COMPLETECONTENTS SECTION00--GENERALINFORMATION Chapter1--GeneralInformation CONTENTS SectionDescription Page SafetyPrecautions2 ............................................................. GeneralInformation2 ......................................................... GasolinePrecautions2 SpecialInformation2 Tools 3 Welding 3 Cleaning 3 ................................................................... FastenerTorqueChart4 .......................................................... SpecialTorques4 ServiceRequirements5 MaintenanceSchedule5 After8hourBreak-InPeriod5 Daily 5 ................................................................... 25HourService5 40HourService5 100HourService5 250HourService/Annually/BeforeSeasonStart-Up5 FluidTypesandCapacities5 ComponentIdentification6 ........................................................ MowerDesignandFunction6 .................................................. NewHollandG5030/G50356 ProductIdentification6 GeneralInformation7 Description 7 ................................................................ HydrostaticDrive7 ........................................................ Brakes 7 ................................................................. ParkingBrake7 Steering 7 EngineIdentification8 SafetyandInstructionDecals9 .................................................... Specifications 13 ................................................................ Troubleshooting 15 ..............................................................
SECTION29--HYDROSTATICTRANSMISSION
SECTION10--ENGINE Chapter1--Engine CONTENTS SectionDescription Page EngineIdentification2 ......................................................... KawasakiFX751VandFX850VEngineServiceManual2 AirCleanerService2 ......................................................... FuelSystemService4 SparkPlugService5 .......................................................... CoolingSystemCleaning6 Throttle/ChokeCable6 ........................................................ FuelShutOffSolenoid7 FuelTank 7 .................................................................. Removal 7 Installation8
Chapter1--HydrostaticTransmission CONTENTS SectionDescription Page HydrostaticTransmission6 HydraulicDiagram7 .......................................................... HydrostaticMaintenance8 ChangingHydraulicFluid8 .................................................... Bleeding/PurgingtheHydraulics10 CheckingtheHydraulicHoses11 ............................................... NeutralAdjustment12 PumpDriveBeltRemoveandReplace13 ....................................... HydrostaticPump14 Removal14 ............................................................. Installation16
Chapter1--HydrostaticTransmission(Continued) CONTENTS SectionDescription Page HydrostaticMotor18 ......................................................... Removal18 Installation18 ............................................................ Hydro-gearPump--PSeries19 Introduction 19 .............................................................. GeneralInstructions19 GeneralDescription19 ExternalFeatures--PRSeries20 HydraulicSchematic21 GraphicalSchematic22 Specifications 23 ProductIdentification24 Safety 25 PersonalSafety25 .......................................................... ToolSafety 25 WorkAreaSafety25 ......................................................... ServicingSafety25 Troubleshooting 26 .............................................................. PumpTroubleshootingChecklist26 PSeriesFlowTestKitInstructions28 .............................................. Description:PSeriesFlowTestKit(PartNumber70661)28 InstallationandTestingProcedures28 .......................................... TestingProcedures28 TestExample29 ......................................................... ServiceandMaintenance30 ExternalMaintenance30 ..................................................... ServiceandMaintenanceProcedures30 Fluids 30 FluidVolumeandLevel30 FluidChange30 Filters 30 PurgingProcedures31 ReturnToNeutralSetting32 ..................................................
