0 5i_p/iA._il_ !' O Zero=Turn IVlfg. No. 1694454 5091000 1694744 20HP 1694460 5091001 5091003 1694745 1694781 44" Mower IVlfg. No. 1694456 1694459 1694754 50" Mower IVlfg. No. 1694457 1694461 1694755 1694782 FERGUSON Riders Description Simplicity 18HP Consumer Zero Turn Rider Snapper Fast Cut ZT18440KH, 18HP Zero-Turn Rider with 44" Mower Massey Ferguson ZT 1844 Zero=Turn Mfg. No. 1694455 MASSEV ATO UAL A 18HP _ Riders Description Simplicity 20HP Consumer Zero Turn Rider Simplicity 20HP ZT 2050 (CE) Snapper Fast Cut ZT20500BV, 20HP Zero-Turn Rider with 50" Mower Snapper Fast Cut ZT20500BV, 20HP Zero-Turn Rider with 50" Mower (CE) Massey Ferguson ZT 2050 Massey Ferguson ZT 2050 (CE) Decks Description 44" Mower Deck 44" Mower Deck (CE) 44" Mower Deck Decks Description 50" Mower 50" Mower 50" Mower 50" Mower Deck Deck (CE) Deck Deck (CE) Form No. 1725764 Revision Rev. TP Date 100-3885-05-CH-SMN 05 7/2004 (ableof Coflteflts Safety Rules & information ................................. identification Numbers ........................................ 2 5 Troubleshooting, Adjustments & Service ....... 21 Troubleshooting the Rider ..................................... 21 Safety Decals ....................................................... 6 Troubleshooting the Mower ................................... 22 Seat Adjustments .................................................. 23 Safety icons ......................................................... 7 Safety Interlock System ...................................... 7 Features & Controls ............................................ 8 Control Functions .................................................... 8 Operation ........................................................... 10 General Operating Safety ..................................... 10 Checks Before Starting ......................................... 10 Starting the Engine ............................................... 11 Stopping the Rider & Engine ................................. 11 Mowing .................................................................. 11 Pushing the Rider by Hand ................................... 11 Zero Turn Driving Practice ..................................... 12 Attaching a Trailer .................................................. Mower Removal & Installation ............................... Regular Maintenance ........................................ Schedule ............................................................... 14 15 16 16 Lubrication ............................................................ 17 Servicing the Mower Blades ................................. 18 Checking Tire Pressures ....................................... 19 Checking/Adding Fuel ........................................... Fuel Filter .............................................................. 19 19 Engine Maintenance ............................................. Check/Fill Transmission Oil ................................... 19 19 Ground Speed Control Lever Adjustment ............. 23 Speed Balancing Adjustment ................................ 23 Cutting Height Adjustment .................................... 24 Roller Bar Adjustment ........................................... 24 Neutral Adjustments .............................................. 24 Parking Brake Adjustment ..................................... 25 Front Suspension Adjustment ............................... 25 PTO Clutch Adjustment ......................................... Blade Brake Check ............................................... 26 26 Mower Deck Leveling ............................................ 27 Roller Bar Leveling ................................................ 28 Hydraulic Pump Drive Belt Replacement .............. 29 Battery Charging ................................................... 29 Mower Belt Replacement ...................................... 30 Mower Belt Tension Adjustment ............................ 30 Specifications .................................................... 31 Parts & Accessories .......................................... 32 Lawn Care & Mowing information ................ LC=I NOTE: In this manual, "left" and "right" are referred to as seen from the operating position. Transmission Oil Filter Change ............................. 20 Battery Maintenance ............................................. 20 Storage .................................................................. 20 AWARNING You must read, understand and comply with all safety and operating instructions in this manual before attempting to set-up and operate your machine. Failure to comply with all safety and operating instructions can result in loss of machine control, serious personal injury to you and / or bystanders, and risk of equipment and property damage. The triangle in the text signifies important cautions or warnings which must be followed. ,d ,WARNING Engine exhaust from this product contains chemicals known, in certain quantities, to cause cancer, birth defects, or other reproductive harm. in Read these safety rules and follow them closely. Failure to obey of unit, severe personal injury or death to you, or bystanders, or This mowing deck is capable of amputating hands and feet The triangle _ in text signifies important cautions or warnings GENERAL OPERATION 1. Read, understand, and follow all instructions in the manual and on the unit before starting. 2. Do not put hands or feet near rotating parts or under the machine. Keep clear of the discharge opening at all times. 3. Only allow responsible adults, who are familiar with the instructions, to operate the unit (local regulations can restrict operator age). 4. Clear the area of objects such as rocks, toys, wire, etc., which could be picked up and thrown by the blade(s). 5. Be sure the area is clear of other people before mowing. Stop the unit if anyone enters the area. 6. Never carry passengers. 7. Do not mow in reverse unless absolutely necessary. Always look down and behind before and while travelling in reverse. 8. Never direct discharge material toward anyone. Avoid discharging material against a wall or obstruction. Material may ricochet back toward the operator. Stop the blade(s) when crossing gravel surfaces. 9. Do not operate the machine without the entire grass catcher, discharge guard (deflector), or other safety devices in place and operational. 10. Slow down before turning. 11. Never leave a running unit unattended. Always disengage the blades (PTO), set parking brake, stop engine, and remove keys before dismounting. 12. Disengage blades (PTO) when not mowing. Shut off engine and wait for all parts to come to a complete stop before cleaning the machine, removing the grass catcher, or unclogging the discharge guard. 13. Operate the machine only in daylight or good artificial light. 14. Do not operate the unit while under the influence of alcohol or drugs. 15 Watch for traffic when operating near or crossing roadways. TRANSPORTING 16. Use extra care when loading or unloading the unit into a trailer or truck. 17. Always wear eye protection when operating this unit. 18. Data indicates that operators, age 60 years and above, are involved in a large percentage of power equipment-related injuries. These operators should evaluate their ability to operate the equipment safely enough to protect themselves and others from injury. 19. Follow the manufacturer's recommendations for wheel weights or counterweights. 20. Keep in mind the operator is responsible for accidents occurring to other people or property. 21. All drivers should seek and obtain professional and practical instruction. 22. Always wear substantial footwear and trousers. Never operate when barefoot or wearing sandals. 23. Before using, always visually check that the blades and blade hardware are present, intact, and secure. Replace worn or damaged parts. 24. Disengage attachments before: refueling, removing an attachment, making adjustments (unless the adjustment can be made from the operator's position). 25. When the machine is parked, stored, or left unattended, lower the cutting means unless a positive mechanical lock is used. 26. Before leaving the operator's position for any reason, engage the parking brake (if equipped), disengage the blades (PTO), stop the engine, and remove the key. 27. To reduce fire hazard, keep the unit free of grass, leaves, & excess oil. Do not stop or park over dry leaves, grass, or combustible materials. 28. It is a violation of California Public Resource Code Section 4442 to use or operate the engine on or near any forest-covered, brush-covered, or grass-covered land unless the exhaust system is equipped with a spark arrester meeting any applicable local or state laws. Other states or federal areas may have similar laws. AND STORAGE 1. When transporting the unit on an open trailer, make sure it is facing forward, in the direction of travel. If the unit is facing backwards, wind lift could damage the unit. 2. Always observe safe refueling and fuel handling practices when refueling the unit after transportation or storage. 3. Never store the unit (with fuel) in an enclosed poorly ventilated structure. Fuel vapors can travel to an ignition source (such as a furnace, water heater, etc.) and cause an explosion. Fuel vapor is also toxic to humans and animals. TP 600-4103-00-ZT-UV these rules could result in loss of control damage to property or equipment. and throwing objects. which must be followed. 4. Always follow the engine manual instructions for storage preparations before storing the unit for both short and long term periods. 