SNAPPER Z120T, Z1251BVJ, Z1251BV, Z140T, Z160T, Z180T, Z1401K, Z1801K, Z1800T, Z2001K, Z2010K, Z1202B, Z1203B, Z1402K, Z1403K, Z1802K, Z1803K, Z2002K, Z2003K, 1810, 2010, ZU 1803K, ZU 2003K, ZU 2013K, ZU 2014K Zero Turning Radius Mower Service Manual

 Zero Turning Radius Mower
o
SNAPPER......... GA., 30253 U.S.A.
E - "3 + , An. Hwee + are Ea a
; + a 'MANUAL No. 07220 (1.R. 11/94)
TABLE OF CONTENTS
Section | - GENERAL INFORMATION ©. . .................. 1.1-1.6
Section Il - TROUBLESHOOTING . . . . . . aaa 2.1-2.6
Section Ill - ELECTRICAL SYSTEM. ......... a 3.1-3.12
Section IV - STEERING CONTROLS ADJUSTMENTS & REPAIRS. . . . . . 4.1 - 4.10
Section V - WHEEL and TIRE REPAIR/REPLACEMENT. ............ 5.1-5.4
Section VI - BUMPER/AXLE & CASTER WHEELREPAIR . . . . . . .... .. 6.1-6.4
Section VII-ENGINE . . . . . . . .. | ae ae 110 | Co. 7176
Section VIII - TRANSMISSION & DRIVE SYSTEM. . . . . . . . 8.1-8.6
Section IX - HYDRAULIC SYSTEM MAINTENANCE & REPAIR . . . . . . . . 9.1-9.12 -
Section X - BRAKE ADJUSTMENTS & REPAIR. . . . . . . . . . …... 101-106
Section XI- CUTTER UNITS . . . . . . as 11.1-11.3
NOTE
When making repairs that require replacement parts or
components, use only original SNAPPER replacement
parts to keep the equipment in top operating condition.
Refer to the appropriate parts manual for correct part
numbers and proper quantities required.
Section I
GENERAL
INFORMATION
Section | - GENERAL INFORMATION
INTRODUCTION
1.1 HOW TO USE THIS MANUAL
This manual contains the Service and Maintenance
information required to properly inspect, service and
repair the SNAPPER Zero Turning Radius Mowers
equipped with 41", 42", 48" and 60" Mower Attach-
ments. The manual is divided into sections for quick,
easy reference. Carefully read all procedures
described for servicing a particular component
BEFORE repairs are started, to avoid needless
disassembly.
C. TIRE SPECIFICATIONS
MODEL Z |
Front Tires - 10" - 12 psi/ 13" - 12 psi
Rear Tires - 18" - 12 psi/ 20" -12 psi _
MODEL ZU
Front Tires - 12 psi
Rear Tires - 12 psi
1.6 SPECIFICATIONS - TORQUE VALUES
Standard Torque Specifications and Capscrew
Markings Chart. The values given here are based
on the use of clean and dry threads. Reduce
torque by 10 percent when threads are lubricated
with engine oil and by 20 percent if new plated
capscrews are used.
NOTE |
References to the RIGHT and LEFT sides are
determined by facing forward while sitting on the
operator's seat.
1.5 SPECIFICATIONS - GENERAL
A. ENGINE SPECIFICATIONS
Refer to the Engine Manufacturer's Manuals.
B. TRACTOR SPECIFICATIONS
The Zero Turning Radius Mowers covered in this -
manual will have one of the following drive
trains:
1. Hydrostat & Chain- reduction
2. Hydrostat & Gear-reduction
3. Unistat Drive (reduction internal)
Please refer to the Models Identification
Chart on Page 1.4 to identify the different
units.
1.2
1.2 WARNINGS & CAUTIONS = CAPSCREW HEAD MARKINGS
Details of standard workshop safety procedures are Manufacturer s Marks.may vary. |
not included in this manual. WARNINGS & Three-line markings on heads ED (<> E” |
CAUTIONS occur where procedures, if improperly shown below - for example,
performed, could cause personal injury,and/or indicate SAE Grade 5.
damage to the mower or its components. These | y on up:
WARNINGS & CAUTIONS do not cover all conceiv- ©. |
able ways hazardous consequences could be > uu mal
created by improperly following the instructions or SAE1or2 . SAES SAE 6 or 7 SAE 8
by the incorrect use of service tools. *
capscrew | SAF, | SAF | dee | Se
— 1.3 SERIAL NUMBER LOCATION BODY SIZE | Torque | Torque | Torque | Torque
The tractor serial number is located on the right rear — |Inches- Thread | Ft-to | Ft-Lb | Ft-Lb | Ft-Lb
side of the chassis.
1/4 - 20 5 8 10 12
1.4 TOOL REQUIREMENTS 5/16 - 28 5 1 lo >
~The normal complement of U.S. Standard tools e 13 19 27
found in most repair shops are all that will normally 3/8 - 16 18 31 34 44
be needed to repair SNAPPER Zero Turning Radius - 24 20 35 49
Mowers. Special tools and meters are mentioned 7/16 - 14 28 49 55 70
. where needed in the manual. Refer to the Parts - 20 30 55 78
Manual for special tools available through SNAPPER 1/2 - 13 39 75 85 105
Dealers. - 20 41 85 120
| 9/16 - 12 51 110 120 155
-18 55 120 1
NOTE . 5/8 - 11 83 150 167 210
Throughout the following sections of this manual, - 18 95 170 240
the word “unit” will be used (in most cases) in 3/4 - 10 105 270 280 375
lieu of ZERO TURNING RADIUS MOWERS. -16 115 295 420
4 .7 WORKSHOP SAFETY HINTS
A. DO NOT run engine in an enclosed area -
exhaust fumes are hazardous to your health.
B. DO NOT smoke, light a fire or create any sparks
near gasoline - it is extremely flammable.
C. DO NOT use gasoline as a solvent. Fumes are
dangerous. Always use non-flammable
solvents.
; D. DO NOT store gasoline in an area where sparks
or flames are present such as near water
heaters or furnaces - gasoline fumes are
extremely explosive.
E. ALWAYS disconnect the spark plug v wires and
secure the ends away from the plugs BEFORE
inspecting, servicing or repairing the unit or
attachments. Precautions prevent accidents
such as unintentional start-ups!
F.
G.
ALWAYS make adjustments and do repairs in
a well lit and well-ventilated area.
ALWAYS wear protective safety goggles when
using pressurized air to clean the machine or
parts. |
DO NOT use a jack to support the unit ina
raised position. Use "jack stands" or other
stable supports that will hold up BOTH sides
of the frame at the same time. This approach
is especially important when raising and
~ supporting the rear end of the unit. With the
front axle pivot, both sides of the frame must
be securely supported. Be sure to chock (block)
the wheels that remain on the surface.
Section | - GENERAL INFORMATION
NOTE |
Read the Operator's & Engine Owner's
Manuals and instructions BEFORE operating
equipment.
1.3
Section | - GENERAL INFORMATION
Models Identification Chart:
Hydrostat & Chain-reduction Models
Model HP Control Deck Mount Style Year 42" 48" 60"
Z120T 12 2-Lever NC-RDB | 89 Z4200M| * *
Z1251BVJ 12 Joystick WC-RDB-EF ‘90 Z4201M * *
Z1251BV 12 2-Lever WC-RDB-EF ‘90 Z4201M *
Z140T 14 2-Lever NC-RDB '89 Z4200M | Z4800M | *
Z160T 16 2-Lever NC-RDB 89 Z4200M | Z4800M | *
Z180T 18 2-Lever NC-RDB '89 Z4200M | Z4800M | *
Z1401K 14 2-Lever WC-RDB-EF '90 Z4201M | Z4801M | *
Z1801K 18 2-Lever WC-RDB-EF 90 Z4201M | Z4801M | *
Z1800T 18 2-Lever WC-RDB-LF ‘90 * * *
Z2001K 20 2-Lever WC-RDB-EF ‘90 Z4201M | Z4801M | *
Z2010K 20 2-Lever WC-RDB-LF 89 * * Z6000M
Hydrostat & Gear-reduction Models
Model HP Control Deck Mount Style | Year 41" | 42" 48" 60"
Z1202B 12 Joystick WC-FDB 91-92 | Z4102M * * *
Z1203B 12 Joystick WC-FDB '93-'94 | Z4102M * * *
Z1402K 14 Joystick WC-FDB 91-92 * 24202М | Z4802M| *
Z1403K 14 Joystick WC-FDB '93-'94 * Z4202M |Z4802M | *
21802K 18 Joystick WC-FDB '91-'92 * Z4202M | Z4802M | Z6002M
Z1803K 18 Joystick WC-FDB 93-94 * Z4202M |Z4802M | Z6002M
22002K 20 Joystick WC-FDB '91-'92 * ZA202M |Z4802M | Z6002M
Z2003K 20 Joystick WC-FDB 93-94 * Z4202M |Z4802M | Z6002M
Unistat Driven Models
Model HP Control Deck Mount Style | Year 48" 60"
1810 18 2-Lever NCU-RDB '89 |ZU4803M *
2010 20 2-Lever NCU-RDB 89 |ZU4803M *
ZU1803K 18 2-Lever NCU-RDB '90-'91| ZU4803M *
ZU2003K 20 2-Lever NCU-RDB '90-'91| ZU4803M *
ZU2013K 20 2-Lever WCU-RDB-EF 92 | ZU4813M-WC-BLK|ZU6003M-WC-BLK
ZU2014K 20 Joystick WC-FDB,WCU-FDB| '93 |ZU4804M, Z4802M |ZU6004M, Z6002M|
Key: NC = Narrow Carriage Mounting, lift arms found inside frame.
