width (raised discharge chute) 62 in. (61" deck), 73 in. (72" deck) Height 46.5 in. Weight BZ6127D BZ7234D 1540 lbs. 1620 lbs. Cutting width 61 in. and 72 in. Cutting height Adjustable 1.[...]

57 TECHNICAL DATA Clutch Electric w/intragal stop brake rating torque rating 300 ft./lbs. Noise Emissions and Cutting Width Measured noise level YY dB(A) Guaranteed noise level 105 dB(A) Cutting width 61 in. and 72 in. Electrical System Type 12 V, negative earth Battery 12 V, maintenance-free Primary fuse Flat pin 20 A Electric clutch Electromagnet[...]

58 SERVICE JOURNAL Delivery Service 1. Charge the battery. 2. Mount the rear wheels. 3. Adjust the tire pressure of all wheels to 16 PSI. 4. Mount the steering controls in the normal position. 5. Connect the lever to the seat stop. 6. Connect the contact box to the cable for the seat’s safety switch. 7. Mount the arm rests on the seat’s back su[...]

59 Action Date, mtr reading, stamp, sign SERVICE JOURNAL 20. Inform the customer about: The need and advantages of following the service schedule. The need and advantages of leaving the machine for service every 300 hours. The effects of service and maintaining a service journal on the machine’s resale value. Application areas for Mulch kit. 21. [...]

60 SERVICE JOURNAL Action Date, mtr reading, stamp, sign 25-Hour Service 1. Check the hydraulic system’s oil level. 2. Check the tire pressures. 3. Lubricate the belt adjuster, mower deck. 4. Lubricate the belt adjuster, hydraulic pumps. 5. Lubricate the belt adjuster, mule drive.[...]

61 50-Hour Service 1. Perform the 25-hour service. 2. Change oil and oil filter for the first time. See engine manual. 3. Check dust load indicator on air filter.Change filter only if indicator is red. See engine manual. 4. Lubricate the front wheel bearings. 5. Lubricate the steering control shafts. 6. Lubricate the mower deck struts. 7. Lubricate[...]

62 100-Hour Service 1. Perform the 25-hour service. 2. Perform the 50-hour service. 3. Change engine oil at 150 hours. See engine manual. 4. Check fuel pump filter. See engine manual. 5. Check fan belt clearance. See engine manual. 6. Clean the cooling fins on the engine and transmission. SERVICE JOURNAL Action Date, mtr reading, stamp, sign[...]

63 300-Hour Service 1. Inspect the machine. Come to agreement with the customer as to which additional work is to be carried out. 2. Perform the 25-hour service. 3. Perform the 50-hour service. 4. Perform the 100-hour service. 5. Check/replace the air cleaner’s safety element. SERVICE JOURNAL Action Date, mtr reading, stamp, sign[...]

64 At Least Once Each Year 1. Replace the air cleaner’s safety element. 2. Replace the air filter’s paper cartridge. 3. Change the engine oil (150 hours). 4. Replace the engine oil filter (300 hours). 5. Change the oil and filter in the hydraulic system (300 hours). 6. Check/adjust the cutting height. 7. Check/adjust the parking brake (50 hours[...]

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