5. Always follow the engine manual instructions for proper start-up procedures when returning the unit to service. 6. Never store the unit or fuel container inside where there is an open flame or pilot light, such as in a water heater. Allow unit to cool before storing. SafetyRulesandinformation SLOPE OPERATION , WARNING Slopes are a major factor related to loss-of-control and tipover accidents, which can result in severe injury or death. Operation on all slopes requires extra caution, if you cannot back up the slope or if you feel uneasy on it, do not operate on it. Never operate on slopes greater than 17.6 percent (10 °) which is a rise of 3-1/2 feet (106 cm) vertically in 20 feet (607 cm) horizontally. Select slow ground speed before driving onto slope. Use extra caution when operating on slopes with rearmounted grass catchers. Control of a walk-behind or ride-on machine sliding on a slope will not be regained by the application of the brake. The main reasons for loss of control are: insufficient tire Mow across the face of slopes, not up and down,use caution when changing directions and DO NOT START OR STOP ON SLOPE. grip on the ground, speed too fast, inadequate braking, the type of machine is unsuitable for its task, lack of awareness of the ground conditions, incorrect hitching and load distribution. 1. Mow across the face of slopes, not up and down. 2. Watch for holes, ruts, or bumps. Uneven terrain could overturn the unit. Tall grass can hide obstacles. 3. Choose a slow speed so that you will not have to stop or change speeds while on the slope. 4. Do not mow on wet grass. Tires may loose traction. 5. Never mow down slopes. 6. Avoid starting, stopping, or turning on a slope. If tires lose traction (i.e. machine stops forward motion on a slope), disengage the blade(s) (PTO) and drive slow off the slope. 7. Keep all movement on slopes slow and gradual. Do not make sudden changes in speed or direction, which could cause the machine to rollover. 8. Use extra care while operating machines with grass catchers or other attachments; they can affect the stability of the unit. Do not use on steeps slopes. 9. Do not try to stabilize the machine by putting your foot on the ground (ride-on units). 10. Do not mow near drop-offs, ditches, or embankments. The mower could suddenly turn over if a wheel is over the edge of a cliff or ditch, or if an edge caves in. 11. Do not use grass catchers on steep slopes. 12. Do not mow slopes if you cannot back up them. 13. See your authorized dealer/retailer for recommendations of wheel weights or counterweights to improve stability. 14. Remove obstacles such as rocks, tree limbs, etc. 15. Use slow speed. Tires may lose traction on slopes even through the brakes are functioning properly. 16. Do not turn on slopes unless necessary, and then, turn slowly and gradually uphill, if possible. Never mow down slopes. TOWED EQUIPMENT (RIDE-ON CHILDREN Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the unit and the mowing activity. Never assume that children will remain where you last saw them. 1. Keep children out of the mowing area and under the watchful care of another responsible adult. 2. Be alert and turn unit off if children enter the area. 3. Before and during reverse operation, look behind and down for small children. 4. Never carry children, even with the blade(s) off. They may fall off and be seriously injured or interfere with safe unit operation. Children who have been given rides in the past may suddenly appear in the mowing area for another ride and be run over or backed over by the machine. 5. Never allow children to operate the unit. 6. Use extra care when approaching blind corners, shrubs, trees, or other objects that may obscure vision. EMISSIONS 1. Engine exhaust from this product contains chemicals known, in certain quantities, to cause cancer, birth defects, or other reproductive harm. 2. Look for the relevant Emissions Durability Period and Air Index information on the engine emissions label. IGNITION UNITS) 1. Tow only with a machine that has a hitch designed for towing. Do not attach towed equipment except at the hitch point. 2. Follow the manufacturer's recommendations for weight limit for towed equipment and towing on slopes. See attaching a trailer under OPERATION. 3. Never allow children or others in or on towed equipment. 4. On slopes, the weight of the towed equipment may cause loss of traction and loss of control. 5. Travel slowly and allow extra distance to stop. 6. Do not shift to neutral and coast down hill. SYSTEM 1. This spark ignition system coplies with Canadian ICES-O02. 3 SafetyRulesandInformtm SERVICE AND MAINTENANCE Safe Handling of Gasoline 1. Extinguish all cigarettes, cigars, pipes, and other sources of ignition. 2. Use only approved gasoline containers. 3. Never remove the gas cap or add fuel with the engine running. Allow the engine to cool before refueling. 4. Never fuel the machine indoors. 5. Never store the machine or fuel container where there is an open flame, spark, or pilot light such as near a water heater or other appliance. 6. Never fill containers inside a vehicle or on a truck bed with a plastic bed liner. Always place containers on the ground away from your vehicle before filling. 7. Remove gas-powered equipment from the truck or trailer and refuel it on the ground. If this is not possible, then refuel such equipment on a trailer with a portable container, rather than from a gasoline dispenser nozzle. 8. Keep nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete. Do not use a nozzle lock-open device. 9. If fuel is spilled on clothing, change clothing immediately. 10. Never over-fill the fuel tank. Replace gas cap and tighten securely. 11. Use extra care in handling gasoline and other fuels. They are flammable and vapors are explosive. 12. If fuel is spilled, do not attempt to start the engine but move the machine away from the area of spillage and avoid creating any source of ignition until fuel vapors have dissipated. 13. Replace all fuel tank caps and fuel container caps securely. Service & Maintenance 1. Never run the unit in an enclosed area where carbon monoxide fumes may collect. 2. Keep nuts and bolts, especially blade attachment bolts, tight and keep equipment in good condition. 3. Never tamper with safety devices. Check their proper operation regularly and make necessary repairs if they are not functioning properly. 4. Keep unit free of grass, leaves, or other debris buildup. Clean up oil or fuel spillage, and remove any fuelsoaked debris. Allow machine to cool before storage. 5. If you strike an object, stop and inspect the machine. Repair, if necessary, before restarting. 6. Never make adjustments or repairs with the engine running. 7. Check grass catcher components and the discharge guard frequently and replace with manufacturer's recommended parts, when necessary. 8. Mower blades are sharp. Wrap the blade or wear gloves, and use extra caution when servicing them. 9. Check brake operation frequently. Adjust and service as required. 10. Maintain or replace safety and instructions labels, as necessary. 11. Do not remove the fuel filter when the engine is hot as spilled gasoline may ignite. Do not spread fuel line clamps further than necessary. Ensure clamps grip hoses firmly over the filter after installation. 12. Do not use gasoline containing METHANOL, gasohol containing more than 10% ETHANOL, gasoline additives, or white gas because engine/fuel system damage could result. 13. If the fuel tank must be drained, it should be drained outdoors. 14. Replace faulty silencers/mufflers. 15. Maintain or replace safety and instruction labels as necessary. 16. Use only factory authorized replacement parts when making repairs. 17. Always comply with factory specifications on all settings and adjustments. 18. Only authorized service locations should be utilized for major service and repair requirements. 19. Never attempt to make major repairs on this unit unless you have been properly trained. Improper service procedures can result in hazardous operation, equipment damage and voiding of manufacturer's warranty. 20. On multiple blade mowers, take care as rotating one blade can cause other blades to rotate. 21. Do not change engine governor settings or overspeed the engine. Operating the engine at excessive speed can increase the hazard of personal injury. 22. Disengage drive attachments, stop the engine, remove the key, and disconnect the spark plug wire(s) before: clearing attachment blockages and chutes, performing service work, striking an object, or if the unit vibrates abnormally. After striking an object, inspect the machine for damage and make repairs before restarting and operating the equipment. 23. Never place hands near the moving parts, such as a hydro pump cooling fan, when the tractor is running. (Hydro pump cooling fans are typically located on top of the transaxle). 24. Units with hydraulic pumps, hoses, or motors: WARNING: Hydraulic fluid escaping under pressure may have sufficient force to penetrate skin and cause serious injury. If foreign fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result. Keep body and hands away from pin holes or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, and not hands, to search for leaks. Make sure all hydraulic fluid connections are tight and all hydraulic hoses and lines are in good condition before applying pressure to the system. If leaks occur, have the unit serviced immediately by your authorized dealer. 25. WARNING: Stored energy device. Improper release of springs can result in serious personal injury. Springs should be removed by an authorized technician. 