Snapper ZF2101DKU, ZF5201M, ZF6101M, ZF2301GKU User Manual

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Page 1

Safety Instructions & Operator’s Manual for

OUT FRONT Z-RIDER

HYDRO DRIVE

SERIES 1

POWER UNIT MODELS

ZF2101DKU ZF2301GKU

MOWER UNIT MODELS

ZF5201M ZF6101M

MODEL NUMBER EXPLANATION

Z F 21 01 D KU

DRIVE SYSTEM TYPE ENGINE MODEL MOWER ORIENTATION ENGINE TYPE ENGINE HP SERIES DESIGNATION

POWER UNIT

Z – Zero Turning – Hydro Drive 21 – Engine Horse Power 01 – Series Designation D – Diesel Fuel Engine KU – Kubota Engine F – Out Front Mower 23 - Engine Horse Power G – Gasoline Fuel Engine

MOWER UNIT

Z – Zero Turning – Hydro Drive 52 – Mower Cutting Width 01 – Series Designation M – Mower Deck F – Out Front Mower 61 – Mower Cutting Width

Thank you for buying a SNAPPER Product! Before operating your machine, read this manual carefully and pay particular attention to the “IMPORTANT SAFETY INSTRUCTIONS” on Pages 2 - 4. Remember that all power equipment can be dangerous if used improperly. Also keep in mind that SAFETY requires careful use in accordance with the operating instructions and common sense!

INSTRUCTION No. 7-3700 (REV 1, 8/29/01)

Page 2

IMPORTANT SAFETY INSTRUCTIONS

WARNING: This powerful cutting machine is capable of amputating hands and feet and can throw objects that can cause injury and damage! Failure to comply with the following SAFETY instructions could result in serious injury or death to the operator or other persons. The owner of the machine must understand these instructions and must allow only persons who understand these instructions to operate machine. Each person operating the machine must be of sound mind and body and must not be under the influence of any substance, which might impair vision, dexterity or judgment. If you have any questions pertaining to your machine which your dealer cannot answer to your satisfaction, call or write the Customer Service Department at SNAPPER, McDonough, Georgia 30253. Phone: (1-800-935-2967).

PROTECTION FOR CHILDREN

Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the machine 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 a responsible adult.

2. DO NOT allow children in yard when machine is operated (even with the blades OFF).

3. DO NOT allow children or others to ride on machine or on attachments (even with the blade OFF). They may fall and be seriously injured.

4. DO NOT allow pre-teenage children to operate machine. Local regulations may restrict the age of the operator.

5. ALLOW only adults or responsible teenagers with mature judgment under close adult supervision to operate machine.

6. DO NOT operate blades in reverse. STOP BLADES. LOOK and SEE behind and down for children, pets and hazards before and while backing.

7. USE EXTRA CARE when approaching blind corners, shrubs, trees, or other objects that may obscure vision.

PROTECTION AGAINST TIPOVERS

Slopes are a major factor related to loss-of-control and tip-over accidents, which can result in severe injury or death. All slopes require extra CAUTION. If you cannot back up the slope or if you feel uneasy on the slope, DO NOT mow it. Use extra care with grass catchers or other attachments; these and turf conditions affect the handling and the stability of the machine.

1. DO NOT operate machine on slopes exceeding 15 degrees (27% grade).

2. Exercise EXTREME CAUTION on slopes above 10 degrees (18% grade). Turn blades OFF when traveling uphill. Use a slow speed and avoid sudden or sharp turns.

3. DO NOT operate machine back and forth across face of slopes. Operate up and down. Practice on slopes with blades off.

4. AVOID uphill starts. If machine stops going uphill or tires lose traction, turn blades OFF and back slowly down the slope.

PROTECTION AGAINST TIPOVERS

(Continued From Previous Column)

5. STAY ALERT for holes and other hidden hazards. Tall grass can hide obstacles. Keep away from ditches, washouts, culverts, fences and protruding objects.

6. DO NOT operate machine near drop offs, ditches, embankments, washouts, culverts, fences and protruding objects. KEEP A SAFE DISTANCE (at least 3 feet) away from edge of ditches and other drop offs. The machine could turn over if an edge caves in.

7. Always begin forward motion slowly and with caution.

8. Use weights or a weighted load carrier in accordance with instructions supplied with a grass catcher. DO NOT operate machine on slopes exceeding 10 degrees (18% grade) when equipped with grass catcher.

9. DO NOT put your foot on the ground to try to stabilize the machine.

10. DO NOT operate machine on wet grass. Reduced traction could cause sliding.

11. DO NOT operate machine under any condition where traction, steering or stability is doubtful.

12. Operator Protective Structures are available for this machine through your local SNAPPER dealer.

PREPARATION

1. Read, understand and follow instructions and warnings in this manual and on the machine, engine and attachments. Know the controls, the safety signs and the proper use of the machine before starting. If the operators or mechanics cannot read English, it is the owner’s responsibility to explain this material to them.

2. Only mature, responsible persons shall operate or service the machine and only after proper instruction and training. The owner is responsible for training the operators. Further, the owner/operator can prevent and/or is responsible for accidents or injuries occurring to themselves, other people or property.

3. Data indicates that operators age 60 and above, are involved in a large percentage of mower-related injuries. These operators should evaluate their ability to operate the mower safely enough to protect themselves and others from serious injury.

Page 3

IMPORTANT SAFETY INSTRUCTIONS

PREPARATION

(Continued From Previous Page)

4. Handle fuel with extra care. Fuels are flammable and vapors are explosive. Use only an approved fuel container. DO NOT remove fuel cap or add fuel with engine running. Add or drain fuel outdoors only with engine stopped and cool. Clean spilled fuel from machine. DO NOT smoke.

5. Practice operation of machine with BLADES OFF to learn controls and develop skills.

6. Check the area to be mowed and remove all objects such as toys, wire, rocks, limbs and other objects that could cause injury if thrown by blades or interfere with mowing.

7. Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job. Only use accessories and attachments approved by SNAPPER.

8. Keep people and pets out of mowing area. Immediately, STOP blades, STOP engine, and STOP machine if anyone enters the area.

9. DO NOT operate machine unless all shields, deflectors, switches, blade controls and other safety devices are in place and functioning properly.

10. Make sure all safety decals are clearly legible. Replace if damaged.

11. Protect yourself when mowing and wear appropriate clothing including safety glasses, long pants, ear protection, hardhat and substantial footwear with good traction. Long hair, loose clothing or jewelry may get tangled in moving parts.

12. Know how to STOP blades and engine quickly in preparation for emergencies.

13. Use extra care when loading or unloading the machine into a trailer or truck.

14. Check grass catcher components frequently for signs of wear or deterioration and replace as needed to prevent injury from thrown objects going through weak or worn spots.

OPERATION

1. Mount and dismount machine from left side.

2. Start engine from operator's seat. Make sure blades are OFF and parking brake is set. Use seat belts if provided.

3. DO NOT leave machine with engine running. Stop engine. Stop blades. Set brake. Remove key.

4. DO NOT operate machine unless properly seated with feet on foot rests or pedal(s).

5. DO NOT operate machine while under the influence of alcohol or drugs.

OPERATION

(Continued From Previous Column)

6. STOP MACHINE on level ground, lower deck, engage parking brake and make sure engine and blades have stopped before removing grass catcher or unclogging mower to prevent injury to hands or feet.

7. Blades must be OFF except when cutting grass. Set blades in highest position when mowing over rough ground.

8. Keep hands and feet away from rotating blades underneath deck. DO NOT place foot on ground while BLADES are ON or machine is in motion.

9. DO NOT operate machine without entire grass catcher or guards in place. DO NOT point discharge at people, passing cars, windows or doors.

10. Slow down before turning.

11. Watch out for traffic when near or crossing roadways.

12. STOP engine immediately after striking an object or if an abnormal vibration occurs. Remove key. Remove and disconnect the sparkplug wire. Make necessary repairs before resuming operation.

13. Mow only in daylight or with good artificial light.

14. Move motion control levers SLOWLY to maintain control during speed and directional changes.

15. Exercise CAUTION when pulling loads. DO NOT pull loads greater than 300 pounds. Avoid jack knifing. DO NOT turn sharply.

16. DO NOT operate engine in enclosed areas. Engine exhaust gases contain carbon monoxide, an odorless and deadly poison.