SECTION29--HYDROSTATICTRANSMISSION
SECTION29--HYDROSTATICTRANSMISSION Chapter1--HydrostaticTransmission(Continued) CONTENTS SectionDescription Page Tools 33 ....................................................................... Torques 33 PRSeriesPumpRepair34 ....................................................... ReturnToNeutralAssembly34 Disassembly34 .......................................................... Inspection34 Assembly34 ControlArm 35 Disassembly35 Inspection35 Assembly35 FanAssembly36 Disassembly36 Inspection36 ............................................................ Assembly36 InputShaftSeal37 .......................................................... Disassembly37 Inspection37 ............................................................ Assembly37 TrunnionArm(ControlArm)Seal38 ............................................ Disassembly38 Inspection38 ............................................................ Assembly38 CheckValves39 ............................................................ Disassembly39 Inspection39 ............................................................ Assembly39 SystemCheckReliefs(SCRís)orShockValves40 Disassembly40 Inspection40 Assembly40
CONTENTS SectionDescription Page PumpBypass41 ............................................................ Disassembly41 Inspection41 ............................................................ Assembly41 StandardorThruShaftChargePump42 ........................................ Disassembly42 Inspection42 Assembly42 AuxiliaryPump(IfEquipped)43 Disassembly43 Inspection43 Assembly43 EndCapandValvePlate44 Disassembly44 .......................................................... Inspection44 Assembly44 ............................................................ CylinderBlock45 Disassembly45 .......................................................... Inspection45 Assembly45 ............................................................ BlockSpring,ThrustWasher,andThrustBearing46 Disassembly46 .......................................................... Inspection46 Assembly46 ............................................................ SwashplateandCradleBearings47 Disassembly47 .......................................................... Inspection47 Assembly47 InputShaft 48 Disassembly48 Inspection48 Assembly48
SECTION29--HYDROSTATICTRANSMISSION Chapter1--HydrostaticTransmission(Continued)
SECTION29--HYDROSTATICTRANSMISSION Chapter1--HydrostaticTransmission(Continued) CONTENTS SectionDescription Page TrunnionArm49 ............................................................ Disassembly49 Inspection49 ............................................................ Assembly49 ItemList--PWSeries51 ..................................................... GlossaryofTerms52 Hydro-gearLSHTWheelMotor53 GeneralInstructions53 GeneralDescription53 Tools 54 RequiredTools54 Torques 54 DrumandBrake55 Disassembly55 .......................................................... Inspection55 EndCover 56 ............................................................... Disassembly56 Inspection56 ............................................................ GearwheelSet57 Disassembly57 .......................................................... Inspection57 CardanShaft58 ............................................................. Disassembly58 Inspection58 ............................................................ DistributorPlate59 Disassembly59 .......................................................... Inspection59 DiscValve 60 Disassembly60 Inspection60 MotorShaft 60 Disassembly60 Inspection60 ............................................................
SECTION29--HYDROSTATICTRANSMISSION Chapter1--HydrostaticTransmission(Continued) CONTENTS SectionDescription Page BalancePlate61 ............................................................ Disassembly61 Inspection61 ............................................................ BearingsandSeals62 Disassembly62 .......................................................... Inspection62 BearingsandSeals63 Assembly63 MotorShaft 64 Assembly64 BalancePlate64 Assembly64 DiscValve 65 Assembly65 ............................................................ CardanShaft65 Assembly65 ............................................................ DistributorPlate66 Assembly66 ............................................................ GearwheelSet67 Assembly67 ............................................................ EndCover 68 Assembly68 ............................................................ DustCoverandWoodruffKey69 Assembly69 ............................................................ BrakeandDrum69 Assembly69 ............................................................ HGM--ESeriesExplodedView70 HGM--EPartsList71
SECTION31--POWERTAKE-OFF(PTO)
Chapter1--PowerTake-Off(PTO)
CONTENTS
SectionDescription Page
PTODriveBelt2 .............................................................
PTORemovalandReplacement3
PTOClutchReplacement4 .................................................... Removal 4
Installation4 ..............................................................
Clutch/WiringInspection5
ClutchSupplyVoltage5
PTOSwitchVoltageDrop5
ClutchCoilResistance5
ElectricClutchìAirGapîAdjustment6
ClutchBurnishing6
PTOClutchEngagementCircuit7
KeySwitchFunctions8
SeatSwitchFunction8 ....................................................
PTOSwitchFunction8
ClutchRelayFunction8 ....................................................
PTOClutchFunction8
PTOClutchEngagementCircuitTroubleshooting9 ................................