WC = Wide Carriage Mounting, lift arms found outside frame.
NCU = Narrow Carriage Mounting for Unistat ZTR only.
- WCU = Wide Carriage mounting for Unistat only.
RDB = Rear Drag Bar, mounts at rear of deck.
FDB = Front Drag Bar, mounts at front of deck.
BLK = Black in color.
Long Frame
LF =
EF =
Extended Short Frame
NOTES
1. All decks are painted red with the exception of decks made specifically for the Unistat Driven Models.
2. 48" & 60" red decks made for the Hydrostat & Gear-reduction Models may be mounted to the ZU2014K only.
(will not fit other Unistat Driven Models).
3. All black decks are manufactured with spindles with a top seal, red decks utilize seals of top bearing.
1.4
SERVICE NOTES
15
SERVICE NOTES
1.6
Section Il
TROUBLESHOOTING
Section Il - TROUBLESHOOTING
ENGINE
1.
ENGINE WON'T TURN OVER
Mowerbladesengaged. . . . . . .. .............
Drive not in neutral
ENGINE WILL TURN OVER, BUT WON'T START
No fuel. . ... . . aaa aaa
Spark plug not firing
Carburetor out of adjustment
Ignition switch faulty
ENGINE HARD TO START
Fuel line clogged
Faulty fuel pump
Spark plug wire loose or grounded
Spark plug(s) faulty or improperly gapped
Electronic ignition defective
Dirty or maladjusted carburetor
ENGINE STARTS, BUT CUTS OUT
Water in fuel. . . . . . . . . . 11110
Clogged fuel line
Vent in fuel cap plugged, . .
Carburetor out of adjustment
Engine stalls when Joystick is raised
ENGINE KNOCKS
Low oillevel. . . . . . . . . aaa aa ne
Ignition timing off
Fuel octane grade too low
ENGINE SOMETIMES SKIPS AT HIGHER SPEEDS
Incorrect ignition timing.
Carburetor out of adjustment
2.2
18 EEE E AE EEE ¥ = wv = + =»
Dirty air filter. . . . . 1.122114 LL LL LL 4 1140
Faulty fuel pump. ........ a
Engine over-heated . . . ....................
Faulty spark plug(s). . . . . . . . . e... eee,
Bouncing off seat. Switch breaking circuit . . . . . ......
Disengage blades.
Move Joystick to neutral "DOWN"
position or, on 2-lever units, move
levers "OUTWARD".
Replace fuse.
Charge or replace.
Test/replace.
Test/replace.
Refer to Engine Manual.
Test/replace.
Refuel, clean/replace fuel filters.
Adjust choke.
Check spark plug. Regap.
Adjust carburetor.
Test/replace.
Clean fuel line. Check fuel filter.
Refer to Engine Manual.
Check spark plug wires.
Check spark plug. Regap.
Refer to Engine Manual.
Clean/adjust carburetor.
Clean or replace air filter.
Drain fuel, clean carburetor. Fill with fresh
fuel.
Clean fuel line. Check fuel filter.
Check/clean vent.
Refer to Engine Manual.
Adjust carburetor.
Park brake set. Release brake.
Check oil. Add oil.
Refer to Engine Manual.
Drain fuel. Fill tank with higher octane fuel.
Stop engine. Allow to cool.
Refer to Engine Manual.
Adjust carburetor.
Check spark plug(s). Regap.
Slow down on rough terrain, check condition
of seat switch.
7.
‘Section Il - TROUBLESHOOTING
ENGINE OVERHEATED
Air intake or cooling fins clogged. . ....... .. eee. Clean intake screen and fins.
Fuel mixture too lean, 1... 11111 LL LL LL A LA LL LL LL LL LL 20
Oil level too high or too low, . ....... LL LL A LL LL Adjust oil level.
Improper ignition timing, ~~. aa, Refer to Engine Manual.
Running engine too slow “. Increase engine speed.
LT TT)
ENGINE IDLES POORLY
Carburetor out of adjustment. ... ... 2.244411 4 1 1 LL 4 4 1214 Adjust carburetor. _
Improper sparkpluggap. . . ............... eee Check plug. Regap.
Air filter dirty aaa aaa Clean/replace air filter.
9. ENGINE BACKFIRES
Carburetor out of adjustment .. . . . . . .................. Adjust carburetor.
10. MOWER LOSES POWER OR TRANSMISSION OVERHEATS
Parking brake not releasing. . . .. Ce LL LL LL LS Disengage park brake.
Transmission oil low, 1. 1111121 LL LL LL A LA A LL LL LL LL Add oil.
Damaged transmission. . . . . ana Replace transmission.
Defective high pressure relief valve (HPRV), . . . . . . . . .. a Replace HPRV (See Page 8.10).
Loose belt, 11.111111 11111 LL LL LL LL LL Adjust belt.
TRANSMISSION
1. ENGINE RUNS, BUT MOWER WON'T MOVE FORWARD OR IN REVERSE
Drive belt loose or broken . . . . . . . . . . . .. . . . . . . г... Adjust belt/replace.
Shift linkage cable disconnected, . . . . . . . . Connect cable.
Transmission shift arm disconnected. . . . . . .. .............. Connect shift arm.
Transmission oil low, , .......... aaa Add oil.
Transmission locks in "UNLOCK" position, . . . . Ce Put in "LOCK" position.
Malfunctioning transmission, . . . . . . . . Replace transmission.
Control linkage to hydro out of adjustment, . . . . . . . . . . Adjust control linkage.
Dump valve on hydro not fully released. . . . . . ............... Release dump valve.
Parking brake isset. .... 1.112111 ea Release park brake.
Control arm roll pin is broken or missing... . 1... 111111111110 Replace roll pin.
Defective Hi-pressure relief valve (HPRV) . . . . 111111 Replace HPRV.
2. TRANSMISSION IS OVERHEATING |
Oillevellow. . 1 1222144444 4 4 4 4 4 4 A 4 4 A 4 4 4 4 A 14 4 Check/add oil.
Oilisofwrongtype. . . . . . . . 1 LL LL LL LL LL LL LL Drain. Replace with specified oil.
See Owner's Manual.
Cooling finsonhydroareclogged. . . . . . ................. Clean fins.
Broken cooling fan blades. .. . 1... 1221 4 4 1 LL LL LL LL 4 44 Replace cooling fan.
Exceeding load rating for tractor. . . . .. ....... aa aa aa Reduce load.
Parking brake not fully released. , . ... . .. Release park brake.
Clogged oil filter. . . ....... ea aa Replace filter.
BRAKE FAILS TO STOP VEHICLE OR HOLD ON HILLS
Brake lever rod out of adjustment , . . .... . . . . . 2.2, Adjust brake lever rod.
Brake pucksworn. . . .... .—... ea aaa Replace pucks.
Brake band worn. . . . . . . eee aaa Replace band.
‘Section Il - TROUBLESHOOTING
4. TRANSMISSION LEAKS OIL OR GREASE
Oil reservoir base on top of reservoir loose (Model BDU1OS . . . . . . . ..
Loose hose clamps or fittings. . . . . . . . . e... e
Oil leaks from shaft seals
Transmission control shaft sealfaulty. . . . . . ................
TRANSMISSION (UNISTAT)
1. TRACTOR WILL NOT MOVE FORWARD OR IN REVERSE
Control linkage to hydro out of adjustment. . . . . . . . ...........
Oillevellow . . . . . 2 aaa ea era
Dump valves are open. . . ...... e... ee eee
Input drive belt is slipping or broken... 1.111111 LL LL A 1 144
Parking brake is set. . . . . . 1.114444 4 44 4 4 4 4 4 4 4 1444 .
High pressure valve "O" ring failed . . . . . . . ...............
2, TRANSMISSION IS OVERHEATING
Oillevellow. . . . . aaa aaa
Oil is of wrong type. .. ..... 1.111111 1 LL LL LL LL
Oilfilterclogged. . . . . . . . LV LL VA LA LL LL ALL 0
Cooling fins on Unistat clogged. . . .. ... 1241444 44 4 14 4 140
Exceeding load rating for tractor. . . . . ... 12444444 4 41 4140
Parking brake not fully released. . . . . . . . ................
3. PARK BRAKE FAILS TO HOLD VEHICLE
Faulty transmission. . ...... 1 LL LL LL LL LV LL 0
Faulty park brake valve. ..... 1111111 LL LL LL LA LE A a 1 4 40
Faulty hydraulic hose or fitting. . . . . . . 1.244414 4 1 11111220
4. PARK LOCK PIN DOESN'T RELEASE/RELEASES SLOWLY
Return hose restricted. . . . . . . . . . . 2... e ea aa
STEERING (JOYSTICK/UNISTAT)
1. MOWER PULLS TO ONE SIDE WHILE OPERATING
Control cable out of adjustment . . . . . . . ... ..............