MAINTENANCE

1. DO NOT store machine or fuel container inside where fumes may reach an open flame, spark or pilot light such as in a water heater, furnace, clothes dryer or other gas appliance. Allow engine to cool before storing machine in an enclosure. Store fuel container out of the reach of children in a well ventilated, unoccupied building. Shut off fuel (when equipped with valve) while storing or transporting machine.

2. Clean grass and debris from engine, mufflers, drives and cutting units to help prevent overheating and fires. Clean up fuel, oil and excess grease.

3. When draining fuel tank, drain fuel into an approved container outdoors and away from open flame.

4. Check brakes frequently; adjust, repair or replace as needed.

5. Keep all bolts, nuts and screws properly tight. Check that all cotter pins are in proper position.

6. Always provide adequate ventilation when running engine. Engine exhaust gases contain carbon monoxide, an odorless and deadly poison.

Page 4

IMPORTANT SAFETY INSTRUCTIONS

MAINTENANCE

(Continued From Previous Page)

7. Disconnect battery before performing maintenance or service. Cranking engine could cause injury. Disconnect negative (black) cable from battery first and positive (red) cable last. Reconnect positive first and negative last. Charge battery in an open, well ventilated area away from spark and flames. Unplug charger before connecting or disconnecting from battery. Wear protective clothing and insulated gloves.

8. Park machine on level ground. DO NOT work under machine without safety blocks.

9. Service engine and clean, adjust or repair only when engine and blades are stopped. Remove spark plug wire(s) from spark plug(s) and secure wire(s) away from spark plug(s).

10. DO NOT change engine governor speed settings or overspeed engine. DO NOT make adjustments with the engine running.

11. Lubricate machine at intervals specified in manual to prevent controls from binding.

12. Mower blades are sharp and can cut. Wrap the blades or wear heavy leather gloves and use CAUTION when handling them. Never straighten or weld blades, only replace them.

13. DO NOT test for spark by grounding spark plug next to spark plug hole; spark plug could ignite gas exiting engine.

14. Carefully release pressure from components with stored energy.

15. Have machine serviced by an authorized SNAPPER dealer at least once a year and have the dealer install any new safety devices. Never allow untrained personnel to service machine.

16. Use only genuine SNAPPER replacement parts to assure that original standards are maintained.

17. If battery is removed, DO NOT operate engine without insulating Positive + battery cable terminal with electrical tape, or sparking from battery cables can result.

Page 5

TABLE OF CONTENTS

IMPORTANT SAFETY INSTRUCTIONS ..........................................................2-4

TABLE OF CONTENTS ......................................................................................5

SECTION 1 – FAMILIARIZATION.......................................................................6

SECTION 2 – SAFETY MESSAGES AND SYMBOLS.....................................7-9

SECTION 3 - OPERATING INSTRUCTIONS ...............................................10-14

Pre-start Checklist ...............................................................................................10

Starting & Stopping Engine, Blades & Parking Brake .....................................11-13

Starting & Stopping Mower Blades ....................................................................... 12

Parking Brake .......................................................................................................13

Cutting Height Adjustment....................................................................................13

Driving & Stopping Machine .................................................................................14

SECTION 4 - MAINTENANCE INSTRUCTIONS .........................................15-19

Change Engine Oil................................................................................................15

Check Mower Blade .............................................................................................15

Check Mower Drive Belt .......................................................................................16

Check Belt Tension ..............................................................................................16

Service – After every 25 Hours (Engine) ..............................................................16

Service – After every 25 Hours (Mower Components) ....................................16-17

Mower Blade Spindle Lubrication...................................................................... 16

Mower Deck Linkage Lubrication ......................................................................16

Front Wheel Bearings Lubrication.....................................................................17

Transaxle Lubrication ........................................................................................17

Power Transfer Shaft Lubrication......................................................................17

Other Lubrication...............................................................................................17

Before Operating Mower ......................................................................................17

Annually - End of Season Service ...................................................................17-18

Fuel Filter Replacement .......................................................................................18

Deck Removal .................................................................................................18-19

Power Transfer Shaft Removal ............................................................................19

SECTION 5 - ADJUSTMENTS AND REPAIR ..............................................20-26

Neutral Position Adjustments ...............................................................................20

Mower Deck Adjustment (Levelness) ..............................................................20-21

Parking Brake Adjustment....................................................................................21

Engine Adjustments & Repair............................................................................... 21

Mower Blade Replacement .............................................................................21-22

Blade Sharpening .................................................................................................22

Mower Drive Belt, Engine Belt & Hydro Pump Belt Removal & Replacement .....23

Battery Removal ...................................................................................................24

Battery Installation ................................................................................................24

Battery Service & Charging ..................................................................................24

Battery Testing......................................................................................................25

New Battery Preparation.......................................................................................25

Mower Spindles (Field Serviceable Spindles) Bearing Replacement................... 26

TROUBLESHOOTING .................................................................................27-28

SERVICE SCHEDULE ......................................................................................29

Maintenance/Replacement Parts .........................................................................29

WARRANTY...................................................................................................... 30

PRIMARY MAINTENANCE ..........................................................................31-34

IMPORTANT

NOTICE: Operator Protective Structures are available as optional kits for the Mid-Mount and Out-Front Z-Rider machines. These structures, when installed and used properly can offer additional security to the operator against serious injury in the event of a tip over accident. Operator Protective Structures may be required by local ordinances. Discuss your mowing application and ordinances with your local Snapper Dealer.

IMPORTANT: DIESEL AND GAS UNITS LOOK VERY SIMILIAR. DO NOT PUT GAS IN DIESEL MACHINE OR DIESEL IN GAS MACHINE. ENGINE DAMAGE MAY RESULT.

Page 6

Section 1 - FAMILIARIZATION

IMPORTANT The figures and illustrations in this manual are provided for reference only and may differ from your specific model. Contact your Snapper dealer if you have questions.

CONTROL PANEL

IGNITION SWITCH

AMP METER

BLADE SWITCH

MOTION CONTROL (JOYSTICK)

CONTROL PANEL (SEE INSET)

DECK HEIGHT OF CUT DECAL

OPERATOR’S SEAT

HOUR METER

FUEL TANK

PARKING BRAKE

ENGINE SPEED CONTROL

LIGHT SWITCH

DECK COVER

DECK LIFT SWITCH

CASTER WHEEL BRACKET

DISCHARGE DEFLECTOR

FIGURE 1.1

1.1 INTRODUCTION

This manual has been prepared for the operator’s of the SNAPPER OUT FRONT Z-RIDER. Its purpose, aside from recommending standard operating procedures and routine service requirements, is to promote SAFETY through the use of accepted operating practices. Read, Understand and Follow the IMPORTANT SAFETY INSTRUCTIONS on Page 2 thru 4 of this manual and All SAFETY messages on the OUT FRONT Z-RIDER and its attachments before operating. SNAPPER recommends returning the OUT FRONT Z-RIDER to an authorized SNAPPER dealer annually for inspection and addition of any new devices which might upgrade the safety of the mower.

1.2 NOMENCLATURE

The nomenclature information above, Figure 1.1, shows the essential parts of the SNAPPER OUT FRONT ZRIDER. It is recommended that all operator’s of this equipment become thoroughly familiar with the controls, components, and operation of this machine before operating. Specific details involving the engine are found in the separate engine owner’s manual. Study these manuals before operating and keep both handy for future reference. For the nearest SNAPPER dealer in your area, check the yellow pages under the heading LAWN MOWERS. For engine parts and service, look for the engine manufacturer’s dealers under the heading, ENGINES - gasoline.

Page 7

Section 2 – SAFETY MESSAGES AND SYMBOLS

CHOKE

“ON”

*CHOKE

CONTROL

CHOKE

“OFF”

RABBIT

“FAST”

ENGINE

CONTROLS

ENGINE

SPEED

TURTLE “SLOW”

*DIESEL POWERED MACHINES ARE NOT EQUIPED WITH ENGINE CHOKE CONTROL

Page 8

Section 2 – SAFETY MESSAGES AND SYMBOLS

MOTION CONTROL MULTI-DIRECTIONAL

HOUR

METER

BLADES ENGAGED

LIGHTS

BLADES DISENGAGED “OFF”

“OFF” “ON”

Page 9

Section 2 – SAFETY MESSAGES AND SYMBOLS

DANGER! ROTATING BLADES

KEEP CHILDREN AND OTHERS OUT OF THE MOWING AREA

DANGER! ROTATING BLADES

Page 10

Section 3 - OPERATING INSTRUCTIONS

3.1 PRE-START CHECK LIST

Make the following checks and perform the service required before each start-up.