SECTION33--BRAKES
Chapter1--Brakes CONTENTS
SectionDescription Page
ParkingBrake2 .............................................................. Adjustment2
Chapter1--ElectricalComponents CONTENTS SectionDescription Page ElectricalComponentLocations2 ............................................... BatteryMaintenance3 InstallingtheBattery4 ........................................................ RemovingtheBattery5 ChargingtheBattery5 CleaningBatteryandTerminals6 ............................................... IgnitionSwitch7 .............................................................. Removal 7 TerminalIdentification7 Testing 8 Installation8 PTOSwitch 9 ................................................................ Removal 9 ............................................................... Testing 10 Installation10 HourMeter 11 Removal 11 .............................................................. Testing 11 ................................................................ Installation11 ............................................................. LeftandRightTransmisisonSafetySwitches12 Removal12 Testing 13 Installation13 SeatSafetySwitch14 ........................................................ Removal14 ............................................................. Testing 14 Installation14 Relays 15 RelayOperation15 Removal15 ............................................................. Testing 16 Installation17 Fuses 17
SECTION55--ELECTRICALSYSTEM
SECTION55--ELECTRICALSYSTEM
Chapter2--ElectricalCircuits
KeySwitchFunctions5 ....................................................
SafetySwitchandRelayFunctions5
StartCircuitTroubleshooting6 .................................................
EngineKillCircuit7
KeySwitchActivatingKillCircuit8
SeatSwitchActivatingKillCircuit8
EngineKillCircuitTroubleshooting9
EngineRunWithoutOperatorPresent10
KeySwitchFunctions11
SeatSafetySwitchFunction11
SafetyRelayFunction11
PTOAndTransmissionControlSafetySwitchOperation11 .....................
EngineRunWithoutOperatorTroubleshooting12
SafetyCircuits13 ............................................................
StartCircuitCheck13
EngineKillCircuit13 ......................................................
CONTENTS
SectionDescription Page ElectricalSchematic2 ......................................................... StartCircuit 4
SECTION58--MOWERDECK Chapter1--MowerDeck CONTENTS SectionDescription Page DeckDriveBeltRemoveandReplace2 ......................................... DeckDriveBeltRouting3 DeckSpindleBeltRemoveandReplace3 ....................................... DeckSpindleBeltRouting4 DeckAdjustments5 .......................................................... LevelingtheMowerDeckSidetoSide5 SynchronizingHeightofCut6 FronttoRearMowerDeckPitch7 Anti-ScalpWheels9 LiftAssistSpring10 BladeMaintenance10 BladeSpindleServicing12 Removal/Disassembly12 Assembly/Installation13 ................................................. CasterWheelBearings15 CasterPivotBearings15 ..................................................... MowerDeck 16 Removal16 ............................................................. Installation17
SECTION00--GENERALINFORMATION--CHAPTER1 0-1 SECTION00--GENERALINFORMATION Chapter1--GeneralInformation CONTENTS SectionDescription Page SafetyPrecautions2 ............................................................. GeneralInformation2 GasolinePrecautions2 ........................................................ SpecialInformation2 Tools 3 Welding 3 Cleaning 3 FastenerTorqueChart4 SpecialTorques4 ServiceRequirements5 MaintenanceSchedule5 After8hourBreak-InPeriod5 Daily 5 25HourService5 ......................................................... 40HourService5 100HourService5 ........................................................ 250HourService/Annually/BeforeSeasonStart-Up5 FluidTypesandCapacities5 ............................................... ComponentIdentification6 MowerDesignandFunction6 .................................................. NewHollandG5030/G50356 ProductIdentification6 ..................................................... GeneralInformation7 Description 7 ................................................................ HydrostaticDrive7 Brakes 7 ................................................................. ParkingBrake7 Steering 7 EngineIdentification8 ......................................................... SafetyandInstructionDecals9 Specifications 13 ................................................................ Troubleshooting 15
SAFETYPRECAUTIONS
GENERALINFORMATION
Thismanualhasbeenwrittenforthemechanicthat willhavetoserviceandrepairtheNewHolland Zero-Turnmower.Donotattempttoserviceorrepair thezeroturnmoweruntilfamiliarwiththecontentsof thismanual.
