60” Zero-Turn Mower MODELS # 103408 & # 104368 Operation Manual ! This safety alert symbol identifies important safety messages in this manual. Failure to follow this important safety information may result in serious injury or death.
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Table of Contents Important Safety Information Intended Use ...............................................................................4 Personal Protective Equipment ...................................................4 General Safety .............................................................................5 Safety Decals ...............................................................................6 Unpacking & Assembly Attaching the Seat............................................................
Important Safety Information ! WARNING WARNING: Read and thoroughly understand all instructions and safety information before assembling or operating the ZeroTurn Mower. Failure to do so may cause serious injury or death. Do not allow anyone to operate this mower who has not read this manual. As with all power equipment, a mower can be dangerous if assembled or used improperly. Do not operate this mower if you have doubts or questions concerning safe operation.
Important Safety Information General Safety Failure to follow warnings, cautions, assembly and operation instructions in the Operation Manual may result in serious injury or death. ! DANGER READ THE OPERATION MANUAL BEFORE OPERATION. • Do not permit children to operate this equipment at any time. •D o not permit others that have not read and understood the complete Operation Manual to operate this equipment.
Important Safety Information Safety Decals Safety labels on the zero-turn mower are to remind you of important information while you are operating the unit. Make sure all safety warning decals are attached and in readable condition. Replace missing or defaced decals. Contact Dirty Hand Tools at 1-877-487-8275 for replacement decals.
Unpacking & Assembly Remove Mower Components from Crate Open container and remove the mower seat assembly, motion control levers, and all packing materials. Disassemble the front side of the crate and push the mower onto a stable, flat surface. Attaching the Seat Remove the seat assembly from the crate and four hex bolts, four flat washers, and four spring washers from the hardware included.
Unpacking & Assembly Attaching the Battery Cables Connect the positive (red) cable to the positive battery terminal first, then the negative (black) cable to the negative battery terminal. Slip insulator boot over the positive terminal. IMPORTANT: Make sure the negative & positive battery cables are connected correctly and the battery charger has an output of 16 volts and 7 amps or less to avoid damaging the battery. ! DANGER Battery contains sulfuric acid.
Overview of Components Safety Switch Incorporated in Seat Fuel Fill Cap Operation Console Dual Motion Control Levers 7 Speed Transmission Automatic Parking Brake Fabricated Steel Deck with Reinforcement Discharge Cover Cutting Height Adjustment 7 Positions Three 16” Blades 60” Cutting Width 9
Operating Precautions ! CAUTION READ, UNDERSTAND AND FOLLOW ALL OF THE PRECAUTIONS BELOW. •N ever operate the mower without safety shields, discharge cover, other guards and switches in place and in good working order. •K eep hands, feet, and clothing away from rotating parts. Keep clear of mower blades at all times. •U se extreme caution when operating on or crossing gravel drives, walks, or roads. Stay alert for hidden hazards or traffic.
Preparation for Operation Pre-Start Inspection 1. M ake sure safety shields are in place and nuts & bolts are secure. 2. C heck fuel supply. Fill the fuel tank no closer than 1 inch from top of tank to provide space for expansion. 3. Inspect air cleaner. Clean or replace as needed. 4. B e sure spark plug wire is attached and is tightened securely. 5. Examine underneath and around engine for oil or fuel leaks. 6. Inspect fuel hoses for tightness and fuel seepage. 7. Look for signs of engine damage. 8.
Operation Operation Console PTO Engagement Switch must be pulled out to the ROTATE position to engage the blades. Switch is pushed in to the STOP position to stop the blades. Choke Control is used to aid in starting a cold engine. Pull the choke switch up (on) to start a cold engine. DO NOT run a warm engine with choke in the up (on) position. Throttle Control is used to control engine speed. Moving throttle lever forward will increase engine speed and moving throttle lever back will decrease engine speed.
Operation Motion Control Lever Parking Brake Position Motion Control Levers: Located on either side of the mower. The left lever controls the left hydrostatic transaxle and controls the left rear drive wheel to go forward and backward. The right lever controls the right hydrostatic transaxle and controls the right rear drive wheel to go forward and backward. NOTE: To begin movement (forward or backward), the operator must be in the seat.
Operation ! WARNING When going forward, if you rapidly pull the motion control levers to the middle T-slot position and push them out, it may cause the parking brake to lock. • If the parking brake is locked, it may cause the machine not to move when trying to go forward again or rotate at high speed. • Operator may lose control of the machine, which may cause damage to the machine or injury.