3.1.1. Check tires and add or release air as needed to bring pressure in drive tires to: 12 psi (Turf Type Tires), 5 psi (All Terrain Type Tires) and 25 psi in rear caster tires. Pressure in front deck caster wheels should be 25 psi.

3.1.2. Check guards, deflectors and covers to make sure all are in place and securely tightened.

3.1.3. Check engine oil and add oil as needed to bring level up to the FULL mark. Refer to engine owner’s manual for oil specifications. See Figure 3.1.

FULL MARK

OIL DIP STICK

AIR FILTER ASSEMBLY IS SHOWN REMOVED

3.1.5. Clean exterior surfaces of cutting deck and

engine of any accumulation of dirt, grass, oil, etc. Keep engine radiator air intake screen and cooling fins clear at all times. Check often in dry operating conditions.

3.1.6. Add fresh fuel to tank of the Out Front Z-Rider outside where fumes can safely dissipate. Make sure fuel filler cap is tight. Refer to engine owner’s manual for fuel specifications.

3.1.7. COLD ENGINE ONLY - Check engine coolant (antifreeze/water) and add coolant in the reserve tank as needed to bring level up to the FULL mark. Refer to engine owner’s manual for coolant ratio specifications. See Figure 3.3.

WARNING

DO NOT remove cap from radiator when engine and coolant are hot. Coolant is pressurized. Severe burns could result.

FIGURE 3.1

3.1.4. Check Blade switch to insure it works freely. Switch

is pulled “OUT” for blade engagement or pushed back “IN” for blade disengagement. See Figure 3.2. IMPORTANT: Disengagement stops blades.

BLADE SWITCH

LIGHT SWITCH

DECK LIFT SWITCH

IGNITION SWITCH

AMP METER

HOUR METER

BLADE SWITCH:

PULL “OUT” TO ENGAGE BLADE.

PUSH “IN” TO DISENGAGE BLADE.

FULL COOLANT MARK

LOW COOLANT MARK (COOLANT SHOULD BE ADDED)

COOLANT RESERVE TAN

FIGURE32.3

3.1.8. (Diesel Engine Models Only) Move fuel cock to

the “ON” position See Figure 4.8.

IMPORTANT: This machine is equipped with a

WARNING beeper. The beeper will sound when engine oil pressure is low or engine temperature is high. If this beeper sounds, stop operation immediately. Do not resume operation until the cause has been determined and proper action taken. Beeper function can be verified (with engine stopped) by turning key to “RUN” position.

FIGURE 3.2

Page 11

Section 3 - OPERATING INSTRUCTIONS

IMPORTANT: This Out Front Z-Rider is equipped with hydrostatic drive. The forward and rearward movement of the machine is controlled by a joystick lever. Joystick operations should be performed only from the operator’s position in the seat. A small movement of the joystick can cause the machine to move instantly. Move joystick very carefully and slowly.

ROLL RELEASE: To roll the machine without the engine running, pressure within the hydraulic pumps must be released. There is one lever on the upper right side of each pump that is used to release the pressure. Rotate lever counter clockwise and secure in that position . See Figure 3.4.

PRESSURE RELEASE LEVER

LEVER IS IN POSITION FOR PROPELLING RIDER UNDER IT’S OWN POWER (RIDER WILL NOT ROLL WITH LEVER IN THIS POSITION)

Moving the joystick farther from the neutral position will cause the speed of motion to increase. To turn, move the joystick towards the side you want to turn to. DO NOT make sudden changes in speed or direction. Always slow machine motion before turning. To stop the motion of the machine bring the joystick back to the neutral position. Engage parking brake.

3.2.1. STARTING ENGINE

When the ignition key is turned to “START”, the engine will not turn over unless the parking brake is engaged and the blade switch is in the “OFF” position! Be seated on the Out Front Z-Rider before attempting to start the engine with the key switch.

1. Complete pre-start checklist.

2. Sit in operator’s seat.

3. Push blade switch in to “OFF”, blades

disengaged position and engage parking brake. See Figure 3.2.

PARKING BRAKE

PRESSURE RELEASE LEVER

LEVER IS ROTATED COUNTER CLOCKWISE AND LATCHED IN A SECURED POSITION FOR ROLLING RIDER (RIDER WILL NOT PROPEL ITSELF WITH LEVER IN THIS POSITION)

FIGURE 3.4

3.2 STARTING & STOPPING – ENGINE, BLADES & PARKING BRAKE

This machine is equipped with dual hydrostatic wheel drive transmissions. Each transmission is controlled by a single motion control lever or joystick. This single control lever (joystick) controls the direction of motion, Forward and Reverse, and the speed of motion. Move the joystick forward to propel the machine forward. Move the control rearward to propel the machine in reverse. The speed of motion is continuously variable from neutral (zero) to maximum.

ENGAGED

DISENGAGED

FIGURE 3.5

4. Move engine speed control to a medium

speed setting. See Figure 3.6.

5. IMPORTANT: (Gasoline Engine Only).

Move engine choke control to the choke position to start a cold engine. After starting, choke control must be moved to "OFF" no choke position.

Page 12

Section 3 - OPERATING INSTRUCTIONS

3.2.1. STARTING ENGINE (Continued from previous page)

FAST ENGINE SPEED POSITION

SLOW ENGINE SPEED POSITION

ENGINE SPEED CONTROL SHOWN IN “FAST” POSITION

FIGURE 3.6

6. IMPORTANT: (Diesel Engine Only) Use the

Glow Plug only if engine is cold or outside temperature is cold. Rotate key counter clockwise to the preheat position (GL letter designation on switch) to allow the glow lamp to heat up. Hold key in the Glow Plug position for a maximum of 5 seconds See Figure 3.7.

7. Rotate key clockwise to the start position until engine starts. See Figure 3.7.

NOTE: If after 5 seconds of cranking the engine does not start, release the key and attempt starting again after waiting for approximately 20 seconds.

DIESEL ENGINE SWITCH POSITION

STOP

POSITION

GLOW PLUG

PRE-HEAT

GAS ENGINE SWITCH POSITION

OFF

POSITION

RUN

POSITION

START

8. After engine starts, allow a brief warm-up until

engine runs smooth.

3.2 STOPPING - ENGINE

3.2.1. ENGINE

1. Stop engine by turning key to the “OFF”

position. Move engine speed control to turtle “SLOW” position and key to “STOP” position. See Figure 3.7.

WARNING

DO NOT leave machine with engine running. STOP blades. STOP engine. Set brake. Remove key.

3.2.2. STARTING MOWER BLADE

1. With engine running, move engine speed

control to the Rabbit or “fast” position.

2. Pull the blade switch out into the “ON” position to engage the mower blades.

3. Release the parking brake.

4. Move joystick carefully in the desired direction to

propel the machine. A small movement of the joystick can cause the machine to move instantly. Move joystick carefully and slowly.

WARNING

DO NOT operate blades in reverse. STOP BLADES. LOOK and SEE behind and down for children, pets and hazards before and while backing.

3.2.3. STOPPING MOWER BLADE

1. Push the blade switch in to “OFF” position to

disengage or stop the mower blades. See Figure

3.2.

WARNING

Once blades are disengaged, they should come to a complete stop in 7 seconds. If the blades continue to rotate after 7 seconds, the electric clutch should be checked. Replacement of electric clutch may be necessary. Return the machine to an authorized Snapper dealer for replacement. DO NOT CONTINUE to operate mower if blades fail to stop in 7 seconds.

STOP

POSITION

OFF

FIGURE 3.7

RUN

POSITION

START

POSITION

Page 13

Section 3 - OPERATING INSTRUCTIONS

3.2.4. PARKING BRAKE

1. Engage parking brake by pulling the parking

brake lever back to the “ON” position. See Figure 3.8.

2. Release parking brake by moving brake lever down to the “OFF” position. See Figure. 3.9.

JOYSTICK IN NEUTRAL POSITION

PARKING BRAKE LEVER IN ENGAGED “ON” POSITION

FIGURE 3.8

3.2.5. CUTTING HEIGHT ADJUSTMENT

1. Adjust cutting height as desired to any

position, using deck lift switch. When in desired height of cut, release switch. See Figure 3.10. Observe the height of cut decal located on the upper right top side of the deck to place deck at the correct height of cut. See Figure 3.10. NOTE: The engine does not have to be running to adjust cutting height, but key switch must be in the “ON” position.