A. Outside cable controls right wheel
B. Inside cable controls left wheel
Transmission dump valve not fully closed. . . . . . . . ... ........
"O" ring in dump valve is damaged. . . . ...................
Зесопа 5!аде апуе Бе! 1$ 10086... . .. . ...... ............
2. MOWER CONTINUES TRAVEL WITH JOYSTICK IN NEUTRAL
~ Control cable out of adjustment. . . . . ....................
A. Outside cable controls right wheel
— B. Inside cable controls left wheel
Unistat shift block out of adjustment. . . . . . . . .......... ee.
2.4
Tighten base. Torque to 100-120
inch/lbs.
Tighten hose/fittings.
Refer to Transmission Manual.
—. Torque housing bolts to 120-160
inch/lbs.
Replace seal.
Adjust control linkage.
Check/add oil.
Close valves.
Adjust/replace belt.
Release park brake.
Replace "O" ring.
Add oil.
Drain. Replace with specified oil.
Replace oil filter.
Clean cooling fins.
Reduce load.
Release park brake.
Replace transmission. See Page
8.10.
Repair/replace valve.
Repair/replace.
Remove obstruction. Install 3/8"
hose.
Adjust control cable.
Close dump valve.
Replace "O" ring.
Tighten drive belt.
Adjust control cable.
Rotate shift block to next hole.
Section Il - TROUBLESHOOTING
3.
SLOW OR NO RESPONSE TO MOVEMENT OF JOYSTICK
Joystick pivot block worn - - . . o.oo oo ooo e Rebuild/replace pivot block.
Joystick pivot block out of adjustment. .. . 1.111111 1 11111110 Adjust pivot block.
Control cable out of adjustment. . . . . . . .............. ~. . . . Adjust control cable.
Both dump valvesareopen, . . . . .................. . . . . Close dump valves.
Drive belt loose orbroken. . . . . .. .....................Adustreplace belt.
Spacers Worn. . . ... . 2. aaa aaa aaa Replace spacers.
Cable belts loose or missing. . . . . . . . . . e e ..eezgre. Tighten/replace.
JOYSTICK DIFFICULT TO MOVE (METAL PIVOT BLOCK)
Lubrication of pivot block reguired. . . . . . . . 2... Lubricate pivot block with Teflon
spray lube.
STEERING (TWO-HANDLE CONTROLS/UNISTAT)
1.
MOWER PULLS TO ONE SIDE WHILE OPERATING
Transmission dump valve notfullyclosed . . . . . . . ............ Close dump valve.
"O" ring in HPRV valve isdamaged. . . . . . . . ... ........... Replace O' ring. See Page 8.10.
Drive beltis loose. . . .. ...... 2, eee e e ea Adjust drive belt.
Pivot stop out of adjustment . ........... 2. e Adjust pivot block.
Rotary mount block out of adjustment. . ............. Adjust mount block.
Primary belt loose or improperly tensioned. . . . . . ............. Adjust drive belt.
MOWER CREEPS WHEN STEERING LEVERS ARE IN NEUTRAL
Rotary mount block out of adjustment. . . . ................. Adjust mount block.
Neutral return block out of adjustment . . . . . . . .............. Adjust neutral return block.
Rod out of adjustment. . .......... aa aa Adjust rod.
STEERING HANDLE FAILS TO RETURN TO NEUTRAL WHEN RELEASED
Transmission internal N-R device worn Replace transmission.
Obstruction in control linkage. . . .. .... 2. nee Replace obstruction.
CUTTER UNIT
1.
MOWS IMPROPERLY
Dullblades. . . . . ..............................Sharpenblades.
Uneven tire pressure, . | . . | . o —... . Inflate tires to specifications.
Deck out of level. ......... aaa aa Level deck.
Deck belt slipping. . . . . . LL LL 111110 Adjust deck belt/check idler arm &
ВЕ loosen if necessary.
Engine speed too low. . . . . . . te eee eae eee eee. Increase engine speed.
Blades bent. . . . . . . . 1 42011 412 4 4 . 4 4 4 4 ee ee ee 1 10 Replace blades. |
EXCESSIVE NOISE OR VIBRATION WITH BLADES ENGAGED
Blades out of balance. ......110 1011111 LL LL LL LL LL LS Balance blades.
Spindle bearings dryorwornout. . . . . ........... a Lubricate/replace.
Idler bushing worn. . ..... . .... aaa Replace bushing.
EXCESSIVE BELT WEAR
Wrong belt installed. .. . ... 1.122141 LL LL A A LL LL LL 0 Install correct belt.
Wrong double idler installed. . . . . . . . . .. aaa a ae a Install correct double idier.
Idierarm bent. ......... 2... aaa aaa Straighten idler arm/replace.
Section II - TROUBLESHOOTING
4. DECK CASTER WHEEL WILL NOT SWIVEL (60" DECK)
Bearings dry or worn out. . . . . .. . e e ae e e eee Lubricate/replace.
Swivel assembly deformed . . . . . ... 422444444444 4 4 44 40 Replace assembly.
5. EXCESSIVE "DUSTING" DURING ARID TIMES OF YEAR
Standard lip baffle kit installed on deck. . . . . . .... 2444444440 . . Install new dust baffle kit.
Underside of deck full of impacted grass - - - + - + + + + + 4444444006 Clean underside of deck.
2.6
Section II
ELECTRICAL
SYSTEM
3.1
Section lll - ELECTRICAL SYSTEM |
INTRODUCTION ~~ pour electrolyte into a new battery when it is
The electrical system of the Zero Turning Radius mounted on the equipment.
Mower consists of three circuits which are the ignition, |
charging and starting circuits. This section covers the e. battery OF a ver suriaco and male place the cap
. es . . | U
starting circuit only. Refer to the engine manuals for | vent holes are open to permit gas to escape
information concerning the ignition and charging circuits | during battery charging.
- these are internal engine circuits. |
STARTING CIRCUIT a NE.
(Principle of Operation) | ВЕ WARNING!
The safety interlock system is an electrical loop contain- Battery acid (electr olyte) is corrosive!
ing four interlock switches; seat, clutch (or mower blade) Use care when handling!
brake and steering control switch. The four switches | |
MUST be closed at the same time before the engine can 3. Remove the caps and fill each cell with 1.265 (*.05)
be started. If any of the four are open, the circuit will not specific gravity battery grade electrolyte to a level
be grounded and the starting solenoid can not be that is no more than 3/16" above the top of the
activated. plates. See Figure 3.2.
After the engine has been started, the clutch switch
(mower blade) brake switch and steering control switch
can be opened. The key switch must remain closed (in
run position) and the operator must remain in the seat to
keep the seat switch closed. The interlock system will
"kill" the engine if the operator vacates the seat UNLESS
the clutch switch (mower blade) has been turned off, the
steering control placed in neutral and the parking brake
set. Figure 3.1 shows the starter system configuration.
ELECTROLYTE
3/16" ABOVE PLATES
KEY SWITCH
M STARTER
G|T ©
yO NOTE
The battery and electrolyte should be at least 70
“degrees Fahrenheit prior to filling. Allow 30 min-
utes to set, then add electrolyte as needed to
SWITCH LOOP bring the level back up to 3/16" above plate level.
Reinstall caps.
SEAT SWITCH
( ‘ ~~ NOTE
| ; Never overfill the battery cells. Maintain the level
at NO MORE than 3/16" above the plates. Use
distilled water to restore correct level. If over-
O, filled, the liquid can overflow and reach the battery
MOWER BLADE CLUTCH/BRAKE terminals creating a path for electrical discharge
SWITCH SWITCH and, also cause corrosion and deterioration of
| ` metal parts. Should corrosion occur, clean
TO MAGNETO terminals with a wire brush, then coat them with
| petroleum jelly.
STARTER SYSTEM CONFIGURATION 4. The recommended rate of charge is 1 Amp for ten
FIGURE 3.1 ~~ hours. If time will not allow this, charge at three
| Amps for four hours. Due to the length of time
3.1 BATTERY SERVICE | required, it is not practical to attempt charging a
A Most dry charge type battery problems result from ~~ new battery with the tractor engine. NEVER USE
improper activation practices and/or the lack of | BOOST CHARGERS!
r maintenance. Acti as follows:
proper battery maintenance. Activate as WS | WARNING!
1. Before activating the battery, remove it from the | HYDROGEN IS EXPLOSIVE! Do not charge
> tractor. See Figure 3.3A. Never attempt to batteries around open flames or sparks!
3.2
Section III - ELECTRICAL SYSTEM
5. After the battery has been properly activated,
inspect it for leaks and electrolyte on surfaces.
Clean and dry all surfaces before installing in
tractor.
6. ALWAYS connect the Positive (+) cable to the
Positive battery terminal BEFORE attaching the
Negative (-) cable to the Negative terminal. This
procedure will prevent accidental arcing should a
wrench or pliers touch the tractor frame during
removal or installation. ALWAYS disconnect the
Negative (-) ground terminal first. See Figure 3.3.
BATTERY CLAMP —-
BRACKET
E nio SEAT
QA (FOLDED FORWARD)
- |. RED BOOTOVER
POSITIVE (+) TERMINAL
BATTERY
FUEL TANK ——$
FIGURE 3.3
B. BATTERY REMOVAL
1. Tilt seat forward.
2. Disconnect negative (black wire) terminal.
3. Slide protective boot aside and disconnect
the positive (red wire) terminal.