26. Models equipped with an engine radiator: WARNING: Stored energy device. To prevent serious bodily injury from hot coolant or steam blow-out, never attempt to remove the radiator cap while the engine is running. Stop the engine and wait until it is cool. Even then, use extreme care when removing the cap. IdentWcationNumbers ID Tag Mower iD Tag North American Models SERIAL 169XXXX Mfg. kw: Engine Ng'._N_ ' 109XXXX _ _' CE Models xxxxI_-__;_=C'I L<ji J, RPM _/3( Model Description Name/Number Vijb:aattiio°nn@ sWelet,,e'_,_ Port Washington,Wl USA 53_/ _9_ XXXXXXX Unit MFG Number Unit SERIAL Number Mower Deck MFG Number Mower Deck SERIAL Number Dealer Name Date Purchased Engine Make Engine Model Engine Type/Spec Engine C0de/Serial Number _'_ When contacting your authorized dealer for replace= ment parts, service, or information you MUST have these numbers. Record your model name/number, manufacturer's identification numbers, and engine serial numbers in the space provided for easy access. These numbers can be found in the locations shown. NOTE: For location of engine identification numbers, refer to the engine owner's manual. CE Models: Place the extra copy of the identification tag in the manual. CE IDENTIFICATION TAG MARKINGS A. Manufacturer's Identification Number B. Manufacturer's Serial Number Mfg. No.: k Serial C. D. E. R Power Rating in Kilowatts Maximum Engine Speed in Rotations per Minute Manufacturer's Address Year of Manufacture 169XXXX XX XX -Engine RPM XXXX LpA: XXX dB(A) -Vibration @ Wheel: XXX m/a 2 @ Seat: XXX ITI/a2 Simplicity G. CE Compliance Logo H. Mass of Unit in Kilograms I. Sound Power in Decibels *** J. K. L. M. No.: _kW: Mfg, Inc. iton, WJ USA 53074-0997 ® Sound Pressure at Operator's Position in Decibels ** Vibration at the Steering Wheel * Vibration at the Seat * Combination Number CE Models: This unit complies with European Harmonized Lawn Mower Standard EN 836, European Machinery Directive 98/37/EC, and European EMC Directive 89/336/EC * Tested according to EN 836:1997/A2:2001, EN 1033:1995 Place copy of Identification Tag here. EN 1032: 1996, ** Tested according to EN836:1997/A2:2001 *** Tested according to 2000/14/EC 5 SafetyDecals SAFETY DECALS This unit has been designed and manufactured to provide you with the safety and reliability you would expect from an industry leader in outdoor power equipment manufacturing. Although reading this manual and the safety instructions it contains will provide you with the necessary basic knowledge to operate this equipment safely and effectively, we have placed several safety labels on the unit to remind you of this important information while you are operating your unit. NORTH AMERICAN Decal - Danger/Operation All DANGER, WARNING, CAUTION and instructional messages on your rider and mower should be carefully read and obeyed. Personal bodily injury can result when these instructions are not followed. The information is for your safety and it is important! The safety decals below are on your rider and mower. If any of these decals are lost or damaged, replace them at once. See your local dealer for replacements. These labels are easily applied and will act as a constant visual reminder to you, and others who may use the equipment, to follow the safety instructions necessary for safe, effective operation. MODELS Part No. 5061106 Decal = Danger, Fire/ Carbon Monoxide Part No. 5049658 ' Do not operate mower ,< ' without deflector or entire ,z _' grass catcher in place. , Decal - Danger, Rotating Blades Part No. 1704277 , under mower deck while bJadeis rotating, ', Decal - Danger, Rotating Blades Part No. 1704276 ALL MODELS Decal - Danger Hot Surface Part No. 1704473 Decal =Transmission Release Valve Part No. 1725941 Decal = ignition Switch Part No. 5048970 Decal - Cutting Height Adjustment Part No. 1725703 CE MODELS Decal -Warning, Mower Deck Part No. 1720389 Decal - Warning, Main Part No. 5061108 Decal = Danger, Fire/ Carbon Monoxide Part No. 5061217 Decal -Warning, Mower Deck Part No. 5061042 SafetyIcons& InteplockSystem SAFETY ICONS Warning: Manual. Read Operator's SAFETY INTERLOCK SYSTEM Read and understand the Operator's Manual before using this machine. This unit is equipped with safety interlock switches. These safety systems are present for your safety, do not attempt to bypass safety switches, and never tamper with safety devices. Check their operation regularly. Danger: Thrown Objects. This machine is capable of throwing objects and debris. Keep bystanders away. Operational Warning: Remove Key Before Servicing. SAFETY Checks TEST 1 -- ENGINE SHOULD NOT CRANK IF: * PTO switch is engaged, OR Remove the key and consult technical literature before performing repairs or maintenance. * Parking brake is not engaged, OR * Motion control handles are not in their NEUTRAL positions. Danger: Machine Rollover. TEST 2 -- ENGINE SHOULD CRANK IF: Operating on steep slopes can cause sliding and loss of steering, control and rollover. Do not use this machine on slopes greater than 10 °. * PTO switch is NOT engaged, AND * Parking brake is engaged, AND * Motion control handles are locked in their NEUTRAL positions. Danger: Machine Rollover. Do not operate on any slopes when wet or slippery. Do not operate near drop-offs or near water. TEST 3 -- ENGINE SHOULD SHUT OFF IF: * Operator rises off seat with PTO engaged, OR Danger: Dismemberment. * Operator rises off seat with parking brake disengaged, OR This machine can amputate limbs. Keep bystanders and children away when engine is running. * Operator moves motion control handles out of their neutral positions before disengaging parking brake. Danger: Dismemberment. TEST 4 -- BLADE BRAKE CHECK This mower deck can amputate limbs. Keep hands and feet away from blades. The mower blades and mower drive belt should come to a complete stop within five seconds after the electric PTO switch is turned off (or operator rises off seat). If mower drive belt does not stop within five seconds, see your dealer. Danger: Dismemberment. This machine can crush and cut. Keep hands away from belts and pulleys. Danger: Carbon Monoxide Poisoning. NOTE: Once the engine has stopped, the PTO switch must be turned off, parking brake must be engaged, and the ground speed control handles must be locked in their NEUTRAL positions in order to start the engine. Do not operate the engine in an unventilated area. , Danger: Fire Hazard. WARNING if the unit does not pass a safety test, do not operate it. See your authorized dealer. Under no circumstance should you attempt to defeat the purpose of the safety interlock system. Keep unit free of grass, leaves and excess oil. Do not add fuel while engine is hot or running. Stop engine and allow to cool for 5 minutes prior to adding fuel. Do not add fuel indoors, in an enclosed trailer, garage or other enclosed areas. Clean up spilled fuel. Do not smoke while operating this machine. 7 Features& Conlrols CONTROL FUNCTIONS The information below briefly describes the function of individual controls. Starting, stopping, driving, and mowing require the combined use of several controls appfied in specific sequences. To learn what combination and sequence of controls to use for various tasks see the OPERATION section. Ground Speed Levers These levers control the ground speed of the rider. The left lever controls the left rear drive wheel and the right controls the right rear drive wheel. Moving a lever forward increases the FORWARD speed of the associated wheel, and pulling back on a lever increases the REVERSE speed. The further a lever is moved away from the neutral position the faster the drive wheel will turn. See the OPERATION section for steering instructions. __ Throttle Control The throttle controls engine speed. Move the throttle forward to increase engine speed and back to decrease engine speed. Always operate at FULL throttle. Choke Close the choke for cold starting. Open the choke once the engine starts. A warm engine may not require choking. Move the lever forward to close the choke. Move the lever back to open the choke. Features& Controls ignition Switch Fuel Tank & Gauge The ignition switch starts and stops the engine; it has three positions: _OFF To remove the cap, turn counterclockwise. The fuel gauge is mounted in the fuel tank and indicates the amount of fuel in the tank. Stops the engine and shuts off the electrical system. _RUN Mower Height Allows the engine to run and powers the electrical system. [_"_ START Attachment Hour Meter / Maintenance Reminder The hour meter measures the number of hours the key has been in the RUN position. The hour meter will flash an initial oil change indicator at 5 hours, and a lubrication reminder every 50 hours. These reminders display for approximately two hours and will automatically reset themselves. _ Switch Oil Fill Transmission oil is added through the transmission oil expansion chamber. It also serves as extra holding capacity for oil as the transmission heats up and the oil expands. See CHECK TRANSMISSION OIL LEVEL for oil level check and fill procedures. Transmission Release Valves The transmission release valves deactivate the transmissions so that the unit can be pushed by hand. See PUSHING THE UNIT BY HAND for operational information. Seat Adjustment Parking Brake DISENGAGE Releases the parking brake. ENGAGE Locks the parking brake. Pull the parking brake lever back to engage the parking brake. Move the lever fully forward to disengage the parking brake. NOTE: To start the unit the parking brake must be engaged. The PTO (Power Take-Off) switch engages and disengages attachments that use the PTO. To engage the PTO, pull UP on the switch. Push DOWN to disengage. Note that the operator must be seated firmly in the rider seat for the PTO to function. Transmission Lever For attachment transport lift, pull the large lift lever back fully to lock the control in the attachment raised transport position. Note: The hour meter will register the passage of time when the key is in the RUN position, even ff the engine is not running. The hour meter has a serf contained power source so the total hours are always visible. _PTO Lift Control & To adjust cutting height, pull the large lever back fully to lock the control in the attachment raised transport position. Position the cutting height selector pin on the appropriate hole to achieve the desired cutting height. Pull back on the small lift latch lever and large lever simultaneously, and lower the mower into cutting position. Cranks the engine for starting. NOTE: Never leave the ignition switch in the RUN position with the engine stopped-this drains the battery. B of Cut Adjustment Knobs The seat can be adjusted forward and backward. Tip the seat forward, loosen the adjustment knobs, slide the seat to the desired position, and tighten the knobs. 