DECK HEIGHT OF CUT DECAL

FIGURE 3.9

PARKING BRAKE DISENGAGED “OFF” POSITION

DECK LIFT SWITCH

FIGURE 3.10

WARNING

DO NOT park the machine on slopes. DO NOT leave machine with engine running. Stop engine. Stop blades. Engage parking brake. Remove key.

Page 14

Section 3 - OPERATING INSTRUCTIONS

3.3 OPERATION – MOTION CONTROL

3.3.1. DRIVING MACHINE IMPORTANT: The joystick lever has to be manually

moved to propel machine. Always return the joystick with hand assistance to the neutral position to stop machine. Release the joystick and it will gradually return toward the neutral position. When the parking brake is engaged, it will lock joystick lever in the neutral position. The engine will only crank or start if parking brake lever is engaged and the blade switch is in the “OFF” position.

1. With engine running, adjust engine speed control to Rabbit or “FAST” position.

2. Release parking brake.

3. Move joystick lever carefully and slowly into

desired speed position. A small movement of the joystick can cause the machine to move instantly. Move joystick carefully and slowly.

FORWARD – Move control forward. REVERSE – Move control to the rear. LEFT TURN - Move control towards left. RIGHT TURN - Move control towards right. ZERO RADIUS TURN – Move control diagonally

from neutral in desired direction. See Figure 3.11.

WARNING

DO NOT make turns at high speed. Slow machine motion. Move motion control lever gently and with caution. DO NOT make sudden changes in speed or direction.

REARWARD MOVEMENT

RIGHT TURN

LEFT TURN

FORWARD MOVEMENT

FIGURE 3.11

Page 15

Section 4 - MAINTENANCE

4.1 INTRODUCTION

To retain the quality of the SNAPPER Out Front Z-Rider, use genuine SNAPPER replacement parts only. Contact a local SNAPPER dealer for parts and service assistance. For the correct part or information for a particular SNAPPER Out Front Z-Rider, always mention the model and serial number. SNAPPER recommends returning the Out Front Z-Rider to an authorized SNAPPER dealer annually for inspection and addition of any new devices which might upgrade the safety of the Out Front Z-Rider. For the nearest SNAPPER dealer in your area, check the yellow pages under the heading LAWN MOW ERS. For engine parts and service, look for the engine manufacturer’s dealers under the heading, ENGINES - gasoline.

4.2 SERVICE - AFTER FIRST 5 HOURS

WARNING

DO NOT attempt any adjustments, maintenance or service with the engine or blades running. Stop blades. Stop engine. Set brake. Remove key. Remove spark plug wires from spark plugs and (gas only) secure wires away from spark plugs. Engine and components are HOT. Avoid serious burns by allowing all parts sufficient time to cool.

4.2.1. CHANGE ENGINE OIL

1. Place a 4 quart minimum capacity container

under the bottom of engine.

2. Remove the oil drain plug. See Figure 4.1.

5. Change oil filter at every oil change. Refer to

your engine owner’s manual for service instructions.

4.2.2. CHECK MOWER BLADE

1. Stop Engine.

2. Engage parking brake.

3. Turn key to “ON” position but DO NOT start

engine. Raise mower deck off the ground using deck lift switch located to the right of operator as viewed from the operator’s position. Turn key to “OFF” position. Remove key.

4. Use a hydraulic floor jack or hoist to raise deck high enough to gain access to the underside of deck. Secure deck with safety blocks.

WARNING

Wear heavy leather gloves when handling or working around cutting blades. Blades are extremely sharp and can cause severe injury. DO NOT use a cutting blade that shows signs of excessive wear or damage. Refer to Section “MOWER BLADE REPLACEMENT” for proper blade inspection and service procedures.

5. Check torque of blade mounting bolts. Torque

to 70 to 80 ft. lbs. See Figure 4.2.

6. Check blade for sharpness, wear, straightness and damage. Refer to Section “BLADE WEAR LIMITS”.

ENGINE IS VIEWED FROM THE REAR

REMOVE OIL FILTER

REMOVE OIL DRAIN

FIGURE 4.1

3. After all the oil has drained, reinstall oil drain

plug and tighten securely. See Figure 4.1. Wipe up any oil that may have spilled. Dispose of drained oil properly.

4. Fill engine crankcase with new oil. Refer to your engine owner’s manual for oil specifications.

(4) BLADE SPACERS

MOUNTING BOLT

AIR LIFT

BLADE

BEVELED WASHER

TIGHTEN TO 70-80 FOOT POUNDS

FIGURE 4.2

Page 16

Section 4 - MAINTENANCE

4.2.3. CHECK MOWER DRIVE BELT

1. Drive Belt Cover Removal

a. Lower deck to lowest setting. b. Remove knobs that secure the deck

cover. See Figure 4.3.

c. Remove cover to gain access to deck belt.

REMOVE FOUR KNOBS

FIGURE 4.3

REMOVE DECK COVE

b. Remove spark plug wire(s) and secure

away from spark plug(s). GAS ENGINE ONLY. c. Raise mower deck to its highest setting. It may be necessary to raise mower deck higher using a hydraulic floor jack. Secure deck with safety blocks. d. Clean underside of mower deck, removing all accumulation of grass clippings and debris. e. Clean top of deck, removing all grass clippings and debris.

5. Mower Blade Spindle - Lubrication

a. Remove four knobs that secure the deck

cover. b. Remove cover to gain access to lubrication fitting located on the top of deck below deck pulleys. Lubricate with Kendall NLGI No. 2 lithium grease or equivalent, from a grease gun until grease purges from vent located on spindle housing underneath deck. See Figure 4.4.

DECK PULLEYS

2. Checking Belt Tension

The idler and spring provide proper belt tension and require no adjustment. If belt is frayed, slit, severed or belt strands exposed, replace belt before operating mower.

4.3 AFTER EVERY 25 OPERATING HOURS

4.3.1. ENGINE

1. Engine Oil

Change engine oil. Refer to Section “CHANGE ENGINE OIL”. Refer to engine owner’s manual for oil specifications.

2. Air Filter

Refer to engine owner’s manual for service instructions.

3. Radiator - SEE WARNING

a. Clean radiator debris screen and cooling

fins thoroughly. Refer to engine owner’s manual for service instructions.

b. Check coolant level in reserve tank.

4.3.2. MOWER COMPONENTS

1. Mower Drive Belt

No adjustment required. Replace belt as needed.

2. Mower Blade

Check blade for sharpness, wear, damage, and torque. Refer to Section “MOW ER BLADE REPLACEMENT”.

3. Mower Deck Levelness

Check mower deck for proper levelness. Adjust as required. Refer to Section “MOW ER DECK ADJUSTMENT – LEVELNESS”.

4. Cleaning Mower Deck

a. Remove key from ignition switch.

LUBRICATE SPINDLE ASSEMBLIES

FIGURE 4.4

6. Mower Deck Linkage - Lubrication

Lubricate all mower deck linkage pivot points with a light coat of motor oil.

WARNING

DO NOT remove cap from radiator when engine and coolant are hot. Coolant is pressurized. Severe burns could result.

Page 17

Section 4 - MAINTENANCE

4.3.3. RIDING MOWER - LUBRICATION

1. Front & Rear Wheel Bearings

Lubricate with Kendall NLGI No. 2 lithium grease or equivalent, from a grease gun. See Figure 4.5.

LUBRICATE BEARINGS

FIGURE 4.5

2. Transaxle

Check the level of fluid in both of the fluid reservoirs. Wipe away all dirt and debris from around reservoir cap before removing. Oil must remain absolutely clean! Check with mower on a level surface with engine “OFF”. Fill reservoir as needed to bring level up to 1-1/2 inches below the top of the filler neck. Use clean, fresh premium hydraulic oil having a viscosity equivalent to SAE 20W-20, SAE 30 or SAE 40. The fluid should be chemically stable, incorporating rust and oxidation inhibitors. Make sure funnels, pouring spouts and oil can are completely clean. Reinstall reservoir cap. See Figure 4.6. IMPORTANT: DO NOT remove or service the transaxle fluid filters. This service should be made periodically by an authorized SNAPPER dealer. See the service schedule to determine the recommended change interval.