— WARNING |
ALWAYS disconnect negative (black wire)
FIRST! ALWAYS connect the negative wire
LAST! |
4. Tilt the seat back to the operating position.
. Remove the battery clamp angle screws from
5
the front panel.
6. Tilt seat forward again.
7. Remove battery clamp angle.
8. Remove battery. See Figure 3.3A.
NS
REMOVE NEGATIVE (-)
CABLE FIRST
FIGURE 3.3A
9. Reinstall battery in reverse order.
C. BATTERY TESTING
A battery which does not perform properly is not
necessarily worn out or defective. It may only need to be
removed from the unit. and brought up to full charge with
a battery charger. If battery trouble is still suspected
after being fully charged, tests should be performed.
If the battery is producing 12 volts and the cables have
continuity, the remainder of the starting system can be
systematically tested. A complete check includes
cleaning and testing the charge with a hydrometer. The
battery must be properly serviced as desribed earlier
before testing.
D. TESTING WITH VOLTMETER
Test battery voltage with a Voltmeter (VOM). Set meter
on DC Volts. Place the red probe on the Positive (+)
- terminal and the black probe on the Negative (-) terminal.
POSITIVE (+)
NEGATIVE (-)
TERMINAL — TERMINAL
12V — Less Than
Recorded 12V
Recorded
Battery OK Battery
for Cranking Discharged or
System Tests Defective
Test Perform
Battery Battery
Cables Maintenance
FIGURE 3.4
E. TESTING WITH HYDROMETER
Test the specific gravity of the battery's electrolyte with a
hydrometer. If the reading is less than 1.225, the battery
. Should be recharged before further testing can be done.
If the battery fails to accept a charge, it is not serviceable
and should be replaced. Cease testing if this is the case.
— See Figure 3.5.
3.3
| NOTE
Hydrometers are generally calibrated to give a
correct reading only at 80% F. When taking a
reading at other temperatures, a correction factor
must be used. This factor is approximately 0.004
(4 points) specific gravity. For each 10 degrees
above 80°F, ADD 4 points. For each 10 degrees
below 80°F, SUBTRACT 4 points. Always correct
~ the readings for temperature variations. Test
_ Specific gravity of each cell.
Section III - ELECTRICAL SYSTEM
To read the hydrometer correctly,
position the top surface of the
electrolyte in the hydrometer at
eye level. Disregard the cur-
vature of the liquid where the
surface rises against the float.
| EXAMPLE
Hydrometer reading is. ..........1.240
Temperature is........................-. OF
Degrees different
than
80” ne... .econennocoreacconecanaaencaconorerrenanar 30
Number of 10° intervals................. 3
Times Correction
{ас!ог........ „оон 3 x 0.004
Correction…..….…..….…..…..…...….….….0….….. 0.012
(Correction is subtracted when
temperature is lower than 80°)
enenvancacanancacoanananononconecuaneccaneneaeeas -0.012
Corrected Hydrometer Reading
eoueoneoncccconorenennue cocer ieneceouecconee ces 1.228
A fully charged battery should
have a specific gravity reading
above 1.225 in all cells before
HYDROMETER
a THERMOMETER
HYDROMETER
Fe
(DISREGARD
i И CURVATURE)
performing full high rate discharge EYE LEVEL
test.
FLOAT N | ELECTROLYTE
Perform the hydrometer specific gravity test as follows:
Carefully insert tip of the hydrometer into the cell to avoid
damaging the separators. Broken separators could
“result in premature failure of the battery. Squeeze bulb
and draw in only enough electrolyte to keep the float
from touching the bottom of the hydrometer barrel when
FIGURE 3.5
3.4
the bulb is released. Keep hydrometer in a vertical
position while drawing in liquid and while taking the
reading. Test each cell.
TESTING CHART on page 3.5 for analysis of test
readings.
Refer to the BATTERY
Section lll - ELECTRICAL SYSTEM
F. BATTERY TESTING CHART
1. 1.215 Specific Gravity 1. Probably Good 1. No correction required if variation among cells not
: over .050 Specific Gravity. Give High Rate
Discharge Capacity Test. If test O.K., check
operation and setting of voltage regulator. Make a
thorough check of the electrical system for short
circuits, loose connections, corroded terminals etc.
2. Less than 1.215 Specific Gravity 2. Questionable 2. Recharge Battery. After recharge, repeat step #1.
3. Cells showing more than 50 points (050) Specific | 3. (A) Short circuit in low cell. 3. Recharge battery. If .050 Specific Gravity variation
Gravity variation. (B) Loss of electrolyte by leak or excessive over- persists, replace battery. If battery accepts charge
charge. =. and variation does not persist, repeat step #1.
(C) Improper addition of electrolyte or contaminants
(D) Natural or premature battery failure
(E) Cracked box partition
4. Battery or cells showing more than half charge. 4. Probably good. | 4. Apply remedy given for #1.
5. Battery or celisshowing less than half charge but 5. Questionable 5. Apply remedy given for #2.
not more than .05 volts variation. : ;
8. If cell connectors are accessible, cells showing 6. See #3 6. Apply remedy given for #3.
more than .05 variation,
7. Use High Rate Discharge Tester in accordance
with manufacturer's recommendations.
(See electrical diagram below for points of
common difficulties.)
[ }- Location on 6 point Terminal Strip ELECTRICAL DIAGRAM (ZU MODEL)
Black Wires - Ground
Red Wires - Power | А
Blue Wires - Kill Circuit — (ON ENGINE)
Yellow Wires - Start Circuit
| Green Wires - Signal Circuit
10
(ON ENGINE)
Blue
R
Blue Р ed Green
(ON ENGINE)
Black
FIGURE 3.6
3.5
Section Ill - ELECTRICAL SYSTEM
[] Location on 6 point Terminal Strip ELECTRICAL DIAGRAM (Z MODEL)
NOTE:
ANTI-BACKFIRE (ORANGE
WIRE) USED ON BRIGGS
TWINS
| J |
COMPONENT KEY STARTER ELECTRIC
CLUTCH
A - Anti - Backfire | æ
SOLENOID.
5 - Fuse Fuse (lB | CLUTCH SWITCH (Red
C - Battery E
D = Starter "= —_ Y
E - Seat Switch | N В SATTERY a E
F - Solenoid — | RE
G - Kev Switch M = G (Yellow) RIGHT K LEFT con
у ЭМ ©! BUZZER REGULATOR ,_ START N.O. | NO.
H - Clutch Switch og SWITCH NEUTRAL SWITCHES
J - Clutch | = ’
K - Neutral Switch CÍA ene Y В ANTE A
L - Hour Meter MAGNETO p Joe =
M - Buzzer 8 Q |: В
N - Oil Switch | (White) =» (White) = | {es}
HEADLIGHT HOUR METER
O - Regulator SWITCH =
P - Magneto | HEADEIGHTS
Q - Headlight Switch
R - Headlights
FIGURE 3.7
3.6
Section III - ELECTRICAL SYSTEM
3.2 INTERLOCK SYSTEM ANALYSIS
A. KEY SWITCH
1. Disconnect wires from the switch terminals. See
Figure 3.8.
2. Place the switch in the OFF position. Connect
continuity light to "M" and "G" terminals only -
there should be contact.
3. Place the switch in ÓN position and connect the
light to the "B" and "L" terminals only - there should
be contact.
4. Hold the switch in the START position after
connecting the light to terminals "B" and "S" - there
should be contact.
5. Reconnect harness wires to switch terminals after
completing test.
FIGURE 3.8
B. SOLENOID TEST
1. Disconnect all wires from the solenoid. See
Figure 3.9.
2. Connect the continuity light to both threaded
terminals.
3. Now apply 12 Volts to the two plug terminals.
, The solenoid should click and the continuity
— light should come on.
4. Reconnect wires to proper terminals.
THREADED TERMINALS
12V. D.C.
PLUG
TERMINALS
terminals.
FIGURE 3.9
C. SEAT SWITCH TEST | |
1. Disconnect wire connectors from terminals.
See Figure 3.10.
2. Attach continuity light wires to the NC and COMM
terminals. When the switch is depressed (making the
circuit ) the light should come on.
. 3. Reconnect wires to the seat switch.
3.7
FIGURE 3.10
D. CLUTCH SWITCH TESTS
1. Disconnect wires from the switch terminals.
See Figure 3.11.
2. Place switch in OFF position and connect tester
wires to the #4 and #5 terminals only - the light
should come on.
3. Place switch in ON position and connect tester
wires to the #1 and #3 terminals only - the light
should come on.
4. Reconnect wires to the proper terminals.
FIGURE 3.11
E. JOYSTICK SWITCH TEST
1. Disconnect wire connectors from terminals.
See Figure 3.12. |
2. Push the joystick DOWN and connect tester wires
to the NC and COMM terminais - the light should
come on.
3. Pull the joystick UP and connect tester wires to
the NO and COMM terminals - the light should
~ come on.
NC
NO
<
| -COMM
"OFF"
\ |
\
A
<
FIGURE 3.12
Section Ill - ELECTRICAL SYSTEM
F. BRAKE SWITCH TEST
1. Disconnect wire connectors from terminals.
See Figure 3.13. ,
— 2. Attach continuity light wires to the NO and COMM
“terminals. When the switch is released ( making the _
circuit ) the light should come on.