9 Operation GENERAL OPERATING SAFETY CHECKS Before first time operation: BEFORE STARTING Check that the crankcase is filled to full mark on dipstick. See the engine owner's manual for instructions and oil recommendations. Be sure to read all information in the Safety and Operation sections before attempting to operate this rider and mower. Make sure all nuts, bolts, screws and pins are in place and secure. Become familiar with all of the controls and how to stop the unit. Adjust the seat position, and make certain you can reach all controls from the operator's position. Drive in an open area without mowing to become accustomed to driving the unit using the parking brake. Fill the fuel tank with fresh fuel. Refer to the engine owner's manual for fuel recommendations. WARNING Never operate on slopes greater than 17.6 percent (10 °) which is a rise of 3=1/2 feet (106 cm) vertically in 20 feet (607 cm) horizontally. Select slow ground speed before driving onto a slope. Use extra caution when operating on slopes with a rear=mounted grass catcher. Mow across the face of slopes, not up and down,use caution when changing directions DO NOT START OR STOP ON SLOPE. and Figure 1. Pre=Start Checks A. Fuel Tank Cap B. Crankcase Oil Fill C. Seat Adjustment Knobs : ,WARNING Never allow passengers to ride on the unit. WARNING Before leaving the operator's position for any reason, engage the parking brake, disengage the PTO, stop the engine and remove the key. Do not load this zero=turn rider on a trailer or truck using two separate ramps. Only use a single ramp that is at least one foot wider than the width of the rear wheels of this rider. This rider has a zero turning radius and the rear wheels could fall off the ramps, or the rider could tip over injuring the operator or bystanders. To reduce fire hazard, keep the engine, rider and mower free of grass, leaves and excess grease. Do not stop or park rider over dry leaves, grass or combustible materials. Gasoline is highly flammable and must be handled with care. Never fill the tank when the engine is still hot from recent operation. Do not allow open flame, smoking or matches in the area. Avoid over-filling and wipe up any spills. 10 Operation AWARNING 5. Engage the PTO by pulling up on the switch. 6. Disengage the parking brake. If you do not understand how a specific control functions, or have not yet thoroughly read the FEATURES & CONTROLS section, do so now. Do NOT attempt to operate the rider without first becoming familiar with the location and function of ALL controls. 7. Move the ground speed control levers from neutral position to operating position (in toward the operator). 8. Begin mowing. See Lawn Care Section for tips on mowing patterns, lawn care, and trouble shooting information. . STARTING THE ENGINE When finished, shut off the PTO. 10. Stop the engine (see STOPPING THE RIDER AND ENGINE). 1, While sitting in the operator's seat, engage the parking brake and make sure the PTO switch is disengaged and the ground speed control handles are locked in the NEUTRAL position. PUSHING THE RIDER BY HAND 1. Disengage the PTO, engage the parking brake, turn the ignition OFF, remove the key, and wait for all moving parts to stop. 2. Set the engine throttle control to FAST throttle position. Then fully close the choke. NOTE: A warm engine may not require choking. 2. Lift the seat plate to gain access to the battery compartment and transmission pumps. 3. Insert the key into the ignition switch and turn it to START. 3. To disengage the pumps (free-wheel position), turn the hydraulic release valves (A, Figure 2) located on the pumps COUNTER-CLOCKWISE a maximum of 2 full turns. 4. After the engine starts, gradually open the choke. Warm up the engine by running it for at least a minute before engaging the PTO switch or driving the rider. 5. After warming the engine, ALWAYS operate the unit at FULL THROTTLE when mowing. 4. Disengage the parking brake. In the event of an emergency the engine can be stopped by simply turning the ignition switch to STOP. Use this method only in emergency situations, For normal engine shut down follow the procedure given in STOPPING THE RIDER, 5. After moving the rider, re-engage the pumps (drive position) by turning the release valves CLOCKWISE and tighten to 80-120 in. Ibs. The rider can now be pushed by hand. STOPPING THE RIDER & ENGINE . . ® Returning the ground speed control levers to the middle position will stop rider movement. Pivot the levers outward and lock them in NEUTRAL. DO NOTTOW RIDER Towing the unit will cause hydraulic pump and wheel motor damage. Do not use another vehicle to push or pull this unit. Disengage the PTO by pushing down on the PTO switch. 3. Engage the parking brake by pulling the handle back until it locks into position. 4. Move the throttle control to idle position and turn the ignition key to OFF Remove the key. MOWING 1. Engage the parking brake. Make sure the PTO switch is disengaged, the ground speed control handles are locked in the NEUTRAL position and the operator is in the seat. Figure 2. Transmission ReJease Valves A. Hydraulic Release Valve (On Each Pump) 2. Start the engine (see STARTING THE ENGINE). 3. Set the mower cutting height. 4. Set the throttle to FULL. 11 Operatm ZERO TURN DRIVING PRACTICE Smooth Travel The lever controls of the zero turn rider are responsive. The lever controls of the zero turn rider are responsive, and learning to gain a smooth and efficient control of the rider's forward, reverse, and turning movements will take some practice. The BEST method of handling the ground speed control levers is in three steps -- as shown in Figure 3. Spending some time going through the maneuvers shown and becoming familiar with how the unit accelerates, travels, and steers -- before you begin mowing --is absolutely essential to getting the most out of the zero turn rider. FIRST place your hands onto the levers as shown. Locate a smooth, fiat area of your lawn -- one with plenty of room to maneuver. (Clear the area of objects, people and animals before you begin.) Operate the unit at mid-throttle during this practice session (ALWAYS operate at full throttle when mowing), and turn slowly to prevent tire slippage and damage to your lawn. SECOND, to go forward gradually push the levers forward with your palms. THIRD, to speed up move the levers farther forward. To slow down smoothly, slowly move the levers toward neutral. We suggest you begin with the Smooth Travel procedure to the right, and then advance through the forward, reverse, and turning maneuvers. You must release the parking brake prior to moving the control levers inward. Figure 3. Move Control Levers Gradually BA SIC DRIVING Forward Travel Practice Reverse Travel Practice Gradually move both ground speed control levers -evenly FORWARD from neutral. Slow down and repeat. LOOK DOWN & BEHIND, then gradually move both ground speed control levers evenly BACK from neutral. Slow down and repeat. NOTE: Straight forward travel takes practice. If necessary, top speed can be balance-adjusted -- see the Speed Balancing Adjustment in the Adjustments section near the back of this manuaL NOTE: Practice backing up for several minutes before attempting to do so near objects. The rider turns as sharply in reverse as when going forward, and backing up straight takes practice, Forward Reverse Travel Travel / ,, ,,/ ", ,, Figure 4. Forward Travel Figure 5. Reverse Travel 12 Operation Practice Turning Around a Corner Practice Turning In Place While traveling forward allow one handle to gradually return back toward neutral. Repeat several times. To turn in place, "zero turn," gradually move one ground speed control lever forward from neutral and one lever back from neutral simultaneously. Repeat several times. NOTE: To prevent pivoting directly on the tire tread, it is best to keep both wheels going at least slightly forward. NOTE: Changing the amount each lever is pulled--forward or back, changes the "pivot point"you turn on. Executing Turns 1 Figure 6. Turning Around a Corner ADVANCED Executing Turn Figure 7. Turning in Place DRIVING an End-Of-Row Zero Your zero turn rider's unique ability to turn in place allows you to turn around at the end of a cutting row rather than having to stop and Yturn before starting a new row. For example, to execute a right end-of row zero turn: . Slow down at the end of the row. 2. Move the LEFT ground speed control lever forward slightly while moving the RIGHT ground speed control lever back to center and then slightly back from center. 