OIL FILL LINE

1-1/2”

3. Power Transfer Shaft

Lubricate power transfer shaft with Kendall NLGI No. 2 lithium grease or equivalent, from a grease gun. See Figure 4.7.

LUBRICATE POWER TRANSFER SHAFT

FRONT WHEEL

FIGURE 4.7

4. OTHER LUBRICATION POINTS

Lubricate traction drive idlers, P.T.O. idlers, deck caster wheel shafts, rear caster wheel shaft, traction drive shaft bearings and mower deck idler arm with Kendall NLGI No. 2 lithium grease or equivalent, from a grease gun.

4.4 BEFORE OPERATING MOWER

1. Clean all dirt and debris from around the two

hydraulic fluid reservoirs. Especially around the top and cap area.

2. Clean all dirt and debris from the radiator debris screen and cooling fins.

3. Clean all dirt and debris from the cooling fins on the engine and from both hydraulic pumps.

4.5 ANNUALLY (END OF EACH SEASON)

Perform all maintenance as required in the SERVICE SCHEDULE.

4.5.1. ENGINE

Service engine according to engine owner’s manual.

HYDRAULIC OIL RESERVOIR

(Continued on next Page)

IMPORTANT: FLUID LEVEL MUST BE ABOVE TOP OF BAFFLE. RESERVOIR CAPACITY IS ONE (1) GALLON. DO NOT OVERFILL.

FIGURE 4.6

Page 18

Section 4 - MAINTENANCE

4.5 ANNUALLY (END OF EACH SEASON) (Continued from previous Page)

4.5.2. FUEL FILTER (DIESEL ENGINE)

Service fuel filter as instructed in engine owner’s manual. Turn key to “OFF” position. Engine MUST be stopped and MUST be cold before removing filter.

1. Move the fuel filter cock handle to the closed position.

2. Remove the fuel filter bowl retaining ring. Fuel filter bowl, two “O” Rings, spring and filter can be removed. See Figure 4.8.

3. Replace filter element. Clean filter bowl with fresh diesel fuel. Reassemble the fuel filter bowl assembly. Tighten retaining ring securely. Check for leakage. Air bleed the fuel system.

4. Fill the fuel tank to the fullest extent. Open the fuel filter cock.

5. Loosen air vent plug a few turns at the top of fuel filter/fuel cock assembly. Allow air bubbles to be released. Close air vent plug when a steady flow of fuel is observed. NOTE: After replacing fuel filter, engine may have to be cranked briefly with air vent plug loosened to purge all air from system.

4.6 DECK REMOVAL

Move machine to an area where the mower deck is to be disconnected. Turn engine “OFF” but leave key switch in the “ON” position. Engage parking brake.

1. The rear of deck must be raised up and both jack stands moved down to the lowest position and both locking pins inserted. NOTE: Jack stands are stored on the left and right rear sides of the mower.

2. Using deck lift switch, lower deck down to rest on jack stands.

3. The hitch latch pins are shown in the latched position. The latched position locks the deck lift arm into position. See Figure 4.9.

HITCH LATCH PIN SHOWN IN LATCHED OR LOCKED POSITION

FUEL COCK

AIR VE NT PLUG

SMALL “O” RING

FUEL FILTER

SPRING

LARGE “O” RING

FUEL BOWL

RETAINING RING

DECK LIFT ARM

HITCH PLATE

FIGURE 4.9

(Continued on Next Page)

WARNING

Allow engine to cool for at least ten minutes before performing service or maintenance. DO NOT smoke near fuel components when performing service or maintenance. DO NOT perform service and maintenance near an open flame. Wipe off any spilled fuel before starting engine. DO NOT run engine indoors.

FIGURE 4.8

Page 19

Section 4 - MAINTENANCE

4.6 DECK REMOVAL (Continued From Previous Page)

4. Rotate spring loaded hitch latch pins (Located

on both hitch plates) to the unlatched position. See Figure 4.10.

5. Move deck lift switch as if to lower deck and the lift arm will move up in the hitch plates. The lift arm needs to be high enough to clear the hitch plates when power unit is driven backward away from mower deck. See Figure 4.9.

6. Pull lock collar back and slide power transfer shaft away from power take off (PTO) shaft. See Figure 4.11.

7. Disconnect wiring harness from mower deck.

8. Start power unit. Disengage parking brake.

Carefully move power unit backward away from mower deck.

NOTE: DECK LIFT ARM SHOWN REMOVED FOR CLARITY. DECK WOULD NOT BE REMOVED AT THIS TIME IN DECK REMOVAL PROCEDURE.

4.7 POWER TRANSFER SHAFT REMOVAL

Engage parking brake. Turn engine “OFF” and remove key. The power transfer shaft connects the power unit to the mower deck. The shaft is telescoping for easy removal. Slide locking collar back toward mower deck and shaft will slide off. See Figure 4.11.

WARNING

HITCH LATCH PIN SHOWN IN UNLATCHED POSITION

PULL LOCK COLLAR BACKWARDS

POWER TRANSFER SHAFT

HITCH PLATE

FIGURE 4.10

LOCK COLLAR

POWER TAKE OFF SHAFT

FIGURE 4.11

Page 20

Section 5 - ADJUSTMENTS & REPAIR

DANGER

Exercise EXTREME CAUTION when making this adjustment, due to close proximity of moving parts.

5.1 NEUTRAL POSITION ADJUSTMENTS

The joystick controls the movement and stopping of the machine. Move the joystick to the center or neutral position to stop mower. IMPORTANT: Always return the joystick with hand assistance to the neutral position. If machine does not come to a complete stop or has any movement when joystick is moved to the neutral position, adjustment must be made.

1. Turn key to “OFF” position.

2. Raise both wheels off the ground. Wheels

should be high enough to rotate freely. Secure with safety blocks.

3. Disconnect parking brake rod from parking brake. See Figure 5.4

4. Engage parking brake lever. NOTE: Engaging parking brake without brake rod connected will lock joystick in center or neutral position.

5. Turn key to start position and start engine.

6. Both wheels should be still, not rotating.

7. If wheel(s) are rotating, disconnect transmission

control rods from cross shaft and turn adjusting bolts located on pump(s) clockwise, or counter-clockwise, until wheel(s) stop rotating. See Figures 5.1and 5.1A.

8. With wheels in neutral, (not rotating) stop engine and readjust the length of the control rods until they fit into the cross shaft arms and reconnect. Tighten securely.

9. Reconnect park brake rod.

10. Start engine. Release park brake. Wheels

should not be rotating if adjusted properly. Repeat adjustment if necessary.

4.2 MOWER DECK & COMPONENT ADJUSTMENTS

The following mower deck and component adjustments and repairs can be made by the owner. However, if there is difficulty in making these adjustments and repairs, it is recommended that these repairs be made by an authorized SNAPPER dealer.

4.2.1. MOWER DECK ADJUSTMENT (LEVELNESS) SIDE to SIDE and FRONT to REAR

Before making deck leveling adjustments, check tires and add or release air as needed to bring pressure to 12 psi in drive tires (Turf Type Tires), 5 psi (All Terrain Type Tires) and 25 psi in rear caster tires. Pressure in front deck caster wheels should be 25 psi. If tires are properly inflated and mowing is still uneven, adjust deck levelness as follows:

1. Place mower on a smooth level surface.

2. Raise deck to highest cutting position.

3. Place 2x4 blocks under front edge of deck beside

caster wheels. Blocks should be on both sides of deck. Make deck relatively level by positioning blocks. Both caster wheels must be off the ground.

4. Loosen leveling bracket at center rear deck support. See Figure 5.2. This allows the lift arm to settle down into hitch brackets.

LOOSEN NUTS

LEVELING BRACKET

TRANSMISSION CONTROL ROD

ADJUSTING

FIGURE 5.1

FIGURE 5.2

TRANSMISSION CONTROL ROD

FIGURE 5.1A

Page 21

Section 5 - ADJUSTMENTS & REPAIR

5.2.1. MOWER DECK ADJUSTMENT (LEVELNESS) SIDE to SIDE and FRONT to REAR (continued from previous page)

5. Retighten leveling bracket bolts.

6. Remove both bolts (one from each side) from the

front portion of the link weldment. See Figure 5.3. The front caster wheel will drop to the ground.