• TheNewHollandZero-TurnMowermeetsor exceedsallcurrentsafetyspecificationsineffect atthetimeofproduction.
UsegenuineNewHollandservicepartswhen servicingorrepairingthezero-turnmower.Offthe shelf(aftermarket)repairpartsmaycompromisethe integrityoftheunit.PartsthatdonotmeetNew Hollandspecificationsmayfail,causinginjury, equipmentorpropertydamage.
GASOLINEPRECAUTIONS
Gasolineusedinthezero-turnmowercanbevery dangerousifhandledimproperly.Payveryclose attentiontothefollowing.
• Gasolinefumesaretoxic.
• Eyeandskininjuriescanbeexperiencedif gasolineishandledimproperly.
• Breathingdifficultycanresultifexposedto gasolinefumesinaconfinedarea.
• Gasolinefumesarehighlyexplosive.
• Gasolineishighlyflammable.
Alwaysstoregasolineinacoolwellventilatedarea. Alwaysstoregasolineinanapprovedcontainer designedspecificallyforgasoline.Neverstore gasolineformorethantwomonths.
SPECIALINFORMATION
Neverruntheengineinanenclosedarea.Carbon monoxidefumesfromarunningenginearevery dangerousandcancausepermanentinjuryordeath. Iftheunitmustberunindoors,makesureahoseor similardeviceisusedtoventengineexhaustfumes tooutsideatmosphere.
Whentheenginehasbeenrunning,theengine,the exhaustsystem, andthehydraulicsystem,can becomeveryhot.Ifcomponentsmustbehandled, wearheavygloves.Betteryet,waitfortheunittocool completelybeforeperformingmaintenance.
Hotengineoilandhydraulicoilcancauseserious burns.Wearheavyglovesandsafetyglassesto protectyourselffromoilthatmaygetsplashed.
Alwaysdirectcompressedairawayfromyouor othersaroundyou.Airdrivenparticlesmaypenetrate theskinoreyescausingseriousinjuryorblindness.
Wearsafetyglassesandhearingprotectionwhen repairing,operating,ortestingthezero-turnmower. Wearsafetyglasseswhenhandlingsprings. Detachedspringscanbouncewithenoughforceto damagepropertyorcausepersonalinjury.
Alwaysweargloveswhenhandlingorsharpening cuttingblades.Donotusebladesthataredamaged enoughwheresharpeningwillnotcorrectthe damage.
Alwayskeeptheworkareaandrepairbenchclean. Dirtingestedintoclosefittingparts,especially hydrauliccomponents,cancausearepeatfailure.
Toavoidafallinginjury,makesuretheworkareais wellilluminated,theflooriscleanandfreeofdirt,oil, water,orotherdebris.
Neverhandleabatterywhensmoking,orwhilenear anopenflame.Explosivegasisformedand containedinthebattery.
Alwayswearsafetyglassesandheavygloveswhen handlingabattery.Blindnessandskinburnscan occurifacidissplashedorspilled.Flushtheexposed areawithfreshwater,andcalladoctorimmediately whenanyaccidentinvolvingabatteryshouldoccur.
DONOTworkunderanypartofthezero-turnmower unlessitissupportedbyahoist,floorjackandjack standsthatarecapableofsupportingtheweightof theunit.
MostserviceworkrequirestheunittobeshutOFF. Removetheignitionkeyandputitinasafeplace. Disconnectthenegative(--)batterycabletoinsure theunitcannotbestarted.
Donotoperatetheunitifshieldsorguardshavebeen removed.Makesureallshieldsandguardsarein placefollowingallserviceorrepairwork.
Manysolvents,cleaningagentsandchemicalsare flammable.Useanon-flammablecleaningagentto avoidtheriskoffire.