3. Reconnect wires to the seat switch.
NC
G. OIL SWITCH TEST FIGURE 3.13
1. Disconnect wire connector from terminal.
— See Figure 3.14. |
2. Connect tester wires to terminal and steel deck plate.
If light on tester glows, switch is good. If light does not
_glow, replace oil switch. |
, FIGURE 3.14 -
H. ELECTRIC CLUTCH TESTS
(MEASURE CLUTCH FIELD COIL)
1. Turn clutch switch and engine switch OFF.
2. Disconnect clutch wire connectors. See
Figure 3.15.
| ~~ FIGURE 3.15 Ш
(CLUTCH FIELD COIL RESISTANCE)
3. Connect OHM meter leads to the two wires in the
clutch connector. Refer to Figure: 3.15.
4. If the meter reading is BELOW 2.40 OHMs or
. ABOVE 3.40 OHMs resistance, the clutch has
failed and must be replaced.
If the meter reads between 2.40 and 3.40 OHMs
resistance, proceed with the CLUTCH CURRENT
DRAW test.
(MEASURE CLUTCH CURRENT DRAW)
1. With the engine switch and clutch switch OFF,
disconnect the clutch wire connector.
See Figure 3.16. -
A
7
D , E
HARNESS CLUTCH
CONNECTOR CONNECTOR
FIGURE 3.16 (CLUTCH CURRENT DRAW)
Use an AMP meter with a 10 AMP scale. Connect
one meter lead to clutch connector wire "A" and
connect the other meter lead to wire "C" in the
harness connector.
Connect a short jumper wire to the wire "B" in
the clutch connector and to wire "D" in the
harness connector.
Turn clutch switch ON.
If the meter reads BELOW 3.5 AMPS, the electical
system has a problem (battery, relay, switches, etc.).
Check the electrical system.
If the meter reads 3.5 AMPS to 4.5 AMPS, proceed
to the AIR GAP SETTING instructions.
(CHECK AIR GAP SETTING)
1. With the engine switch and clutch switch OFF,
locate the three air gap check "slots" as shown.
See Figure 3.17.
a
6.
^^. ENGINE PULLEY
PULLEY =
ADJUSTING | ©
NUT 017 INCH
FEELER GAUGE
AIR GAP CHECK "SLOT"
(THREE TOTAL)
— FIGURE 3.17 (USING FEELER GAUGE)
2. Insert a .017 feeler gauge into each of the 3 slots.
3. If the gaps do not fall between .010 and .025,
reset the spring-loaded adjustment nuts until the
gaps are measured at .017 on the feeler gauge.
THEREFORE IF...
A. The resistance falls between 2.40 and 3.40 OHMs...
B. The amperage draw is 3.50 AMPS to 4.5 AMPS...
C. The air gaps are between .010" and .025" (or have
been reset to .017"), the electric clutch is within
factory specifications and is not the source of a
problem - check the remainder of the electrical
system.
38
Section lll- ELECTRICAL SYSTEM
WIRING SCHEMATIC- 12 Hp. Models Only
BLACK
CLUTCH A BLUE
SWITCH <
BLACK JS
RED
CLUTCH
a
6 pt COMM,
AL TERMINAL
Na. ave STRIP
ss
FACTORY COUPLER
WIRE (RED)
CABLE
(Solenoid
fo Starter)
BATTERY
(12 Volt, 30 Amp.Hour)
SOLENOID
CONTACTS
N.O.
BRAKE SWITCH [+]
(BLUE) T N.C.
SEAT w
wd
m
| a
N.O."
SOLENOID | 4]
JOYSTICK |
©. | CLUTCH
= SWITCH | SWITCH
& START BED, |
SWITCH | CLUTCH
RED) TE
(BLACK)
REGULATOR
(BLUE)
*= 20 AMP SLO BLO FUSE
MAGNETO
FIGURE 3.18
1-5
— 39
‘Section lll- ELECTRICAL SYSTEM
WIRING SCHEMATIC- 14, 18 & 20 Hp. Models Only
BLACK
CLUTCH e a
SWITCH EOL eu |
Са QU NOTE: WIRES ON ENGINE SIDE OF PACKARD CONNECTOR MAY BE PAINTED BLACK.
BLACK CNS SCRAPE BLACK PAINT OFF FOR WIRE COLOR IDENTIFICATION,
RED
BLACK
оао > WIRE HARNESS
SWITCH pue BRAKE
COM PA BUZZER DSSWITOH
| „© COMM.
N.C. 6 pt. | BLUE
O“. PRESSURE SWITCH
WHITE WIRE TO KILL SWITCH
GREEN Æ 1
BLUE S
& x TERMINAL NON
GREEN WIRE TO NN TN STRIP >
A $ N = N
сеет 8 > > KEY
A SN ER |
É se << <> SWITCH
-
—
aS
3 -
En de YA (Solenoid
N T Ly 7 to Starter)
ENGINE sou и Di
POSITIVE
(RED)
BATTERY
(12 Volt, 30 Amp.Hour)
SOLENOID
CONTACTS
NO.
STARTER
{RED) Й | (RED) A
BRAKE SWITCH D
(BLUE) c
SEAT m
SWITCH 2
BLUE)
| .
JOYSTICK | CLUTCH
MO. SWITCH | SWITCH
* START
SWITCH | CLUTCH
x (RED) (BLACK 4]
a BUZZER p
E \
MY Y
- OIL
* = 20 AMP SLO BLO FUSE SWITCH
FIGURE 3.19
3.10
SERVICE NOTES
3.11
SERVICE NOTES
3.12
Section IV
STEERING CONTROLS
ADJUSTMENTS & REPAIRS
‘Section IV - STEERING CONTROLS ADJ & REPAIRS
INTRODUCTION
This section covers procedures for the adjustment, _ It should be noted that most service bulletins (prior to
disassembly and repair of the steering controls found on 1994) concerning steering controls will be found
earlier and present-day (1994) SNAPPER Zero Tuming incorporated in the following pages. Future service
Radius Mowers. bulletins should be inserted in this section for quick
reference. For component breakdowns of the different
These controls include the joystick (older version), steering controls see Figures 4.1, 4.2 and 4.3.
joystick (present version) and the two-handle steering
. systems found on earlier models of the unit.
FOAM
GASKET
HANDLE GRIP
1/4 - 20 NYLOK NUT
ROLL PIN, 3/16" x 1"
BALL JOINT
BUSHING
1/4 - 28 FEMALE
BALL JOINT BELLOWS BOOT
BALL JOINT
BUSHING
PIVOT BLOCK/PIVOT SHAFT —
(DELRIN PLASTIC)
BALL JOINT
BUSHING JOYSTICK SHAFT
1/4 - 28 FEMALE
BALL JOINT
NS
BALL JOINT — <>
BUSHING le
49)" Fe 1/4" - 20 x 1/2" SCREW
1/4" - 20 x 3"
CAP SCREW
TOP PLATE
PIVOT BLOCK
(DELRIN PLASTIC)
25 1/2" PUSH-PULL
| CABLE
On SHIM WASHER
(.005, .010 OR .020 THICK)
бу SNAP RING, Spirlock
BALL PLUNGER
SNAP RING, 1/2"
55" PUSH-PULL CABLE
#4-40 x 3/4" SCREW
LOCKWASHER, #4 STAR
SHIM WASHER
(.005, .010 OR .020 THICK)
JOYSTICK YOKE
SWITCH, SPDT MINIATURE — — — —
JOYSTICK STEERING CONTROL PARTS —
FIGURE 4.1
42
Section IV - STEERING CONTROLS ADJ & REPAIRS
LEI
ROTARY MOUNT BLOCK
NYLON WASHER:
1-1/2" O.D.
HANDLE MOUNTING —
LOWER ARM
WELDMENT Da
UPPER HANDLE GRIP
SCREWS, 1/4"-20 X 7/8" 1 и
NYLON WASHER
1/2"1.D. X 1" O.D.
CAPSCREW
1/4"-28 X 1-1/4"
(ONE EACH SIDE)
SOCKET HEAD SET SCREW
- 4/4"-20 X 1/4"
—UPPER STEERING HANDLE
— NYLON WASHER
1/2 1.D. X 1" O.D.
WASHER, 1/2" NARROW
| TYPEB
— LOCKNUT
1/2"-20 NYLOK
— CABLE MOUNTING
CLIP
—— HEX NUT -
1/4"-28
—LOCKWASHER
1/4" STD SPLIT
— HEX NUT
1/4"-28
PUSH-PULL CABLE
(SERIES 40)
. BRONZE BUSHING
5/16" 1.D. X 1/4" LG
e THRUST WASHER
(В 5/16" LD. X 1/32" THK
e STRIPPER BOLT
A
Sr) 1/4"-20 X 3/4"
WASHER, NYLON
1/2" 1.D. X 1" O.D.