7. Turn ball joint in or out until ball joint anchor hole aligns with mounting hole. Reinstall bolt and tighten securely. Use same procedure on other caster wheel. See Figure 5.3.

8. Reinstall bolts and tighten securely.

9. Remove blocks from under front of deck.

10. Side to Side Level: Check blade tips by

rotating blades until tips are pointing to the side of the deck. Check the measurement of outside blade tips to the ground on both blades. The measurement of each outside blade tip should be within 1/8” of each other.

11. Front to Rear Level: Check blade tips by rotating blades until tips are pointing to the front and rear of deck. Check the blade tip measurements of each blade. Front to rear measurement should be 1/4” to 3/8” higher in the rear.

5.3 PARKING BRAKE ADJUSTMENT

5.3.1 The park brake can be adjusted by

removing the rod from the lever and rotating clockwise to increase brake tension. When properly adjusted the park brake lever should require 18 to 22 pounds force to set the brake. If this adjustment does not result in proper brake action, contact your authorized Snapper dealer for corrective action. See Figure 5.4.

WARNING

DO NOT operate machine if brakes are not functioning properly.

5.4 ENGINE ADJUSTMENTS & REPAIR

Refer to the engine owner’s manual for engine adjustments and/or repairs.

5.5 MOWER BLADE REPLACEMENT

5.5.1. BLADE WEAR LIMITS

1. Inspect blade frequently for signs of

excessive wear or damage. See Figure 5.5.

CASTER WHEEL BRACKET

ROTATE BALL JOINT IN

REMOVE BOLT

OR OUT TO ALIGN WITH HOLE IN CASTER WHEEL

FIGURE 5.3

WARNING

PARKING BRAKE LEVER

ROTATE BRAKE ROD CLOCKWISE TO TIGHTEN BRAKE

PARKING BRAKE ROD

FIGURE 5.4

Page 22

Section 5 - ADJUSTMENTS & REPAIR

5.5 MOWER BLADE REPLACEMENT

5.5.1. BLADE WEAR LIMITS (continued from previous page)

(4) BLADE

NEW BLADE

WEAR LIMIT (NOTCH STARTS)

DANGEROUS CONDITION! DO NOT USE ON MOWER! REPLACE WITH NEW BLADE.

SPACERS

MOUNTING BOLT

AIR LIFT

BLADE

BEVELED WASHE

FIGURE 5.5

WARNING

DO NOT use a cutting blade that shows signs of excessive wear or damage. Refer to Figure 4.5. Wear heavy leather gloves when handling or working around cutting blades. Blades are extremely sharp and can cause severe injury.

5.5.2. BLADE SHARPENING

1. Remove blade. See Figure 5.6.

2. Inspect condition of blade.

Refer to Figure 5.5.

3. If blade is in good condition, sharpen at 22 to 28 degrees. DO NOT sharpen beyond original cutting edge. See Figure 5.7.

4. Check blade balance after sharpening. If necessary, correct blade balance by grinding the heavy end of blade. IMPORTANT: Blade balancing should be performed by a qualified dealer.

5. Reinstall blade. See Figure 5.6. Torque blade mounting bolts to recommended range of 70 to 80 ft. lbs.

DO NOT SHARPEN BEYOND ORIGINAL

BLADE

FIGURE 5.6

22º TO 28º

BLADE TIP

ORIGINAL CUTTING EDGE

FIGURE 5.7

Page 23

Section 5 - ADJUSTMENTS & REPAIR

5.6 MOWER DRIVE BELT, ENGINE BELT & HYDRO

PUMP BELT REPLACEMENT

Inspect all belts Replace belt if it shows signs of excessive wear, damage and/or is broken.

WARNING

5.6.1. MOWER DRIVE BELT REMOVAL

1. Remove mower drive belt cover.

2. Remove old belt.

5.6.2. MOWER DRIVE BELT REPLACEMENT

1. Route belt around blade pulleys and idler

pulley in the same position as old belt was removed. It may be necessary to use a pry bar to pull idler pulley back to install belt. See Figure 5.8.

2. Reinstall belt cover.

3. Remove the 3 nuts and 3 bolts that

secure the front drive shaft bearing housing to the frame.

4. Disconnect the drive shaft coupling from the engine adaptor. Slide drive shaft assembly forward. Remove engine belt from around pulleys and fan.

5. Install new belt in reverse order.

6. Attach drive shaft coupling to engine

adaptor. Attach front bearing housing to frame. Reinstall alternator cover and radiator screen. Reinstall all nuts and bolts Tighten all nuts and bolts securely.

RADIATOR SCREEN

FRONT OF

FIGURE 5.8

DISCHARGE CHUTE NOT SHOWN

ALTERNATOR COVER

DRIVE SHAFT

ASSEMBLY

ENGINE

ADAPTOR

5.6.3. ENGINE BELT REMOVAL

1. Remove radiator screen.

2. Remove nut and bolt that secure the top

portion of alternator cover. Rotate cover to the side. See Figure 5.9.

3. Remove left and right transmission drive belts.

FRONT

DRIVE SHAFT COUPLING

FIGURE 5.9

Page 24

Section 5 - ADJUSTMENTS & REPAIR

5.7 BATTERY

5.7.1. BATTERY REMOVAL

1. Remove battery retainer.

2. Slide battery from battery box to gain

access to terminal cables.

3. Observe and note cable positions on

battery. See Figure 5.10.

4. Disconnect cables from battery terminals,

disconnecting BLACK (Negative) cable first, then disconnect RED (Positive) last. Retain mounting bolts and nuts.

WARNING

Cables must be connected to battery terminals in the proper position. RED (Positive) cable must go to the ( + ) terminal. BLACK (Negative) cable must go to the ( - ) terminal.

5.7.2. BATTERY INSTALLATION

1. Slide battery partially into battery

compartment.

2. Connect cables to battery terminals. Connect RED (Positive) cable first. Connect BLACK (Negative) cable last.

3. Reinstall battery retainer and positive terminal cover.

BATTERY REMOVAL:

DISCONNECT BLACK CABLE (NEGATIVE) FIRST,

DISCONNECT RED CABLE (POSITIVE) LAST.

WARNING

The electrolyte (acid) produces a highly explosive gas. Keep all sparks, flame and fire away from area when charging battery or when handling electrolyte or battery. Electrolyte (acid) is a highly corrosive liquid. Wear eye protection. Wash affected areas immediately after having eye or skin contact with electrolyte (acid). Battery acid is corrosive. Rinse empty acid containers with water and mutilate before discarding. If acid is spilled on battery, bench, or clothing, etc., Flush with clear water and neutralize with baking soda.

5.7.3. BATTERY SERVICE

1. Remove battery.

2. Place battery in a well ventilated area on

a level surface.

3. Using distilled water, refill cells as required to cover cell plates.

4. With cell caps removed, connect battery charger to battery terminals. RED to positive (+) terminal and BLACK to negative (-) terminal.

5. Slow charge battery at 1 amp for 10 hours. An alternative fast charge should be no more than 2.5 amps for four hours.

6. If battery will not accept charge or is partially charged after 10 hours of charging at 1 amp, replace with new battery.

(Continued on Next Page)

CONNECT RED CABLE (POSITIVE) FIRST,

BATTERY INSTALLATION:

CONNECT BLACK CABLE (NEGATIVE) LAST.

TERMINAL COVER

POSITIVE TERMINAL

TERMINAL COVER MUST SHIELD POSITIVE TERMINAL AFTER INSTALLATION

FIGURE 5.10

WARNING

If the battery is removed, DO NOT operate engine without insulating Positive + battery cable terminal with electrical tape, or sparking from the battery can result.

NEGATIVE TERMINAL

Page 25

Section 5 - ADJUSTMENTS & REPAIR

5.7 BATTERY

Battery Condition Chart

State of Charge Syringe Hydrometer Digital Voltmeter Five Ball Hydrometer

100% Charged w/ Sulfate Stop 1.280 12.80v Five Balls Floating 100% Charged 1.265 12.60v Four Balls Floating 75% Charged 1.210 12.40v Three Balls Floating 50% Charged 1.160 12.10v Two Balls Floating 25% Charged 1.120 11.90v One Ball Floating 0% Charged Less than 1.100 Less than 11.80v Zero Balls Floating

WARNING

Shield the positive terminal with terminal cover located on battery harness. This prevents metal from touching the positive terminal which could over heat battery and/or battery cable and cause sparks. DO NOT attempt to charge battery while installed on the Zero Turning Radius Mower. DO NOT use “BOOST” chargers on the battery.