Alwaysdisposeofdirtycleaningagents,oldengine andhydraulicoil,incontainersthatcanbesealed. Followallgovernmentregulationswhendisposingof thesematerials.
SECTION00--GENERALINFORMATION--CHAPTER1 0-2
SECTION00--GENERALINFORMATION--CHAPTER1
Allreferencestorightorleft,forwardorrearward, usedinthismanualreferstothatdirectionasviewed fromtheoperatorísseatfacingforward.
ThesafetycircuitontheNewHollandMoweris incorporatedintothedesignofthisunitforthe purposeofoperatorsafety.Itisintendedtokeepthe unitfrombeingoperatedifanypartofthe electrical/motioncontrolsystemisnotadjustedor positionedcorrectly.Neverattempttobypassthe safetycircuit.Neveroperatethemowerwitha malfunctioningsafetycircuit.
TOOLS
Mostmaintenanceprocedurescanbeperformed usingstandardmechanicshandtools.FootPound (lbft),InchPound(lbin)orNewtonMeter(N m) torquewrenchesarealsorequired.Alwaysusethe correctsizetoolforjobbeingaccomplished.
Airwrenchesandairratchetsareacceptablefor disassemblyandreassembly.However,atorque wrenchshouldbeusedtoinsurethefasteneris correctlytorqued,especiallythecuttingblade fastenertorque.
Allfastenersmustbetorquedaccordingtothe TorqueChartfoundonpage4ofthismanual.This chartcontainsspecialtorquesthatarecriticaltothe operationofthemower.
WELDING
Thefollowingprecautionsapplytoallformsof electrical,wirefeedorMIGwelding.
Electricalcomponents(alternator,clutch,switches, etc.)usedonthezero-turnmoweraresensitiveto voltagespikes,shorts,andexternalelectricalinput. Wheneverpossible,theitemtobeweldedshouldbe removedfromtheunit.
Ifitisnotpossibletoremovethecomponent,the followingproceduresmustbeobserved.
Makesurealldrygrasshasbeenremovedfromthe unittoavoidapossiblefirewhilewelding.
• RemoveBOTHcablesfromthebattery.
• Disconnecttheenginepigtailwiringfromthe mainunitharness.
• Disconnectthepigtailwiringfromtheclutch.
• Makesurethegroundleadwirefromthewelder isconnectedtoabare(unpainted)surface.It maybenecessarytoremovethepaintwherethe groundleadwillfasten.
• Connectthegroundleadfromthewelderas closeaspossibletotheareabeingwelded.
CLEANING
Themowerunitshouldbekeptclean.Thisisbest accomplishedwithcompressedairoraleafblower. Grassbuild-upunderthedeckmustbescrapedout.
NOTICE: Regularwaterwashingofthezero-turn mowerisnotrecommended,andneverwhentheunit isstillhotfromoperation.Iftheunitmustbewashed, waittilltheunitiscoolandblowoffexcesswaterwith compressedairoraleafblower.
Keepthezero-turnmowerandcuttingdeckclean. Grease,drygrass,andotherdebrisallowedto build-upcouldcatchfire.
Inwetorlushconditions,grassclippingsallowedto build-upunderthedeckwillchangedischarge patterns.Thiswillcauseclumping,windrowing,and poordischargecomplaints.Thisbuild-upmayhave toberemovedregularlywhileoperatinginthese conditions.
0-3
FASTENERTORQUECHART
AllfastenerslocallypurchasedforuseontheNew HollandMowermustbeGrade5orequivalent, unlessotherwisespecifiedintheNewHollandparts manual.UsethetorquechartforallGrade5 fasteners.Specialfastenertorquesareshownbelow thechart.
IMPORTANT: Alltorquespecificationsapplyto platedorlightlyoiledfasteners,hosesorfittings. TorquespecificationsSHOULDNOTbefollowed whenfasteningplasticparts.