Operation Mowing Tips For best cutting appearance, be sure to slightly overlap the mower into the previously cut area. This helps reduce the load on the engine and reduce the chance of plugging the discharge area. If the grass is allowed to grow longer than normal or if it contains a high degree of moisture, raise the cutting height higher than usual and cut the grass at this setting for a first pass then cut again using the lower normal height setting.
Operation Deck Leveling For best cutting appearance, be sure to that the deck is level. An uneven deck will result in uneven grass cutting height. 1. Place the mower on a flat surface. 2. Stop the engine, wait for all moving parts to stop, and remove key. 3. Check tire pressure in drive tires. Proper inflation pressure for the drive tires is 12psi. It is important for both left and right tires to be of equal inflation for proper deck level. 4. Check tire pressure in caster tires.
Operation Moving the Mower Figure 7 Drive Wheel Neutral Lever: Located on both sides of the rear of the frame (see Figure 7). The Neutral Lever is used to control the relief valve of the hydrostatic transaxle. It releases the oil pressure, allowing the machine to be pushed without the engine running. Transporting the Mower Use a heavy-duty trailer or truck to transport the machine. Lock brake and block wheels. Securely fasten the machine to the trailer or truck with straps, chains, cable, or ropes.
Maintenance ! WARNING BEFORE PERFORMING ANY MAINTENANCE PROCEDURE STOP THE ENGINE, WAIT FIVE (5) MINUTES TO ALLOW ALL PARTS TO COOL. Disconnect the spark plug wire, keeping it away from the spark plug. Regular maintenance is the way to ensure the best performance and long life of your machine. Please refer to this manual and the engine manufacturer’s owner’s manual for maintenance procedures.
Maintenance ! WARNING Turn off engine and detach spark plug wire. Engine must be cool before performing any maintenance. Wood Block 1. M ake sure unit is on a level surface, stop engine, and wait for all moving parts to stop. Check with engine cold. 2. C lean area around dipstick. Remove dipstick and wipe oil off. Reinsert the dipstick. Do not screw into place. Remove the dipstick and read the oil level. 3.
Maintenance ! WARNING Do not rely solely on mechanical or hydraulic jacks for support. Use adequate jack stands or equivalent support. Motion Control Lever Linkage Adjustment. 1. Adjustment must be made with the drive wheels turning. Raise the frame and block so that drive wheels rotate freely. 2. Remove the electric circuit of the seat safety switch under the seat. Install a jumper wire to the end of the harness connector temporarily. 3.
Maintenance Dust Cap Hex Nut Spring Washers Figure 10 Caster Pivot Bearing Adjustment Remove dust cap from caster and tighten nylon nut with torque of 37ft-lbs. (50N-m). Rotate or spin the yoke by hand. It should only turn 1 revolution or once around if the torque is correct. If disassembled, make sure the spring washers are reinstalled as shown (see Figure 10). The caster wheels should be checked in the same manner. Brake Cable Adjustment 1. Place the mower on a flat surface. 2.
Troubleshooting ! WARNING BEFORE PERFORMING ANY MAINTENANCE PROCEDURE STOP THE ENGINE, WAIT FIVE (5) MINUTES TO ALLOW ALL PARTS TO COOL. Disconnect the spark plug wire, keeping it away from the spark plug. PROBLEM The engine will not start. 22 SOLUTION • Check that the battery is fully charged. • Check that the PTO switch is disengaged. • Check that the parking brake is set and motion control levers are moved out (neutral lock position). • Check that the fuel valve is open.
Troubleshooting PROBLEM SOLUTION Mower pulls to the left or to the right. • Check air pressure in tires and inflate to recommended psi. • Check the motion control lever adjustments. Excessive mower vibration. • Check blade mounting bolts for tightness. • Check cutting blades for sharpness and straightness. Bent blades or excessively worn blades may cause vibration. • Check drive belt for wear, replace if needed. Drive belt wears out quickly. • Check belt pulleys, replace if bent or worn.
Warranty & Specifications IMPORTANT NOTICE We, the manufacturer, reserve the right to change the product and/ or specifications in this manual without notification. The manual is for information usage only and the pictures and drawings depicted herein are for reference only. Warranty Repair and Service Do not return this product to the store for warranty issues or repair. Call our customer service department at 720-287-5182, 1-877-487-8275, or visit www.dirtyhandtools.