3. Begin mowing forward again. This technique turns the rider RIGHT and slightly overlaps the row just cut --eliminating the need to back up and re-cut missed grass. As you become more familiar and experienced with operating the zero turn rider, you will learn more maneuvers that will make your mowing time easier and more enjoyable. Remember, the more you practice, the better your control of the rider will be! Figure 8. Executing 13 an End-Of-Row Turn Operatm ATTACHING A TRAILER The maximum weight of a towed trailer should be less than 200 Ibs (91 kg). Secure the trailer with an appropriately sized clevis pin (A, Figure 9) and clip (B). Excessive towed loads can cause loss of traction and loss of control on slopes. Reduce towed weight when operating on slopes. The surface being driven on greatly impacts traction and stability. Wet or slippery surfaces can greatly reduce traction and the ability to stop or turn. Carefully evaluate the surface conditions before operating the unit and trailer, and never operate on slopes greater than 10 °. See SLOPE OPERATION and TOWED EQUIPMENT in the safety section of this manual for additional safety information. i O ,41 10 ° (lm) 20' (6m) Figure 9. Trailer Weight Recommendations A. Clevis Pin B. Clip 14 Operation FRONT Figure 10. Mower Belt Routing A. Arbor Pulleys B. Back-Side Idlers C. PTO Pulley D. Belt Tension Release Lever MOWER REMOVAL iNSTALLATiON AND NOTE: Perform mower installation and removal on a hard flat surface such as a concrete floor. Removal 1. Disengage the PTO, engage the parking brake, turn off the ignition, remove the key, and wait for all moving parts to stop. 2. Remove the cutting height pin and lower the attachment lift (H, Figure 11) to its lowest position. 3. Use the mower belt tension lever (D, Figure 10) to release belt tension and remove the mower belt from Figure 11. Mower Installation & Removal A. Front Right Clevis Pin B. Front Left Clevis Pin C. Right Lift Link Clevis Pin D. Left Lift Link Clevis Pin E. Right Stabilizer Rod Clevis Pin F. Left Stabilizer Rod Clevis Pin G. Belt Tension Lever H. Attachment Lift Lever I. Roller Control Clevis Pin (Champion Models) the PTO pulley (C). 4. Remove the following pins (Figure 11): A, B, C, D, E, F, and I. Retain the bushings and pins. 5. Pivot the front wheels out of the way and slide the mower deck out from under the unit. Installation 1. Disengage the PTO, engage the parking brake, turn off the ignition, remove the key, and wait for all moving parts to stop. 2. Remove the cutting height pin and lower the attachment lift (H, Figure 11) to its lowest position. 3. Pivot the front wheels out of the way and slide the mower under the unit. . Install the clevis pins, clips, and bushings in the following locations (Figure 11): A, B, C, D, E, F, and I. You may need to lift the back of the mower to install the rods. 5. Release tension from the tensioning idler pulley using the belt tension lever (D, Figure 10) and install the belt as shown in Figure 10. 15 MAINTENANCE SCHEDULE & PROCEDURES The following schedule should be followed for normal care of your rider and mower. You will need to keep a record of your operating time. Determining operating time is easily accomplished by observing the elapsed time recorded by the hour meter. SAFETY ITEMS Before Each Use Every 5 Every 25 Hours Hours Every 100 Hours Every 250 Hours Spring Fall Check Safety Interlock System • • Check Rider Brakes • • Check Mower Blade Stopping Time RIDER MAINTENANCE ITEMS • Before Each Use Every 5 Every 25 Hours Hours Check Rider / Mower for loose hardware Every 100 Hours *** Lubricate Rider & Mower ** • Clean Battery & Cables Spring Fall & Spring Fall & • • Check Tire Pressure • Clean Deck & Check/Replace Mower Blades** • Check Transmission Oil • • Change Transmission Oil Filter ** ITEMS Check Engine Oil Level • Before Each Use Every 5 Every 25 Hours Hours Every 100 Hours • Check / Change Engine Air Filter * Change Engine Oil & Filter * Inspect Spark Plug(s) * Check/Replace Every 250 Hours • Check / Adjust PTO Clutch MAINTENANCE • • Check / Clean Engine Cooling Fins ENGINE & Fuel Filter * * Refer to engine owner's manual. Change original engine oil after initial break-in period. ** More often in hot (over 85 ° F: 30 ° C) weather or dusty operating conditions. *** Service after the first 25 hours of operation, then every 250 hours of operation. 16 Every 250 Hours ReguJap MaJflteflaflce LUBRiCATiON Lubricate the unit at the following lubrication points as well as those shown in Figure 12. Oil: Grease: * control handle pivots 1_ * discharge chute hinge • roller straps (deck lift pivots) front caster axles •* mower deck wheel idler arm Generally, all moving metal parts should be oiled where contact is made with other parts. Keep oil and grease off belts and pulleys. Remember to wipe fittings and surfaces clean both before and after lubrication. • mower deck arbors Use grease fittings when present. Disassemble parts to apply grease to moving parts when grease fittings are not installed. Not all greases are compatible. lithium grease. Use automotive-type Lube Idler Arm Pivot Figure 12. Lubrication 17 RegularMaJflteflaflce WARNING For your personal safety, do not handle the sharp mower blades with bare hands. Careless or improper handling injury. , of blades may result in serious WARNING For your personal safety, blade mounting capscrews must each be installed with a hex/spline washer and spring washer, then securely tightened. Torque blade mounting capscrew to 45 - 55 ft. Ibs. (61 - 75 N.m.) LOOSEN Figure 13. Blade Removal SERVICING THE MOWER BLADES Service Interval: Every 10 Hours or As Required 1. Remove mower deck (see "Mower Deck Removal"). 2. See Figure 13. To remove blade for sharpening, use a block of wood to prevent blade rotation while loosening the capscrew. 3. Remove the capscrew (D, Figure 15), spring washer (C), hex washer (B), and blade. Nail 4. Use a file to sharpen blade to a fine edge. If blade is damaged, it must be replaced. Figure 14. Balancing The Blade 5. Balance the blade as shown in Figure 14. Center the blade's hole on a nail lubricated with a drop of oil. A balanced blade will remain level. 6. Reinstall the blade (Figure 15) with the tabs pointing up toward the mower deck as shown. 7. Reinstall the hex washer (B, Figure 15), spring washer (C) and capscrew (D). Use a wooden block (A) to prevent blade rotation while tightening the capscrew (D) to 61-75 N.m (45-55 ft. Ibs.). Figure 15. Blade Installation A. 4x4 Wood Block B. Hex Washer C. Spring Washer D. Blade Capscrew 18 RegularMaintenance CHECK TIRE PRESSURES Tire pressure should be checked periodically, and maintained at the levels shown in the chart. Note that these pressures may differ slightly from the "Max Inflation" stamped on the side-wall of the tires. The pressures shown provide proper traction, improve cut quality, and extend tire life. CHECKING / ADDING FUEL Tire Pressure To add fuel: Front 40 psi (2,76 bar) 1. Remove the fuel cap (see A, Figure 17). 2. Fill the tank to the bottom of the filler neck. This will allow for fuel expansion. Rear 15 psi (1,03 bar) Figure 16. Checking Tire Pressure NOTE: Do not overfill. Refer to your engine manual for specific fuel recommendations. ,WARNING 3. Install and hand tighten the fuel cap. Gasoline is highly flammable and must be handled with care. Never fill the tank when the FUEL FILTER engine is still hot from recent operation. Do not allow open flame, smoking or matches in the area. Avoid over=filling and wipe up any spills. Do not remove fuel filter when engine is hot, as spilled gasoline may ignite. DO NOT spread hose clamps further than necessary. Ensure clamps grip hoses firmly over filter after installation. The fuel filter is located in the fuel line between fuel tank and fuel pump. If the filter is dirty or clogged, replace as follows: 1. Shut off the fuel valve or drain the fuel tank. 2. Disconnect the negative battery cable. 3. Place a container below the filter to catch spilled fuel. Do not use gasoline containing METHANOL, gasohol containing more than 10% ethanol, gasoline additives, premium gasoline, or white gas because engine/fuel system damage could result. 4. Using a pliers, open and slide hose clamps from fuel filter (C, Figure 17). 5. Remove hoses from filter. 6. Install new filter in proper flow direction in fuel line. 7. Secure with hose clamps. 8. Reconnect the negative battery cable when finished. ENGINE MAINTENANCE Refer to engine owners manual for all engine maintenance procedures and recommendations. CHECK/FILL TRANSMISSION OIL Oil Type: Mobil 1TM15W-50 synthetic oil, Castrol Syntec TM 5W-50 oil, or 20W-50 conventional detergent motor oil. 1. Check the oil level when the unit is cold. The inspection port is located on the inside of the right tank cover. The oil level should be within 1/2" (1.3 cm) of the horizontal level mark (D, Figure 18). If the oil is below this level, proceed to step 2. Figure 17. Maintenance A. Fuel Tank Cap B. Transmission Oil Cap C. Fuel Filter D. Locking Tab E. Locking Screw 2. Before removing the reservoir cap, make sure the area around the reservoir cap and fill neck of the reservoir is free of dust, dirt, or other debris. Loosen the locking capscrew (E, Figure 17) securing the locking tab (D), slide the lock tab back, and remove the cap (B). 19 RegWPMaintenance 3. Add oil up to the full mark (D, Figure 18). 