WASHER, 1/2"
NARROW TYPE В
LOCKNUT
1/2"-20 NYLOK
CAM FOLLOWER 1/2" DIA
LOCKWASHER
1/4" SPLIT RING
SCREW, 1/4"-28 X 1/2"
ROUNDHEAD SLOTTED
——LOCKWASHER 1/4" SPLIT RING
WASHER, 1/4" WIDE
ТУРЕ В
TWO-HANDLE STEERING CONTROL PARTS
For Hydrostat & Chain - Reduction Models
FIGURE 4.2
4.3
Section IV - STEERING CONTROLS ADJ & REPAIRS
ROTARY BLOCK —
ARM STOP —
1/4" - 20 HEX NUT —
5/16" SPLIT SPRING
LOCKWASHER
HEX CAPSCREW
5/16" - 24 x 1”
LOCKWASHER, 1/4
HANDLE GRIP —,
WASHER, 1/2" 1.D. x 1" O.D. NYLON —
SHIFT LEVER-——
(FITS BOTH SIDES)
HANDLE CONNECTOR
WELDMENT (L.H. &
R.H. REQUIRED) —
| -CAPSCREW
3/8" - 16 x 1 1/4" GR5
T
—é 3/8" - 24 BALL JOINT
3/8" SPLIT — | PLAIN FEMALE
SPRING A
LOCKWASHER — @ LINKAGE ROD
||
В
”
2
„”
—— NUT, 3/8 - 24 HEX
MODEL ZU2013K
a
9”
SPLIT SPRING bls
| LOCKNUT, |
CAPSCREW, 1/4 -20 NYLOC
- 1/4-20x11/2 |
CAPSCREW, SHIFT
1/4 - 20x 1 GR5 PLATE
À
>
2
FIGURE 4.3
4.4
CONTROL
ARMS
Section IV - STEERING CONTROLS ADJ & REPAIRS
4.1 JOYSTICK NEUTRAL ADJUSTMENT
Use the following steps to adjust "NEUTRAL" on
Joystick units:
A.Operate the unit for at least 15 minutes to warm
up the hydros. Push the joystick all the way down
and engage the parking brake. If the parking brake
holds the unit, do not make creep adjustment. If it
still creeps thru the parking brake, take the addi-
tional steps,
B. Shut the engine "OFF".
C. Jack rear wheels off the ground and remove both
wheels.
D. With the joystick all the way down, start the en-
gine and observe both axles. If they rotate, re-
‘move the two bolts shown in Figure 4.4. Also, re-
move the heat shield. You should then be able to
look directly down at the area where the control
cables hook to the control arms on the pumps.
REMOVE BOLTS
REMOVE
HEAT SHIELD
FIGURE 4.4
E. Remove the bolt from the control arm and the con-
trol cable. See Figure 4.5. You can now move the
control arms by hand. Move them until all move-
ment ceases. Shut the engine "OFF".
REMOVE BOLTS
FIGURE 4.5
4.5
F. Now, adjust the ball joints'onthe end of the con-
trol cables until they align with the hole in the con-
trol arm. Reinstall the bolts through the control
cable into the control arm.
G. Reinstall the wheels and perform a function check.
NOTE
It is recommended that all control cable adjust-
ments be made at the control arms on the trans-
missions. Although steering cables can be
adjusted at the joystick, this practice is discour-
aged in order to prevent the loss of parts.
4.2 DETENT ADJUSTMENT
A. If joystick does not lock in the "UP" position, turn
the detent adjustment screw clockwise until a de-
sirable locking action is obtained. See Figure 4.6.
JOYSTICK HANDLE |
CROSS BOLT NUT —
BALL JOINT
(2)
JOYSTICK PIVOT
SHAFT |
JOYSTICK
SPACERS BOOT
(2 ea CABLE)
RS
A
A 7 (O) »
) 5
©
TT
- BALL JOINT
LOCKNUT (2)
CABLE MOUNTING
NUTS (2 ea CABLE)
AU]
DETENT ADJUSTMENT SCREW
FIGURE 4.6
B. If joystick is hard to slide up and down, turn the
detent adjustment screw counterclockwise until a
desirable sliding action is obtained.
4.3 JOYSTICK LUBRICATION
(Z Models With Metal Pivot Block)
A. Place a few drops of Teflon™ spray lubricant on
joystick shaft where it enters the pivot block, then
work joystick up and down and rotate it to distrib-
ute oil around the joystick shaft and into the pivot
block.
B. Pull up on joystick to lock it in the "UP" position. If
joystick will not lock in the "UP" position, adjust
the detent screw per instructions in 4.2, DETENT
ADJUSTMENT.
4,4 JOYSTICK SENSITIVITY ADJUSTMENT
To quicken sideways turning response, adjust as
follows: | ВЕ ВЕ LS
‚А. Remove right hand fender skirt to expose joystick
assembly.
SECTION IV - STEERING CONTROLS ADJ & REPAIRS
B. Remove lock nut, cross bolt and spacers. See
Figure 4.7. |
— JOYSTICK MOUNTING PANEL
ACCESS HOLE
3" LONG CROSSBOLT |
SHORT SPACERS (2)
LONG SPACER
PIVOT SHAFT
FIGURE 4.7 | —
C. Reassemble spacers as desired. More spacers
between the ball joint and joystick pivot shaft
quicken the response, less slows the response.
NOTE
It is important that there is a spacer on each
side of the turnbuckles to prevent damage
to the ball joints or cables.
4.5 JOYSTICK SENSITIVITY ENHANCEMENT
PROCEDURE
For even quicker response side-to-side, the control
cables need to be spread apart at the pivot shaft. Pro-
ceed as follows:
Additional parts required: 1/4" washers (6 max.)
1/4 - 20 x 3" long bolt
A. Remove the right hand fender skirt to access the
joystick components.
B. Remove the crossboit that holds the cable ball
joints and bushings to the pivot shaft. Make sure
not to lose the bushings.
C. Install the desired amount of washers on each side
of the pivot shaft to spread the cable ends apart.
Use no more than 3 washers per side. Excess
washers will bend the cables and cause them to
break. The 3" long bolt should be installed with
the head on the inside (closest to the seat) to pre-
vent it from hitting the joystick mounting panel.
— See Figure 4.8.
4.6
JOYSTICK MOUNTING
PANEL ACCESS HOLE:
3" LONG
CROSSBOLT
LONG BUSHING
1/4"
| MAKE SURE that Long and Short
| Bushings are located WHERE
SHOWN and with shoulder portions
facing IN towards ball joints.
FIGURE 4.8 |
D. Make sure the bushings are in the same order as
before. Refer to Figure 4.8. There is a difference
in the bushings. After all parts are assembled and
tight, rotate the joystick, making sure it moves
freely without striking anything or pinching wires,
etc.
NOTE
First try 1 washer per side, and, if the re-
sponse is not quick enough, keep adding
washers until a desired response is
achieved - no more than 3 per side.
4.6 STEERING LEVEL ADJUSTMENT
(Models 2-LEVER & ZU-RIDERS)
With the engine running, if the machine travels for-
ward or rearward when the steering levers are in the
neutral position, stop the engine and adjust as fol-
lows: |
A. LEFT WHEEL ADJUSTMENT
1. Tilt the seat forward to gain access to the ro-
tary mount blocks.
2. If control lever does not rotate freely into neu-
tral slot without applying forward or back pres-
sure on the handles, adjust as follows:
(a) Remove the control linkage bolt from the
rotary mount. See Figure 4.9.
Section IV - STEERING CONTROLS ADJ & REPAIR
NN Ns
VW |
ADJUSTING SCREWS a | |
(ROTARY MOUNT BLOCK)
LOCKING ee
„NUT a
| Ss Sea J
e e = Po “
LINKAGE e q
ROD +0 . 7
o» N В
— CONTROL
LINKAGE
BOLT
FIGURE 4.9
(b)Loosen the locking nut and adjust the link-
age to find neutral.
4.7 SHIFT BLOCK LINKAGE ADJUSTMENT
If steering control adjustments cannot be completed
at the joystick or steering lever sections, then adjust
the ‘shift block end of the controls as follows:
A. ADJUSTING SHIFTING BLOCK
1. Remove capscrew from end of ball joint. See
Figure 4.10.
ACCESS HOLE
IN REAR DECK
REMOVE CAPSCREW
FROM BALLJOINT
FIGURE 4.10 |
2. Screw ball joint IN or OUT to adjust shift block
to desired position.
3. Reattach ball joint end to shift block and test
adjustment.
4. Repeat procedure as required until steering is
adjusted to satisfaction.
. MAJOR ADJUSTMENT TO SHIFT BLOCKS
If the drive unit cannot be adjusted to perform as
desired from either the joystick end or shift block
end, then the shift block may be installed in the
wrong hole and movement of the shift block on
the shaft may be required. Proceed as follows:
1. Remove capscrew and ball joint from shift block.
2. Drive out roll pin. See Figure 4.11.
4.7
ROLL PIN —
SHIFT BLOCK
WAVE SPRING
WASHER
DRIVE UNIT
(UNISTAT SHOWN)
FIGURE 4.11
Rotate shift block to next hole.
Reinstall roll pin.
Reattach ball joint.
Adjust ball joints at both ends to optimum set-
ting. Test unit for performance.
4.8 NEUTRAL RETURN ADJUSTMENT
2-LEVER MODELS
A.-Should either of the steering controls fail to return
to neutral upon release, then the neutral return
assembly should be checked/adjusted as follows:
1. Loosen fender cap, then remove fender assem-
bly from that side of the unit being checked.
See Figure 4.12.
. Jack up rear of unit and support with jackstands.