5.7.4. BATTERY TESTING

There are two types of battery tests: Unloaded and Loaded. The unloaded test is the procedure that will be discussed. It’s the simplest and most commonly used. An unloaded test is made on a battery without discharging current. To perform unloaded testing, check charge condition using either a hydrometer or voltmeter.

1. Using a voltmeter, voltage readings appear instantly to show the state of charge. Remember to hook the positive lead to the battery’s positive terminal, and the negative lead to the negative terminal.

2. A hydrometer measures the specific gravity of each cell. The specific gravity tells the degree of charge; generally, a specific gravity of about 1.265 to 1.280 indicates full charge. A reading of 1.230 to 1.260 indicates the battery should be charged before testing. The Battery Condition chart shows the charge level as measured by syringe float hydrometer, digital voltmeter and five ball hydrometer.

separately) to proper level. Fill to 3/16” above cell plates. Filling battery with electrolyte will bring the battery to 80% charged state.

4. With cell caps removed, connect battery charger to battery terminals; RED to positive (+) and BLACK to negative (-) terminal.

IMPORTANT: 3/16” above cell plates is the recommended level. DO NOT place anything in battery other than specified electrolyte.

5. Slow charge the battery at 1 amp for 2 hours to bring the battery to full charge.

6. After charging, check level of electrolyte and add as needed to bring level to 3/16” above cell plates.

7. Reinstall cell caps.

8. Install battery into power unit.

9. Connect positive (+) cable (red) first,

from wiring harness to the positive terminal (+) on battery using bolt and nut provided in hardware bag. Connect negative (-) cable (black) last, to negative terminal (-) on battery using bolt and nut. Apply a small amount of grease over terminals to prevent corrosion.

5.7.5. NEW BATTERY PREPARATION

1. Remove battery from carton.

2. Place battery in a well ventilated area on a

level non-concrete surface.

WARNING

DO NOT OVERFILL!

3. Remove battery cell caps. Fill cells as

required with electrolyte (purchased

Page 26

Section 5 - ADJUSTMENTS & REPAIR

5.8 MOWER SPINDLES (Field Serviceable Spindles) BEARING REPLACEMENT

In the event that a spindle bearing requires replacement, the SNAPPER Field Serviceable Spindles have been designed so that no special tools or presses are required.

1. Remove belt. Loosen blade nut and remove. Allow blade bolt, washer, blade and four spacers to drop down out of the spindle housing. See Figure

5.11.

REMOVE NUT

REMOVE BELT FROM SPINDLE

REMOVE BLADE BOLT

FIGURE 5.11

2. Remove spindle pulley from spindle shaft.

3. Locate circular retaining ring on spindle shaft at

top bearing. Remove retaining ring. Allow spindle shaft to drop out of housing.

4. Top and bottom bearings are now removable. Pull out on inner race to slide bearing from housing. See Figure 5.12.

5. Thoroughly clean all parts removing all old contaminated grease.

6. Install new bottom bearing first. NOTE: The bearing is sealed/shielded on one side

only. The bottom bearing must be installed with the sealed/shielded side DOWN.

7. Insert spindle shaft up through the bottom bearing. Slide spacer down over spindle shaft.

8. Install new top bearing. Install the top bearing with the seal/shield UP.

9. Slide circular retaining ring down spindle shaft until it fully locks into groove on shaft.

10. Place spindle pulley and spacer on top of spindle shaft.

11. Reinstall blade bolt, washer, blade and four spacers. See Figure 4.2.

12. Torque blade bolt and nut to 60 to 75 ft. lbs.

IMPORTANT: Spindle housing must be filled with grease before operating mower. Failure to fill housing will cause premature bearing failure.

13. Pump grease into spindle housing until grease

purges from vent on housing.

14. After the first 5 hours of operation, grease spindle housing to insure it is full, then every 25 hours.

BEARING

SPINDLE HOUSING

INNER RACE

BEARING

SPINDLE SHAFT

PULLE

RETAINING RING

BEARING

BEARING SEAL

FIGURE 5.12

Page 27

TROUBLESHOOTING

PROBLEM PROBABLE CAUSE CORRECTIVE ACTION

Starter Will Not Crank

Engine

Engine Will Not Start

Engine Stalls After

Running

Engine Loses Power

Engine Backfires When

Turned To “STOP”

Excessive Vibration

Engine Over Heats

1. Battery dead. 1. Service battery.

2. Blown fuse. 2. Replace fuse.

3. Electrical connections loose or corroded. 3. Clean and check connections for good contact.

4. Defective ignition switch.

1. Blade engagement switch in the “ON” position. 1. Move blade engagement switch to “OFF”.

2. Park brake not set. 2. Set park brake.

3. Fuel tank empty. 3. Fill fuel tank with fresh diesel fuel.

4. Fuel filter clogged. 4. Remove and clean fuel filter of all debris.

5. Fuel cock in the “OFF” position. 5. Move fuel cock lever to the “ON” position.

6. Battery weak or dead. 6. Service battery.

7. Faulty parking brake, blade or ignition switch.

1. Operator not in seat. 1. Sit in operator’s seat.

2. Fuel injection nozzle clogged with carbon. 2. Clean or replace fuel injection nozzle.

3. Fuel tank empty. 3. Fill with fuel to proper level.

4. Engine air cleaner dirty. 4. Clean air cleaner of all debris.

5..Insufficient lubrication. 5. Check engine oil lubricating system.

6. Fuel filter clogged. 6. Remove and clean fuel filter of all debris.

7. Water, debris or stale fuel in fuel system. 7. Drain and clean fuel system.

1. Excessive load on engine. 1. Lessen load.

2. Engine air pre-cleaner or air cleaner dirty 2. Clean or replace filters.

3. Engine oil level low. 3. Fill with engine oil to proper level.

4. Fuel injection nozzle clogged with carbon. 4. Clean or replace fuel injection nozzle.

5. Water, debris or stale fuel in fuel system. 5. Drain and clean fuel system.

1. Throttle control set too “FAST”. 1. Set throttle control to “SLOW” and allow engine

1. Damaged or bent mower blades. 1. Service mower blade(s).

2. Loose blade components. 2. Service and tighten loose parts.

3. Loose or missing air lift (if equipped). 3. Replace air lifts. Tighten to proper torque.

1. Insufficient engine lubrication. 1. Check engine oil lubrication system.

2. Fan belt broken or out of adjustment. 2. Replace fan belt or adjust to proper tension.

3. Insufficient coolant level. 3. Check coolant level and replenish supply.

4. Thermostat defective. 4. Replace thermostat of correct heat range.

5. Radiator screen or radiator cooling fins clogged. 5. Clean all debris from radiator screen and fins.

6. W ater pump, fan & radiator cap defective. 6. Replace cooling system parts that are defective.

7. Incorrect fuel injection timing.

8. Excessive concentration of antifreeze. 8. Change coolant(water/antifreeze) mixture ratio.

9. Cooling system clogged with debris. 9. Drain and flush cooling system.

4. Contact authorized SNAPPER dealer.

7. Contact authorized SNAPPER dealer.

to idle. Then, turn key to “OFF”.