4. Reinstall the reservoir cap, move the locking tab between two notches, and tighten the locking capscrew. TRANSMiSSiON Change Interval: OiL FILTER CHANGE Every 250 Hours Filter Part Number: 1719168 1. Locate the transmission oil filter (C, Figure 18) at the rear of the battery compartment under the seat. 2. Clean the area around the filter base and remove the filter. Do NOT drain the hydraulic system oil. 3. Lubricate the new filter base with a few drops of transmission oil. Fill the filter half full of oil. 4. Thread the new filter onto the filter base until the gasket makes contact, then tighten 3/4 of a turn more. Figure 18. Battery Compartment A. Positive (+) Cable & Terminal B. Negative (-) Cable & Terminal C. Transmission Filter D. Transmission Fill Level Mark 5. Run the unit for several minutes and check the transmission oil level (see previous page). IMPORTANT NOTE: Use caution after changing the filter; air in the hydraulic system may affect the responsiveness of the control levers. Repeat step 5 until the air is out of the system. WARNING BATTERY MAINTENANCE Cleaning the Battery Be careful when handling the battery. Avoid spilling electrolyte. Keep flames and sparks away from the battery. When removing or installing battery cables, disconnect the negative cable FIRST and reconnect it LAST. Jf not done in this order, the positive terminal can be shorted to the frame by a tool. and Cables 1. Disconnect the cables from the battery, negative cable first (B, Figure 18). 2. Clean the battery terminals and cable ends with a wire brush until shiny. 3. Reinstall the battery and reattach the battery cables, positive cable first (see A, Figure 18) WARNING 4. Coat the cable ends and battery terminals with petroleum jelly or non-conducting grease. Never store the unit (with fueJ) in an enclosed, poorly ventilated structure. Fuel vapors can travel to an ignition source (such as a furnace, water heater, etc.) and cause an explosion. STORAGE Before you store your unit for the off-season, read the Maintenance and Storage instructions in the Safety Rules section, then perform the following steps: Fuel vapor is also toxic to humans and animals. * Battery life will be increased if it is removed, put in a cool, dry place and fully charged about once a month. If the battery is left in the unit, disconnect the negative cable. * Disengage the PTO, set the parking brake, & remove the key. * Perform engine maintenance and storage measures listed in the engine owner's manual. This includes draining the fuel system, or adding stabilizer to the fuel (do not store a fueled unit in an enclosed structure - see warning). Before starting the unit after it has been stored: * Check all fluid levels. Check all maintenance items. * Perform all recommended checks and procedures found in the engine owner's manual. * Allow the engine to warm up for several minutes before use. 2O & Service TROUBLESHOOTING , WARNING While normal care and regular maintenance will extend the life of your equipment, prolonged or constant use may eventually require that service be performed to allow it to continue operating properly, To avoid serious injury, perform maintenance on the rider or mower only when the engine is stopped and the parking brake engaged. Always remove the ignition key, disconnect the spark plug wire and fasten it away from the plug before beginning the maintenance, to prevent accidental starting of the engine. The troubleshooting guide below lists the most common problems, their causes and remedies, See the information on the following pages for instructions on how to perform most of these minor adjustments and service repairs yourself, If you prefer, all of these procedures can be performed for you by your local authorized dealer, TROUBLESHOOTING THE RIDER PROBLEM Engine will not turnover or start. CAUSE REMEDY 1. 2. 1. Engage parking brake. 2. Place in OFF position. 3. 4. 5. 6. 7. 8. Parking brake not engaged. PTO (electric clutch) switch in ON position. Out of fuel. Engine flooded. Gas is old or stale. Battery terminals require cleaning. Battery discharged or dead. Wiring loose or broken. Solenoid or starter motor faulty. 10. Safety interlock switch fa uIty. 11. Spark plug(s) faulty, fouled or incorrectly gapped. 12. Water in fuel. 9. Engine starts hard or runs poorly. Engine knocks. Excessive 1. 2. oil consumption. Engine exhaust 1. 2. is black. Fuel mixture too rich. Spark plug faulty, fouled, or incorrectly gapped. Low oil level. Using wrong grade oil. 1. Engine running too hot. 2. 3. Using wrong weight oil. Too much oil in crankcase. 1. 2. Dirty air filter. Engine choke control is in closed position. 21 3. If engine is hot, allow it to cool, then refill the fuel tank. 4. Open the choke. 5. Drain fuel & replace with fresh fuel. 6. Clean the battery terminals 7. Recharge or replace. 8. Visually check wiring & replace broken or frayed wires. Tighten loose connections. 9. Repair or replace. See authorized dealer 10. Replace as needed. See authorized service dealer. 11. Clean and gap or replace. See engine manual. 12. Drain fuel & refill with fresh fuel. 1. Clean air filter. Check the choke. 2. Clean and gap or replace. (See engine manual.) 1. Check/add oil as required. 2. See engine manual. 1. Clean engine fins, blower screen and air cleaner. 2. See engine manual. 3. Drain excess oil. 1. Replace air filter. See engine manual. 2. Open choke control. Troubleshooting, Adjustmflts,& Service Rider Troub/eshooting Continued. CAUSE 1. Hydraulic release valve(s) PROBLEM Engine runs, but rider will not drive. REMEDY 1. Turn valve(s) clockwise to close. 2. 3. 4. in "open" position. Belt is broken. Drive belt slips. Brake is not fully released. 2. See Drive Belt Replacement. 3. See problem and cause below. 4. See authorized service dealer Rider drive belt slips. 1. 2. Pulleys or belt greasy or oily. Belt stretched or worn. 1. Clean as required. 2. Replace belt. Brake will not hold. 1. 2. Brake is incorrectly adjusted. Brake caliper pads worn. 1. See Brake Adjustment. 2. See your dealer. Rider steers or handles poorly. 1. 2. Steering linkage is loose. Improper tire inflation. 1. Check and tighten any loose connections. 2. See Regular Maintenance Section. TROUBLESHOOTING THE MOWER PROBLEM CAUSE REMEDY Mower will not raise. 1. Lift linkage not properly attached or damaged. 1. See authorized service dealer for repair. Mower cut is uneven. 1. 2. Mower not leveled properly. Rider tires not inflated equally or properly. 1. See Mower Adjustment. 2. See Regular Maintenance 1. 2. 3. Engine speed too slow. Ground speed too fast. Blades are dull. 4. Mower drive belt slipping because it is oily or worn. Blades not properly fastened to arbors. 1. Set throttle to full. 2. Decrease Ground Speed. 3. Sharpen or replace blades. See Mower Blade Service. 4. Clean or replace belt as necessary. Mower cut is rough looking. 5. Engine stalls easily with mower engaged. Excessive mower vibration. belt wear or breakage. Mower drive belt slips or fails to drive. 5. See Servicing the Mower Blades. 1. Set to full throttle. 2. Decrease Ground Speed. 3. Cut tall grass at maximum cutting height during first pass. 4. Cut grass with discharge pointing toward previously cut area. 1. 2. 3. Engine speed too slow. Ground speed too fast. Cutting height set too low. 4. Discharge chute jamming with cut grass. 1. 2. 1.Tighten to 45-55 ft.lbs. (61-75 N.m.). 2. Check and replace as necessary. 4. Blade mounting bolts are loose. Mower blades, arbors, or pulleys are bent. Mower blades are out of balance. Belt installed incorrectly. 1. 2. Bent or rough pulleys. Using incorrect belt. 1. Repair or replace. 2. Replace with correct belt. 1. Idler pulley spring broken or not properly attached. Mower drive belt broken. 1. Repair or replace as needed. 3. Excessive Section. 2. 22 3. Remove, sharpen, and balance blades. See Maintenance Section. 4. Reinstall Correctly. 2. Replace drive belt. TroubJeshooUflg, Adjustmflts,& Service \\ \ Figure 20. Control Lever Adjustment A. AJignment Hardware B. Placement Hardware C. Ground Speed Control Lever Figure 19. Seat Adjustment A. Adjustment Knobs B. Seat Springs SEAT ADJUSTMENTS The seat and ground speed control levers should be adjusted so that operator's elbows are supported by the arm rests when his/her hands are on the controls, and the ground speed control levers can be moved through their full range of motion without contacting the operator's legs. Seat Position Figure 21. Top Speed Adjustment A. Forward Top Speed Adjustment Bolt B. Control Lever Base C. Reverse Top Speed Adjustment Bolt Adjustment See Figure 19. The seat can be adjusted forward and back. Remove the knobs (A), move the seat to the desired position, then reinstall and tighten the knobs. Seat Spring SPEED BALANCING Adjustment AWARNING Move the seat springs (B, Figure 19) into the front of the adjustment slot for lighter operators, and to the rear for heavier operator's. GROUND SPEED CONTROL ADJUSTMENT ADJUSTMENT DO NOT adjust the rider for a faster overall speed forward or reverse than it was designed for. LEVER If the rider veers to the right or left when the ground speed control levers are in the maximum forward or reverse position, the top speed of each of these levers can be balanced by turning the adjustment bolt(s) (A & C Figure 21). Only adjust the speed of the wheel that is traveling faster. The control levers can be adjusted in three ways. The alignment of the control levers, the placement of the levers (how close the ends are to one another) and the height of the levers can be adjusted. To Adjust the Handle Alignment: Loosen the mount bolts (A, Figure 20) and pivot the lever(s) (C) to align with each other. TO REDUCETHE To Adjust the Handle Placement: Loosen the jam nuts and adjust the placement bolt (B, Figure 20) in or out to properly adjust the lever end spacing. 