3. Start engine. The wheel on the side needing
adjusting will begin to rotate.
4. Visually check the neutral return assembly for
broken or worn parts (i.e., extension spring;
eccentric cam (loose); cam follower (loose/
worn); etc.
SC SQ
N -
- LOOSEN (OR REMOVE)
FENDERCAP |
STEERING
CONTROL
RH. SIDE
| SHOWN
REMOVE FENDER
ASSEMBLY
FIGURE 4.12
Section IV - STEERING CONTROLS ADJ & REPAIR
(a) Extension Spring
If unhooked, reattach. If missing or broken,
replace.
(b)Eccentric Centering Cam
Check for tightness. Also, check adjustment
- this is the most likely cause for failure to
return to neutral. To adjust, loosen cam set
screw and rotate eccentric centering cam
until rotary mount block returns system to
neutral. Retighten cam set screw. See Fig-
ure 4.13. |
—"E"-RING
— THRUST
WASHER-
— CENTERING
| CAM BLOCK
CAM SET
SCREW
ECCENTRIC |
CENTERING
|
CAM
! (CHECK FOR WEAR)
|
PIVOT STOP + |
ADJUSTMENT ROTARY
W Sn |
SCRE BLOCK EXTENSION -
SPRING >“
FIGURE 4.13
(c) Cam Follower
Check for tightness and wear. [f worn,
replace with new part.
(d)Push/Pull Cable
If any of the preceding parts do not re-
quire replacement/adjustment, then
check the push/pull cable.
* Loosen locking nuts at steering control
end of cable.
* Adjust cable in or out as required until
wheel ceases to rotate and neutral is
achieved. See Figure 4.14.
LOOSEN LOCKING NUTS
AND ADJUST PUSH/PULL
CABLE IN OR OUT
PIVOT STOP,
ADJUSTMENT
SCREW i
FIGURE 4.14
"7
B. The pivot stop adjustment screws are set to limit
the forward and rearward movement of the rotary
mount.block (and steering handles). These stop
Screws, on rare occasion, could cause the steer-
ing controls to fail to return to neutral upon release.
If no other adjustment solves the problem, adjust
the stops as follows: .
1. With unit elevated at the rear and the engine
running and a wheel is still rotating, check each
pivot stop screw for setting. |
2. If a pivot stop screw is touching its respective
stop, loosen the lock nut and adjust the screw
IN until rotary mount block moves to put drive
in neutral. Refer to Figure 4.14.
‘4.9 JOYSTICK PIVOT ASSEMBLY REPLACEMENT
PROCEDURE
A. Removing the Current Pivot Block and Pivot
1.
Shaft. See Figure 4.15.
With the joystick in the "UP" position, remove the
roll pin from the joystick handle and the joystick
handle from the joystick shaft. Hold a block of
wood on the opposite side you are driving the roll
pin out of, to prevent damage to the joystick parts.
Remove the fender skirt. Remove the bolts from
the fender cap and push it out of the way. Make
sure not to pull any wires loose during this pro-
cess.
Remove the bolt from the back of the pivot shaft
holding the ball joints in place. Discard the long
bushings and keep the short bushings.
Slide the joystick boot off the joystick shaft. Re-
move the top plate from the yoke (locate the screw
heads and cut the foam pad around them). There
Is a set screw in each of the threaded holes. Re-
move them and discard. This allows the trunnion
pins holding the pivot block in place to be removed
and discarded. In order to get the trunnion pins
out, screw a 1/4-20 bolt into the pin and pull the
pin out. Do this for both sides.
. Remove and discard the old pivot block. Once re-
moved, slide the joystick shaft out through the
bottom, keeping the snap ring in place. See Fig-
ure 4.15,
Section IV - STEERING CONTROLS ADJ & REPAIRS
1/4" TOP PLATE
| SCREW (2)
SHORT
BUSHING
LONG BUSHINGS
SET SCREW (2)
(DISCARD)
E> TOP PLATE
BALL JOINT ~ YOKE
ASSEMBLY (2) | NS
SHORT < J)
TRUNION PIN (2) —
OLD PIVOT (DISCARD) II PIVOT BLOCK
ASSEMBLY | ~ (DISCARD)
FIGURE 4.15
B. Installation of New Pivot Block and Pivot
Shaft See Figure 4.16. |
1. Rotate the two halves of the pivot block so
that the projections are side by side and
place them into the yoke. The studs on the
back of each half go into the holes that the trun-
nion pins were in. The trunnion pins are no
longer required. Rotate the halves to form a
circle in the center cut-outs on the pivot blocks.
2. Test fit the pivot shaft into the pivot block as-
sembly. If the pivot shaft is loose, remove it
and the pivot blocks, place proper thickness of
shims on the studs of the pivot blocks. Repeat
the test fitting of this assembly until the pivot
shaft and pivot blocks rotate freely and without
any excessive play. If the pivot shaft does not
turn freely without any shims installed, it may
be necessary to deburr the inside of the trun-
nion pin holes. Place the large snap-ring on
the front of the pivot shaft to retain it in place.
REPLACEMENT
PIVOT ASSEMBLY
SHORT
BUSHING
BALL JOINT
ASSEMBLY (2)
1/4" LOCKNUT
TOP PLATE
SCREW (2)
<=
E TOP
® PLATE
PIVOT SHAFT - YOKE
BOLT |
PIVOT BLOCK
HALVES
(Mate as shown)
|!
LARGE SNAP
RING
DETENT BALL
PLUNGER
(AS REQUIRED) |
FIGURE 4.16
3. Inspect to see that the snap -ring on the joy-
stick shaft is intact. Replace if necessary.
Rotate the pivot shaft assembly and insert the
joystick shaft with the snap-ring at bottom.
4. Replace the top plate. DO NOT use the trun-
nion pin set screws.
5. Reassemble the ball joints to the pivot shaft.
DO NOT use the two long bushings from the
previous assembly.
6. Insert the detent ball plunger into the front of
the pivot shaft. This locks the joystick shaft in
the "UP" position. Adjust as desired to obtain
the proper locking action.
7. Replace the joystick boot. Replace the fender
cap.
8. With the joystick in the "UP" position, replace
the joystick handle. Hold a block of wood on
the opposite side you are driving the roll pin
into. This prevents damage to the joystick parts.
9. Start the mower to check for creeping (neutral
positioning). If the mower creeps forward or
reverse, adjust for neutral. Replace the fender
skirt.
SERVICE NOTES
4.10
Section V
WHEEL and TIRE
REPAIR/REPLACEMENT
Section V - WHEEL AND TIRE REPAIR/REPLACEMENT
INTRODUCTION
The Models Z & ZU units: use tubeless tires on both
front and rear. Should rim leakage occur, and cannot
be solved by dressing the rim, it is recommended that
an inner tube be installed in lieu of replacing the wheel
and tire assembly. Tubes should be sized to fit. if a
wheel and tire assembly is replaced, use only the newer
DICO™ tire and wheel assemblies as found in the
current (1994) pants books; these are a softer, self-
cleaning tire and will improve performance. Do not use
ATV tires on the unit! They are much too aggressive
and will cause damage to most lawns!
5.1 FRONT WHEEL REMOVAL
A. Raise front end of unit and support with
jackstands.
B. Remove nut and bolt as shown in Figure 5.1.
FRONT
CASTER
BOLT
(AXLE),
WHEEL & TIRE
ASSEMBLY
Model ZU
SHOWN
FIGURE 5.1
C. Repair or replace tire (or) wheel and tire
| assembly.
D. inspect wheel bearing and axle components
for signs of wear, breakage, etc. Repair or
replace as required. See Figure 5.2.
BEARING
SHIELD
BEARING BEARING
— BEARING
o ‘SPACER
BEARING —
SHIELD |Model ZU
| SHOWN |
FIGURE 5.2
52
NOTE
The front casters and wheel assemblies
use sealed bearings and do not require
lubrication. A light coating of 30W motor
~ oil to prevent rust and to facilitate assembly
is all that is required.
E. Reinstall wheel bearings and tire assembly in
reverse order.
5.2 REAR WHEEL REMOVAL
(Without removing hub - UNISTAT Models with
23" TIRES )
A. Raise rear end of unit and support with
jackstands.
B. To remove wheel and tire assembly only,
loosen, then remove the five 7/16" lug nuts.
See Figure 5.3.
TORQUE
55 ft/lbs
FIVE (5)
7/16" LUG NUTS |
WHEEL & TIRE
ASSEMBLY
Model
ZU2014K
Shown
FIGURE 5.3
NOTE
Models 1810, 2010 & ZU2013K have four
(4) 1/2"-20 x 60 degree lug nuts each. They
should be torqued to 85 ft/Ibs.
C. Repair or replace tire (or) wheel and tire
assembly.
D. Reinstall tire assembly in reverse order.
5.3 REAR WHEEL & HUB REMOVAL
(Hub removal - UNISTAT Models)
A. Raise rear end of unit and support with
jackstands. Remove wheels.
Remove grease cap.
Remove 1" - 14 NF PLATED hex nut.
Remove 1" SPLIT GALV. lockwasher.
Remove hub from UNISTAT drive shaft ( a heavy-
duty gear - puller is required). Be careful not to
lose woodruff key!
Repair or replace tire (or) wheel and tire
assembly.