7. Contact authorized SNAPPER dealer.

(Trouble Shooting Continued on Next Page)

Page 28

TROUBLESHOOTING

PROBLEM PROBABLE CAUSE CORRECTIVE ACTION

Tractor Will Not Move

Loss Of Traction

Blade(s) Not Cutting

Cutting Grass

Improperly

Poor Grass Discharge

Battery Will Not Charge

Oil Leaking

Deck Will Not Lift

Properly

1. Joystick in the neutral “N” position. 1. Place joystick in desired speed position.

2. Roll release lever is in “ROLL” position. 2. Move roll release lever to the engaged position.

3. Low transmission hydraulic oil level. 3. Bring hydraulic oil to proper level.

4. Parking Brake engaged. 4. Move parking brake to disengaged position.

5. Traction drive belt requires replacement. 5. Replace traction drive belt.

1. Blade engagement switch in the “OFF” position. 1. Move blade switch to the “ON” position.

2. Clutch belt slipping. 2. Replace clutch belt.

3. Mower belt slipping. 3. Replace mower belt.

4. Electric clutch not functioning.

5. Check gearbox for damage.

6. Power transfer shaft disconnected or damaged. 6. Connect power transfer shaft or repair damage.

1. Uneven tire pressure. 1. Bring to proper pressure.

2. Cutting height too low or high. 2. Adjust cutting height.

3. Engine speed too slow. 3. Move throttle control to “FAST” position.

4. Forward speed too fast. 4. Move joystick to a slower speed.

5. Terraced cut, side to side. 5. Adjust side to side level.

6. Excessive deck pitch, front to rear. 6. Adjust front to rear level.

7. Cutting blade(s) dull or damaged. 7. Sharpen cutting edges or replace blade(s).

8. Blade belt slipping. 8. Replace blade belt.

9. Check electric clutch. 9. Adjust to proper specifications.

10. Check clutch belt. 10. Replace clutch belt.

11. Check gearbox for damage.

1. Engine speed too slow. 1. Move throttle control to “FAST” position.

2. Forward speed too fast. 2. Move joystick to a slower speed.

3. Grass is wet. 3. Mow when grass is dry.

4. Excessively worn or damaged blade(s). 4. Service mower blade(s).

5. Build up of grass clippings and debris under deck. 5. Clean deck.

6. Improper blade(s) installed on deck.

7. Blade(s) installed improperly on deck. 7. Install blades properly.

1. Poor cable connections. 1. Clean cables and battery terminals.

2. Bad battery cell(s). 2. Replace with new battery.

3. Faulty alternator. 3. Contact engine manufacturer’s dealer.

1. Loose or missing hydraulic reservoir cap. 1. Check oil level and replace reservoir cap.

2. Leaking hose fittings, clamps or reservoir. 2. Verify fittings and hose clamps are tight.

1. Loose or disconnected electrical harness. 1. Connect electrical harness.

2. Electric screw jack malfunctioning.

3. Key switch is in “OFF” position. 3. Turn key switch to “ON” position.

4. Contact authorized SNAPPER dealer.

5. Contact authorized SNAPPER dealer.

11. Contact authorized SNAPPER dealer.

6. Install proper SNAPPER blades.

2. Contact authorized SNAPPER dealer.

Page 29

SERVICE SCHEDULE

ITEM SERVICE PERFORMED REF. EACH

Engine Oil

Air Cleaner

Fuel Filter

Engine Cooling

System

Engine Cooling

System

Battery

Tires

Check Oil Level Page 10

Initial Oil Change Page 15

Periodic Oil Change Page 16

Change Oil Filter Engine Manual

Clean or Replace Engine Manual

Replace Page 18

Clean Radiator Screen & Fins

Check coolant level Engine Manual

Check Electrolyte Page 24-25

Charge Battery Page 24-25

Testing Battery Page 25

Check Air Pressure Page 10

Engine Manual & Page 16

100

USE5HRS25HRS50HRS75HRS

XX X

HRS

X**

EACH

SEASON

X***

Drive Belts

Mower Blades

Mower Deck

Lubrication

Points

Hydrostatic

Trans. Oil

Hydrostatic

Trans. Filter

*Change oil every 25 hours when operating under heavy load or high temperatures.

** Clean more often under dusty conditions or when air debris is present

*** Charge battery every one or two months as specified by engine owner’s manual.

Check For Wear And Tension Check For Wear, Damage & Replacement Clean Outside & Underside of Debris Accumulation Grease or Oil Pages 16-17

Check Oil Level Page 17

Replace Filter Page 17 First Change at 200 Hours.

Page 16

Pages 15, 2122 Page 16

MAINTENANCE PARTS

4.8.1. MAINTENANCE/REPLACEMENT PARTS

MAINTENANCE PARTS

Mower Blades (52” Deck) (Hi Lift) 2-9246 (3) Mower Blades (52” Deck) (Low Lift) 7-3395 (3) Mower Blades (61” Deck) (Standard Lift) 1-7081 (3) Mower Blades (61” Deck) (Hi Lift) 2-9251 (3) Mower Blades (61” Deck) (Low Lift) 7-3396 (3) Mower Deck Belt (52” Deck) 4-2776 Mower Deck Belt (61” Deck) 3-5542 Upper Drive Shaft To Hydro Pump Belt 3-5544 (2) Deck Drive Shaft To Electric Clutch Belt 4-1830 (2) Battery 3-5610

Thereafter every 500 Hours.

Page 30

2 YEAR LIMITED WARRANTY

For two (2) years from purchase date for the original purchaser's use, SNAPPER, through any authorized SNAPPER dealer will replace, free of charge (except for taxes where applicable), any part or parts found upon

examination by the factory at McDonough, Georgia, to be defective in material or workmanship or both.

SNAPPER FIELD SERVICEABLE SPINDLES and their components used on SNAPPER PRO® Mid Size walks and SNAPPERZRIDER® ride on commercial equipment have a three (3) year limited warranty against defects in material or workmanship or both.

All transportation costs incurred by the purchaser in submitting material to an authorized SNAPPER dealer for replacement under this warranty must be paid by the purchaser.

This warranty does not apply to engines and their components, and batteries, as these items are warranted separately. This warranty does not apply to parts that have been damaged by accident, alteration, abuse, improper lubrication, normal wear, or other cause beyond the control of SNAPPER. This warranty does not cover any machine or component that has been altered or modified, changing safety, performance, or durability.

Batteries have a one (1) year prorated warranty period with free replacement if required during the first ninety (90) days from the original purchase date. SNAPPER will not be responsible for any installation cost incurred. The battery warranty only covers original equipment batteries and does not cover damage to the battery or machine caused by neglect or abuse, destruction by fire, explosion, freezing, overcharging, improper maintenance, or use of improper electrolyte.

There is no other express warranty.

DISCLAIMER OF WARRANTY Implied warranties, including those of merchantability and fitness for a particular purpose, are limited to two (2) years from purchase date for the original purchaser's use, and up to the extent permitted by law and all implied warranties are excluded. This is the exclusive remedy. Liabilities for consequential damages, under any and all warranties are excluded.

Some states do not allow limitations on how long an implied warranty lasts, or do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you.

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

WARNING: THE USE OF REPLACEMENT PARTS OTHER THAN GENUINE SNAPPER PARTS MAY IMPAIR THE SAFETY OF SNAPPER PRODUCTS AND WILL VOID ANY LIABILITY AND WARRANTY BY SNAPPER ASSOCIATED WITH THE USE OF SUCH PARTS.

IMPORTANT: Please fill out the attached SNAPPER Product Registration Card immediately and mail to:

Snapper’s Product Registration Center, P.O. Box 1379, McDonough, Georgia. 30253

Page 31

PRIMARY MAINTENANCE

Page 32

PRIMARY MAINTENANCE

Page 33

PRIMARY MAINTENANCE

Page 34

PRIMARY MAINTENANCE

Page 35

NOTES

Page 36

Safety Instructions & Operator’s Manual for

OUT FRONT Z-RIDER HYDRO DRIVE SERIES 1

IMPORTANT

Snapper products are built using engines that meet or exceed all applicable emissions requirements on the date manufactured. The labels on those engines contain very important emissions information and critical safety warnings. Read, Understand, and Follow all warnings and instructions in this manual, the engine manual, and on the machine, engine and attachments. If you have any questions about your Snapper product, contact your local authorized Snapper dealer or contact Snapper Customer Service at Snapper, McDonough, GA. 30253. Phone: (1-800-935-2967).

WARNING

BATTERY POSTS, TERMINALS AND RELATED ACCESSORIES CONTAIN LEAD AND LEAD COMPOUNDS, CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER AND BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM.

WASH HANDS AFTER HANDLING.

WARNING

ENGINE EXHAUST, SOME OF ITS CONSTITUENTS, AND CERTAIN VEHICLE COMPONENTS CONTAIN OR EMIT CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER OR OTHER REPRODUCTIVE HARM.

INSTRUCTION No. 7-3700 (REV 1, 8/29/01)

Snapper ZF2101DKU, ZF5201M, ZF6101M, ZF2301GKU User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Safety Instructions & Operator’s Manual for

IMPORTANT SAFETY INSTRUCTIONS

OPERATION

IMPORTANT SAFETY INSTRUCTIONS

IMPORTANT

FIGURE 1.1

FIGURE 3.10

FIGURE 3.11

FIGURE 5.4

WARNING

PRIMARY MAINTENANCE

Safety Instructions & Operator’s Manual for