2. Turn the top speed adjustment bolt COUNTERCLOCKWISE to reduce the speed. To Adjust the Handle Height: Remove the mounting hardware and reposition the handle either up or down from its original position. You will need to readjust the handle alignment as described above. SPEED OFTHE FASTER WHEEL 1. Loosen the jam nut securing the top speed adjustment bolt (A, C). 3. Retighten the securing nut when adjustment is complete. 23 TroubleshootJflg, Adjustmflts,& Service CUTTING HEIGHT ADJUSTMENT The cutting height adjustment pin (A, Figure 22) controls the mower cutting height. The cutting height is adjustable between 1-1/2" (3,8 cm) and 4-1/2" (11,4cm). Pulling the lever back fully locks the control in transport position. To adjust cutting height: 1. Pull the adjustment lever (B, Figure 22) back fully until it locks in transport position. 2. Remove the cutting height adjustment pin (A) and insert it into the desired hole. 3. Pull back on the adjustment lever (B), squeeze the smaller transport release lever (C), and allow the lever to move forward until it is supported by the cutting height adjustment pin (A). ROLLER BAR ADJUSTMENT The rollers on this Zero Turn unit are not intended to ride on the ground. DO NOT adjust rollers to ride on the ground. Rollers riding on the ground will damage turf and or unit. NEUTRAL Figure 22. Cutting Height Adjustment A. Cutting Height Adjustment Pin B. Deck Lift / Cutting Height Lever C. Transport Release Lever ADJUSTMENT If the unit creeps forward or backward with the control levers in their neutral positions, see your dealer. 24 TroubJeshootJflg, Adjustmflts,& Service PARKING BRAKE ADJUSTMENT Brake Adjustment 1. Disengage the PTO, stop the engine, block the front wheels, remove the ignition key, and engage the parking brake. 2. Elevate the rear end of the unit and remove the rear wheels. 3. Check the brake spring (A, Figure 23) length (both wheels). With the brake engaged the compressed spring length should be 2" (5 cm). If not, adjust the Iocknut (C, Figure 23) to achieve the compressed spring length of 2" (5 cm). 4. After achieving the correct spring compression, check the set collar gap (B, Figure 23). With the parking brake engaged, the set collar gap should be 3/16" (5 mm). If not, loosen the set collar screw and move the collar to the correct position. FRONT SUSPENSION (SELECT Figure 23. Parking Brake Adjustment A. Brake Spring B. Set Collar C. Locknut ADJUSTMENT MODELS) The shock assembly can be adjusted to vary the amount of pre-load applied to the springs. This allows the operator to customize the ride according to operator's weight and operating conditions. iNCREASE DECREASE G 0 LESS PRE-LOAD: * Light operator weight * Softer, more cushioned ride * Best for relatively flat terrain MORE PRE-LOAD: * Heavy operator weight * Stiffer, more rigid ride Figure 24. Front Suspension Adjustment A. Pre=Load Adjustment Collar * Better handling and greater stability on hilly terrain TO ADJUST THE SPRING PRE-LOAD: 1. Park machine on a flat, level surface. Disengage the PTO, stop the engine and engage the parking brake. 2. See Figure 24. Turn the pre-load adjustment collar (A) CLOCKWISE to increase the pre-load, turn COUNTER-CLOCKWISE to decrease the pre-load. Make sure both shocks are set to the same amount of pre-load. 25 TroubleshootJflg, Adjustmflts,& Service Figure 26. Adjust PTO Clutch A. Window B. Adjustment Nut C..016"-.018" (0,40-0,45mm) Feeler Gauge Figure 25. PTO Clutch Adjustment A. Adjustment Window (Qty. 3, one shown) B. Adjustment Nut PTO CLUTCH ADJUSTMENT WARNING Check the PTO clutch adjustment after the initial 25 hour break-in period and then after every 250 hours of operation. Also perform the following procedure if the clutch is slipping or will not engage, or if a new clutch has been installed. To avoid serious injury, perform adjustments only with engine stopped, key removed and rider on level ground. BLADE 1. Remove key from ignition switch and disconnect spark plug wires to prevent the possibility of accidental starting while the PTO is being adjusted. BRAKE CHECK Mower blades and mower drive belt should come to a complete stop within five seconds after electric PTO switch is turned off. 2. See Figure 25. Note the position of the 3 adjustment windows (A) in the side of the brake plate and the nylock adjustment nuts (B). 1. With parking brake engaged, PTO disengaged and an operator in the seat, start the engine engine. 3. Insert a .016"-.018" (0,40-0,45mm) feeler gauge (C) through each window, positioning the gauge between the rotor face and the armature face as shown in 2. Have an assistant observe the mower drive belt through the opening between the frame and top of mower deck. Engage the PTO and wait several seconds. Disengage the PTO and check the amount of time it takes for the mower drive belt to stop. Figure 26. 4. Alternately tighten the adjustment nuts (B, Figure 25) until the rotor face and armature face just contacts the gauge. 3. If the mower drive belt does not stop within five seconds, perform the PTO Clutch Adjustment. If the belt still does not stop within 5 seconds, see your dealer. 5. Check the windows for an equal amount of tension when the gauge is inserted and removed, and make any necessary adjustments by tightening or loosening the adjustment nuts. NOTE: The actual air gap between the rotor and armature may vary even after performing the adjustment procedure. This is due to dimensional variations on component parts, and is an acceptable condition. 6. Check the mower blade stopping time. The mower blades and mower drive belt should come to a complete stop within five seconds after the electric PTO switch is turned off. 26 TroubieshootJflg, Adjustmflts,& Service Figure 27. Orient Blades Side=to=Side Figure 28. Measure Blade Tips to Ground A. Mower Deck C. Level Ground B. Blade Tip MOWER DECK LEVELING Perform these adjustments on a flat level surface. Note: Do not adjust the mower rift height rod (H, Figure 29) as it will effect the mower deck lift height, SIDE-TO=SIDELEVELING 1. With the mower installed, place the rider on a smooth, level surface such as a concrete floor. Turn the front wheels so they are straight. 2. Check for bent blades and replace if necessary. 3. Place the mower cutting height pin in the 4th hole from the bottom (C, Figure 29). Arrange the outside mower blades so that they are pointing from side-to-side (Figure 27). 4. Measure the distance between the outside tips of each blade and the ground (Figures 27 & 28). If there is more than 1/8" (3mm) difference between the measurements on each side, proceed to step 5. If the difference is 1/8" (3mm) or less, proceed to step 6. Figure 29. Mower Leveling A. Front Leveling Jam Nuts B. Rear Leveling Rods C. 4th Cutting Height Hole D. Rear Hanger Rods 5. Use the rear leveling rods (B, Figure 29) to adjust the side-to-side leveling of the deck. Repeat step 4 if necessary. FRONT=TO-BACKLEVELING 6. Arrange the blades so they face front-to-back 30). E. F. G. H. Front Hanger Rods Set Collars Stabilizer Mower Height Rod (Figure 7. Measure the distance from the ground to the front tip of the center blade, and from the ground to rear tips of left-hand and right-hand blades (Figures 28 & 30). The front tip of the center blade should be 1/4" (6mm) higher than rear tips of left-hand and right-hand blades. If not, proceed with steps 8 - 11. Figure 30. Orient Blades Front-to=Back 8. Check the length of the hanging rods: the rear (D, Figure 29) should be 15" (38,1cm) and is not adjusted. The front rods (E) should be initially adjusted to 14-3/4" (37,5cm). To adjust the pitch of the mower deck, adjust the front pitch rods only. 10. Re-check the blade measurement then repeat steps 7-11 as necessary. 9. To lower the front of mower deck, loosen the set collars (F, Figure 29) and slide towards the mower deck, loosen the jam nuts (A) and adjust the clevises out. Reverse this to raise the front of the mower. Be sure to raise or lower both clevis the same amount. 11. Reposition the deck stabilizers (G) against the jam nuts (A) and push the set collars (F) up to meet the stabilizer and tighten. 27 TroubleshootJflg, Adjustmflts,& Service ROLLER BAR LEVELING (if Equipped) 1. First level the mower deck using the procedure found in MOWER DECK LEVELING. 2. With the mower installed, place the rider on a smooth, level surface such as a concrete floor. Turn the front wheels so they are straight. 3. Place the mower cutting height pin in the 4th hole from the bottom (C, Figure 29). 4. Measure the distance between the outside ends of the roller bar and the ground. If there is more than 1/8" (3mm) difference between the measurements on each side, proceed to step 5. 5. Locate the roller bar leveling eccentric and Iocknuts (A, Figure 31). Loosen the Iocknut and turn the eccentric to raise or lower a side. When the correct level is achieved, hold the eccentric with a wrench and tighten the Iocknut. Repeat step 4 if necessary. Figure 31. Roller Bar Leveling A. Eccentric and Locknut 28 Troubleshooting, Adjustmflts,& Service HYDRAULIC PUMP DRIVE BELT REPLACEMENT 1. Park the rider on a smooth, level surface such as a concrete floor. Disengage the PTO, engage the parking brake, turn off the engine, and remove the ignition key. 2. Remove the PTO drive belt (see MOWER BELT REPLACEMENT for removal instructions). 3. Loosen the nut towards the front of the machine on the spring anchor hook (H, Figure 32) to release the majority of the belt tension. Use caution and remove the nut to completely release the tension. 4. Remove the old belt and replace it with the new one. Make sure the V-side of the belt runs in the grooves of the crankshaft pulley and pump pulleys (B & C). 