SPECIALTORQUES
Chart--Grade5Fasteners FastenerSize lbft N m 1/4--20 7--9 9--12 5/16--18 10--15 14--20 3/8--16 20--25 27--34 7/16--14 30--40 40--54 1/2--13 50--60 68--82 9/16--12 70--90 95--122 5/8--11
IMPORTANT: DONOTusethepulleynuttoholdthespindlewhiletighteningthebladeasthepulleynutcould beovertorqued.Thiscouldcausespindlespacerandbearingdamage.
MowingBladeBolt--9/16--12x13/4Grade8125lbft(170N m) ...................................
SpindlePulleyNut--3/4--16UNF80lbft(109N⋅m)
SpindleHousingNuts--7/16--20UNF40lbft(54N m)
RearWheelNuts--1/2--20LugNut95lbft(129N m) .............................................
PTOClutchBolt--7/16--20x21/445lbft(61N⋅m)
SteeringDampenerNuts--M8--1.2524lbft(33N m)
ìTDîWheelMotorTieBoltsñ1/2--13,Grade560lbft(82N m) ....................................
BDP--16AìByPassValveî108lbin(12.2N⋅m)
BDP--16AHydraulicPumpEndCapBolts215lbin(22N m)
BDP--16AChargePumpScrews120lbin(14N m) ...............................................
HighPressurePump/MotorHoses/Fittings(MUSTbelightlyoiled)60lbft(82N⋅m)
SECTION00--GENERALINFORMATION--CHAPTER1 0-4
100--120 136--163
180--210 245--286
3/4--10
............................................
MAINTENANCESCHEDULE
After8hourBreak-InPeriod
SERVICEREQUIREMENTS
• ChangeEngineOilandHydraulicOilFilter.
Daily
• Sharpen,balanceandtorquecuttingbladesasneededformowingconditionsencountered.
• Checktirepressures.
• Checkengineoillevel.
• Checkhydraulicoillevelinreservoir.
25HourService
• Performdailyservice.
• Clean/changeprimaryaircleanercartridge,moreregularlyifconditionsareverydusty.
• Lubricatemowerdeckspindles.
• Lubricatemowerdeckbelttensionpivotandpumpbeltidlerarmpivot.
• Checkfastenertorques,especiallybladeboltsandspindlepulleynuts.
40HourService
• Perform25hourservice.
• Lubricatecasterwheelaxles.
• Lubricateliftlinkpivots.
• Lubricatefrontaxlepivot
• Lubricatedraglinkpivots.
• Check/adjustparkingbrakelinkages.
100HourService
• Perform25and40hourservice.
• Changeengineoilandfilter.
• Changefuelfilter.
• Cleancoolingfansontheengineandhydraulicpumps.
250HourService/Annually/BeforeSeasonStart-Up
• Perform25,40and100hourservice.
• LubricateCasterYokeBearings
• Changehydraulicoilandfilter.
• Replaceprimaryandsecondaryaircleanercartridges.
• InspectentireNewHollandmowerandadviseownerofadditionalconcerns.
WARNING
Servicerequirementsmustbeperformedwiththemowershutoffandtheignitionkeyremoved.
FluidTypesandCapacities
EthanolBlendGasolineLeadFree--Minimum87Octane11.8U.S.gallons(44.7liters) EngineOilSAE30WMotorOil(*1)1.8U.S.quart(1.7Liter)(*2) HydraulicOilSAE20W--50MotorOil(*3)(*4)1.0U.S.gallon(3.8liters)(*3) GunGreaseSAEMPLithiumBaseAsRequired
(*1)=APIServiceClassMotorOil:SF,SG,SH,orSJ
(*2)=Includesoilfilterrequirement.
(*3)=APIServiceClassMotorOil:SJ/CD
(*4)=DONOTuseanytypeofìhydraulicîoilorsystemdamagecouldresult.
SECTION00--GENERALINFORMATION--CHAPTER1 0-5
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