G. Reinstall tire assembly in reverse order.
moowm
Section V - WHEEL AND TIRE REPAIR/REPLACEMENT
5.4 REAR WHEEL REMOVAL
(Without removing hub - HYDROSTAT Models)
A. Raise rear end of unit and support with
_ jackstands. _ |
В. To remove wheel and tire assembly only, loosen
then remove the four 1/2" lug nuts. See
Figure 5.4.
—— FOUR (4) —
1/2" LUG NUTS
.—. REAR
WHEEL 8 TIRE
ASSEMBLY
Model Z
SHOWN
FIGURE 5.4
~ SERVICE NOTES
5.4
Section VI
BUMPER/AXLE & CASTER
WHEEL REPAIR
Section VI - FRONT BUMPER/AXLE & CASTER WHEEL REPAIR
INTRODUCTION
This section covers procedures for the removal and These components include the front bumper/axle
replacement of those front bumper/axle and caster assemblies, caster assemblies and front wheel
wheel components used on the Z & ZU Series Zero assemblies. See Figure 6.1.
Turning Radius Riding Mowers.
SLOTTED NUT
WASHER
GREASE | | CONE BEARING
CAP BEARING CUP
COTTER PIN | SO 6 —
BEARING CUP
À \
Tx pd > CONE BEARING
FRONT CHANNEL > Е (2 OIL SEAL
WELDMENT | © BEARING SPACER
VE No
x © —PIVOT
BOLT
LOCKWASHER
FLAT WASHER:
BEARING CAP
BEARING
(W/O COLLAR)
BUMPER/CHANNEL
WELDMENT
CASTER BEARING
SPACER
BEARING
(W/O COLLAR)
AXLE NUT
CASTER
WE STE SPIROL PIN
AXLE BOLT
BEARING SHIELD
BEARING
BEARING SPACER
13 X 5.6 TIRE & WHEEL
(RIBBED TREAD)
‘BEARING SHIELD
BEARING
FIGURE 6.1
6.2
6.1 FRONT BUMPER /AXLE PIVOT
BEARING REPLACEMENT
A. Raise front end of unit and support side
rails with jackstands.
| МОТЕ |
Removal of the front caster wheel assemblies
will make the front bumper/axle more managable
| during removal. Refer to Figure 6.3.
B. Remove front caster wheels (See NOTE
above).
C.. Pry off grease cap then remove cotter pin and
slotted nut (These are located behind the
front channel weldment. Refer to Figure 6.2.
SLOTTED NUT: R.H. FRAME
WASHER SIDE
(STILL IN POSITION) OT
COTTER PIN
"VIEW LOOKING FORWARD UNDERNEATH
_FROML.H.SIDE |
FIGURE 6.2
D. Grip front bumper/axie firmly and pull forward
to remove it from the front channel weldment.
E. Remove bearing components from axle pivot
shaft and front channel weldment. Refer to
Figure 6.1.
F. Replace bearings and oil seal with new parts.
Inspect spacer, bearing cups, washer, etc. for
signs of wear. Replace as required.
G. Lubricate all parts, then reassemble in reverse
order.
6.2 CASTER BEARING REPLACEMENT
A. Raise front end of unit high enough to allow
caster removal. Support side rails with
jackstands.
B. Remove 1/4" - 20 x 5/8" bolt, 1/4 lockwasher
and flat washer.
C. Lift off bearing cap.
D. Using a soft-metal mallet, tap the top of the
caster shaft until it can be pulled out from the
bottom of the bumper/axle.
E. Inspect bearings, spacer, etc. for wear. Replace
parts as required. See Figure 6.3.
Section VI - FRONT BUMPER/AXLE & CASTER WHEEL REPAIR
CASTER/WHEEL
ASSEMBLY
BOLT
LOCKWASHER
WASHER
-——— BEARINGS
SPACER
SPIRAL PIN
(INSTALLED)
FIGURE 6.3
6.3 FRONT CASTER WHEEL BEARING
REPLACEMENT
A. Raise front of unit and support with jackstands.
B. Remove axle nut and bolt from caster wheel.
C. Remove bearing shields, bearings and bearing
spacer from caster wheel assembly.
See Figure 6.4.
| AXLE BOLT —
‘BEARING
CASTER
WELDMENT
— FRONT
BUMPER/AXLE
BEARING
SHIELD
BEARING
BEARING
SPACER
SHIELD BEARING
6.3
FIGURE 6.4
Clean and inspect bearing bore of caster wheel.
Clean and grease bearing spacer.
Install bearing spacer and new bearings in -
caster wheel. |
G. Reinstall caster wheel assembly in reverse order.
amo
SERVICE NOTES
6.4
Section VII
~~ ENGINE
“Section VII - ENGINE
INTRODUCTION
This section covers procedures for the maintenance
and disassembly of those engine components which
power the different units.
These components include the engine, transmission
(Unistat; Hydrostat), idler pulleys and belts.
7.1 ENGINE MAINTENANCE
(The following information is applicable to most
engines; regardless of make, model or horsepower).
A. ENGINE OIL
1. Change engine oil on a regular schedule.
Use only those oils classified for Service
SF, SE, SD or SC (These oils will keep the
engine cleaner and will help retard the
formation of gum and varnish deposits).
DO NOT use oil additives!
2. Refer to the following chart for recommend-
ed grades to use with temperature range
anticipated before next oil change.
RECOMMENDED SAE VISCOSITY GRADES
5W-20, 5W-30 Ma
°F -20 0 20 40 60 80 100
°C-30 -20 -10 0 10 20 30 40
Temperature Range Anticipated Before Next Oil Change
“ * If not available, a synthetic oil may be used having
5W-20 or 5W-30 viscosity. |
B. SPARK PLUGS
Spark plugs should be cleaned or replaced
(if necessary) and gap reset to .030 or .035
every 100 hours of operation or every 6
months, whichever comes first.
2. To clean, remove spark plug from engine,
scrape or wire brush and wash with a
commercial solvent. DO NOT blast clean.
NOTE
Sparking can occur if wire terminal does not
fit firmly on spark plug. Compress terminals
if necessary.
C. MUFFLER
1. When servicing engine, inspect muffler for
signs of damage or deterioration. Replace
as required.
2. Make sure that muffler guard (if applicable)
is always in place and secure before
allowing mower to leave the shop.
7.2
CAUTION
Worn out mufflers are more than just a noise
nuisance and should be replaced immediately.
Continued use could result in fire or explosion!
D. AIR CLEANER
(Consult Engine Manual for part number of filter
element).
1. Inspect filter during every engine service or
—. every 25 operating hours (More often if
mower is used under extremely dirty or
dusty conditions). See Figure 7.1.
KOHLER un
20 HP ‘
ENGINE
SHOWN
WINGNUT
AIR CLEANER
COVER
FILTER
ELEMENT
BASE ScREW—E A A
C3) BASE
FIGURE 7.1
2. Replace filter as required.
3. Always clean cover inside and out, and
clean base before reassembly.
E. FUEL FILTER
WARNING!
Gasoline is flammable and must be handled
with care. DO NOT allow open flame, matches
or smoking in area. Wipe up any spills. Use
approved (RED) fuel container.
Shown in Figures 7.2 & 7.3 are the two types of fuel
filters found on most units.
‚1. Check the In-Line Fuel Filter at frequent
intervals and replace before the screen
become clogged with sediment. Make sure
‘the replacement is correctly installed with
the arrow on filter pointing toward the
engine. Check the Fuel System
Components frequently and replace any
parts showing worn spots or cracks.
See Figure 7.2.
Section VII - ENGINE
FUEL -
LINE
— FILTER
— ARROW ON FILTER
POINTED TOWARD
ENGINE
FIGURE 7.2
2. Make sure the replacement filter is correctly
installed with "IN" marking toward the fuel
tank and "OUT" toward the engine. Replace
any parts which appear worn. See Figure
7.3.
TOWARD
ENGINE Kw
FUEL TANK
FIGURE 7.3
7.2 ENGINE REMOVAL 8 INSTALLATION
The following procedures are for the removal and
reinstallation of the units engine. Refer to
the engine manufacturer's service/repair manual
for information concerning engine repairs.
A. ENGINE REMOVAL (KOHLER) |
1. Tilt operator's seat forward and disconnect the
battery's negative (black wire) terminal.
2. Slide protective boot aside and disconnect the
battery's positive (red wire) terminal. See Figure
7.4. |
WARNING! |
ALWAYS disconnect negative (black wire)
FIRST! ALWAYS connect the negative
wire LAST! В
REMOVE NEGATIVE (-)
CABLE FIRST
FIGURE 7.4
7.3
3. Roli the deck drive belt off the center deck
pulley, then pull the belt slack up to the
engine clutch pulley and remove the belt.
4. Remove the air breather cover and filter
element, then remove mounting screw and
filter base. See Figure 7.5.
| WING NUT
AIR BREATHER
COVER
FILTER
ELEMENT
MOUNTING
SCREW
FILTER BASE
DISCONNECT
ELECTRICAL
HARNESS
DISCONNECT THE
CHOKE AND THROTTLE
CABLES FROM ENGINE
DISCONNECT FUEL
LINE FROM FUEL
FILTER
. FIGURE 7.5
5. Separate the connectors of the engine and
tractor's electrical wir">