5. Reinstall the anchor hook (H) into the anchor tab and loosely fasten the nut. Adjust the spring until a measurement of 7-3/4" (19,7cm) is achieved from the outside of the spring hooks. Tighten nut. Figure 32. Hydraulic Pump Drive Belt Replacement (Shown from Below) A. Pump Drive Belt B. Crankshaft Pulley C. Pump Pulley D. Idler Pulley (stationary) E. Idler Pulley E Idler Arm G. Spring H. Spring Anchor Hook 6. Reinstall the PTO drive belt. BATTERY CHARGING WARNING A dead battery or one too weak to start the engine may be the result of a defect in the charging system or other electrical component, if there is any doubt about the cause of the problem, see your dealer. If you need to replace the battery, follow the steps under Cleaning the Battery & Cables in the Regular Maintenance Section. Keep open flames and sparks away from the battery; the gasses coming from it are highly explosive. Ventilate the battery well during charging. To charge the battery, follow the instructions provided by the battery charger manufacturer as well as all warnings included in the safety rules sections of this book. Charge the battery until fully charged (until the specific gravity of the electrolyte is 1.250 or higher and the electrolyte temperature is at least 60 ° F). Do not charge at a rate higher than 10 amps. 29 TroubleshootJflg, Adjustmflts,& Service FRONT Figure 33. Mower BeJt Routing A. Arbor Pulleys B. Back-Side Idler Pulleys C. PTO Pulley D. BeJt Tension ReJease Lever Figure 34. Belt Covers A. Right Side Belt Cover B. Left Side Belt Cover MOWER BELT REPLACEMENT PRYavoid BELTS OVER PULLEYS. To damaging belts, DO NOT 1. Park the rider on a smooth, level surface such as a concrete floor. Disengage the PTO, engage the parking brake, turn off the engine, and remove the ignition key. 2. Remove the capscrews securing the left and right belt covers (A, B Figure 34) and remove the covers. 3. Raise the mower deck to transport position. Use the lever (D, Figure 33) to release tension on the mower belt and remove the belt from the PTO pulley (C). 4. Remove the old drive belt and install the new one as shown in Figure 33. Note that the back of the drive belt must ride against the back-side idler pulleys (B). Use the belt tension lever (D) to release tension on the idler pulley for installation. MOWER BELT TENSION ADJUSTMENT Figure 35. Mower Drive Belt Tension Adjustment A. idler Bracket B. Tensioning Spring If the mower drive belt stretches over time, the idler pulley bracket can be adjusted to provide more belt tension. The initial setting of the bracket is shown in Figure 35. 1. Place the mower cutting height control in the 4-1/2" position (C, Figure 29). 2. Measure the extended length of the belt tensioning spring (B, Figure 35). The spring length (from inside end of the hook to inside end of hook) should be greater than 7" (17.8 cm). If not, adjust the bracket accordingly. 30 NOTE: Specifications are correct at time of printing and are subject to change without notice. * Actual sustained equipment horsepower will likely be lower due to operating limitations and environmental factors. ENGINE: TRANSMISSIONS: 18 HP* Kohler Make Model Horsepower Displacement Electrical System Oil Capacity 20 HP* Briggs Make Model Horsepower Displacement Electrical System Oil Capacity HydroGear Kohler Command PRO 18 18 @ 3400rpm 30.08 Cu. in (493 cc) 12 Volt, 15 amp. Alternator, 2 qt. ( 1 .gL) w/Filter Type Hydraulic Battery: 340 CCA Fluid Speeds @ 3400 rpm Continuous Torque Output Maximum Weight on Axle & Stratton Briggs & Stratton Vanguard 20 @ 3400 rpm 34.75 Cu. in (570 cc) 12 Volt, 16 amp. Alternator, 56 Oz. (1.7 L) w/Filter BDP-10A / HGM-12P Pump and Wheel Motor Mobil 1TM 15W-50 synthetic oil, Castrol Syntec TM 5W-50 oil, or 20W-50 conventional detergent motor oil Forward: 0-7 MPH (0-11.27 kin/h) Reverse: 0-5 MPH (0-8.05 kin/h) 266 ft. Ibs. (359 N.m.) 2000 Ibs. (907 Kg) per Axle DIMENSIONS: Battery: 340 CCA Overall Length Overall Width Height Weight (apx..) With 50" Mower Deck With 44" Mower Deck CHASSIS: Fuel Tank Rear Wheels Capacity: 6.5 Gallons (24.6 L) Tire Size: 20 x 8.00 -10 Front Wheels Inflation Pressure: 15 psi (1,03 bar) Tire Size: 11 x 4.00-5 Inflation Pressure: 40 psi (2,76 bar) 31 78" (190,5 cm) 41.5" (105 cm) 42" (107 cm) 723 Ibs. (328 kg) 712 Ibs. (322 kg) Accessories REPLACEMENT PARTS TECHNICAL Replacement parts are available from your authorized dealer. Always use genuine Simplicity/Snapper Service Parts. MAINTENANCE Additional copies of this manual are available, as well as fully illustrated parts lists. These manuals show all of the product's components in exploded views (3D illustrations which show the relationship of parts and how they go together) as well as part numbers and quantities used. Important assembly notes and and torque values are also included. ITEMS Many convenient and helpful service and maintenance items are available from you authorized dealer. Some of these items include: Engine Oil Touch-Up Paint Grease Gun Kit 8 oz. Grease Tube MANUALS For applicable manuals currently available for your model, contact our Customer Publications Department at 262-284-8519. Have the information listed in the box below available when phoning in your request. Technical manuals can be downloaded from www.simplicitymfg.com or www.snapper.com Tire Sealant Degrimer/Degreaser Gas Stabilizer Model: Mfg. No.: Your Name: Address: City, State, Zip: 32 Visa/Mastercard No.: Card Expiration Date: LawnCare & MowingInformation HOW AND WHEN TO HOW TO WATER YOUR LAWN WATER, FERTILIZE AERATE The best method of watering a lawn is to imitate a slow, soaking rain, applying about 1 inch of water. HOW TO FERTILIZE YOUR LAWN & Most lawns are watered too often, but with too little water. However too much water can allow development of diseases with your lawn. It is best to water the lawn only when necessary, and then to water it slowly, evenly, and deeply--imitating a slow, soaking rain. WHEN TO WATER YOUR LAWN When the lawn begins to wilt, the grass's color dulls, or footprints stay compressed for more than a few seconds, the lawn is beginning to dry out, and needs additional moisture. The best time to water is early morning to allow the water to soak deeply into the lawn and reduce the amount that evaporates in the hot afternoon sun. Fertilizing with a slow-release fertilizer provides missing nutrients which help create slow, even growth. Remember that over-fertilizing can cause harm, and that most fertilizing should be applied in the spring so that it will release into the lawn through the summer. AERATING YOUR LAWN Consider aerating your lawn in spring. Using an aerator to remove cores of soil from the lawn increases the speed of clipping decomposition and encourages deeper root growth by opening up the soil and permitting greater movement of water, fertilizer and air. HOW HIGH TO MOW THE GRASS Cut less than 1/3 Cutting the grass too short causes weak, thin grass plants, which are easily damaged by dry periods and pests. cutting point at less than 113 from top of grass blade Letting grass grow a bit longer--especially when it is hot and dry--reduces heat build-up, preserves needed moisture and protects the grass from heat damage and other problems. Cutting down to this area contributes to thatch problems Cutting off too much at one time shocks the plant's growth system and weakens the grass plants. A good rule of thumb is the 1/3 rule: to cut no more than one third of the grass height, and never more than 1 inch at a time. Cut Here On First Pass JfII/IJIdI_lf\,_/ Cut Here On Tall Grass Requires Second Pass For extremely tall grass, set the cutting height at maximum for the first pass, and then reset it to the desired height and mow a second or third time. Incremental Cutting Don't cover the grass surface with a heavy layer of clippings. TP 600-2136-03-W-SHA LC-1 LawnCare& MowingInformation WHEN AND HOW OFTEN TO MOW The time of day and condition of the grass greatly affect the results you'll get when mowing. For the best results, follow these guidelines: • Mow when the grass is between 3"-4" (7,5-10 cm) high. • Mow with sharp blades. Short clippings of grass one inch or shorter decompose more quickly than longer blades. Sharp mower blades cut grass cleanly and efficiently, preventing frayed edges which harm the grass. • Mow at time of day when the grass is cool and dry. Late afternoon or early evening often provide these ideal mowing conditions. • Avoid mowing after rain or even heavy dew, and never mulch when the grass is wet (moist grass does not mulch well, and clumps beneath the mower deck). Note: Always PROPER MOWING operate the engine at full throttle SPEED ENGINE SPEED & GROUND SPEED Always operate the engine at full throttle when mowing. If you hear the engine slowing down, you are mowing too fast--maintaining a slower ground speed will improve the cutting efficiency of the blades and prevents many common cutting problems. Select an appropriate ground speed for the thickness and height of the grass you are cutting (3rd gear or slower for manual gear models, or mid-range or slower for hydro models). If you hear the engine slowing down you are mowing too fast, use a slower ground speed. HOW MUCH GRASS TO CUT OFF Mow when the grass is 3"-4" inches (7,5-10cm) long. Do not cut off more that 1" (2.5cm) of grass in a single pass. LC-2 when mowing. PRODUCTS, INC. McDonough, GA., 30253 www.snapper.com MANUFACTURING, INC. 500 N Spring Street / PO Box 997 Port Washington, Wl 53074-0997 www.simplicitymfg.com © Copyright 2004, Simplicity Manufacturing, All Rights Reserved. Printed in USA. Inc.