Snapper ZF2300GKU, ZF2100DKU, ZF5200M, ZF6100M User Manual

Safety Instructions & Operator’s Manual for

OUT FRONT Z-RIDER

HYDRO DRIVE

SERIES 0

POWER UNIT MODELS

ZF2100DKU ZF2300GKU

MOWER UNIT MODELS

ZF5200M ZF6100M

MODEL NUMBER EXPLANATION

Z F 21 00 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 00 – 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 00 – 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 & 3. 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. 4-5182 (REV. 3, 8/20/99)

IMPORTANT SAFETY INSTRUCTIONS

WARNING: This powerf ul cutting machine is capab le of amputating hand s and feet and can throw objects that can cause injury and damage! Failure to comply with the follow ing SAFETY instru ctions could resu lt 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 occu r 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.

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

6. DO NOT operate blades in reverse. STO P BLADES. LOOK and SEE behind an d 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 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 slop es 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.

PROTECTION AGAINST TIPOVERS

(Continued From Previous Column)

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

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. 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 instructio ns 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 and the proper use of the machine before starting.

2. Only mature, responsible persons shall operate the machine and only after proper instruction.

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

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 fuel outdoors only with engine stopped and cool. Clean spilled fuel from machine. DO NOT smoke.

IMPORTANT SAFETY INSTRUCTIONS

PREPARATION

(Continued From Previous Page)

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

8. Check shields, deflectors, switches, blade controls and other safety dev ices frequently for proper operation and location.

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

10. Protect yourself w hen mowing and wear safety glasses, long pants and substantial footwear.

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

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

13. 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, if possible. Make sure blades are OFF and parking brake is set.

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 feet rests or pedal(s).

5. STOP BLADES and ENGINE and make sure blades have stopped before removing grass catcher or unclogging mower to prevent loss of fingers or hand.

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

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

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

9. Slow down before turning.

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

OPERATION

(Continued From Previous Column)

11. STOP engine immediately after striking an obstruction. Inspect machine and repair damage before resuming operation.

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

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

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

15. DO NOT operate engine in enclosed areas. Engine exhaust gases contain carbon monoxide, a deadly poison.

MAINTENA NCE

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 enclosu re. Store fuel container out of the reach of children in a well ventilated, unoccupied building.

2. Keep engine free of grass, leaves or excess grease to reduce fire hazard and engine overheating.

3. When draining fuel tank, drain fuel into an a pproved container outdoors and away from open fla me.

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.

7. Disconnect negative (black) cable from battery before performing maintenance or service. Cranking engine could cause injury.

8. DO NOT work under machine without safety blocks.

9. Service engine and make adjustments only when engine is 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.

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.

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

14. Have machine serviced by an autho rized SNAPPER dealer at least once a year and have the dealer install any new safety devices.

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

TABLE OF CONTENTS

SECTION 1 - IMPORTANT SAFETY INSTRUCTIONS....................................2-3

TABLE OF CONTENTS...................................................................................... 4

SECTION 1 – FAMILIARIZATION.......................................................................5

SECTION 2 - OPERATING INSTRUCTIONS.................................................6-10

Pre-start Checklist .................................................................................................6

Starting & Stopping Engine, Blades & Parking Brake .........................................7-9

Starting & Stopping Mower Blades.........................................................................8

Parking Brake.........................................................................................................9

Cutting Height Adjustment......................................................................................9

Driving & Stopping Machine.................................................................................10

SECTION 3 - MAINTENANCE INSTRUCTIONS ......................................... 11-15

Change Engine Oil................................................................................................11

Check Mower Blade .............................................................................................11

Check Mower Drive Belt.......................................................................................12

Check Belt Tension ..............................................................................................12

Service – After every 25 Hours (Engine)..............................................................12

Service – After every 25 Hours (Mower Components).........................................12

Mower Blade Spindle Lubrication......................................................................12

Mower Deck Linkage Lubrication ......................................................................12

Front Wheel Bearings Lubrication.....................................................................13

Transaxle Lubrication........................................................................................13

Power Transfer Shaft Lubrication......................................................................13

Other Lubrication...............................................................................................13

Before Operating Mower ......................................................................................13

Annually - End of Season Service ...................................................................13-14

Fuel Filter Replacement .......................................................................................14

Deck Removal.................................................................................................14-15

Power Transfer Shaft Removal ............................................................................15

SECTION 4 - ADJUSTMENTS AND REPAIR.............................................. 16-22

Neutral Position Adjustments ...............................................................................16

Mower Deck Adjustment (Levelness)..............................................................16-17

Parking Brake Adjustment....................................................................................17

Engine Adjustments & Repair...............................................................................17

Mower Blade Replacement .............................................................................17-18

Blade Sharpening.................................................................................................18

Mower Drive Belt, Engine Belt & Hydro Pump Belt Removal & Replacement .....19

Battery Removal...................................................................................................20

Battery Installation................................................................................................20

Battery Service & Charging ..................................................................................20

Battery Testing......................................................................................................21

New Battery Preparation.......................................................................................21

Mower Spindles (Field Serviceable Spindles) Bearing Replacement...................22

TROUBLESHOOTING................................................................................. 23-24

SERVICE SCHEDULE...................................................................................... 25

Maintenance/Replacement Parts .........................................................................25

WARRANTY ..................................................................................................... 26

PRIMARY MAINTENANCE.......................................................................... 27-30

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.

Section 1 - FAMILIARIZATION

SWITCH

MOTION CONTROL (JOYSTICK)

OPERATOR’S SEAT

CONTROL PANEL

IGNITION

PARKING BRAKE

AMP METER

HOUR METER

FUEL TANK

ENGINE SPEED CONTROL

BLADE SWITCH

LIGHT SWITCH

DECK LIFT SWITCH

CONTROL PANEL (SEE INSET)

DECK HEIGHT OF CUT DECAL

DISCHARGE DEFLECTOR

FIGURE 1.1

1.1 INTRODUCTION

This manual has been prepar ed 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 and 3 of this manual and All SAFETY messages on the OU T FRON T 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.

DECK COVER

CASTER WHEEL BRACKET

1.2 NOMENCLATURE

The nomenclature inf ormation above, Figure 1.1, shows the essential parts of the SNAPPER OUT FRONT ZRIDER. It is recommended that all operator’s of this equipment becom e thoroughly fam iliar 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 referenc e. For the nearest SNAPPER dealer in your area, check the yellow pages under the heading LAWN MO WERS. For engine parts and service, look for the engine manufacturer’s dealers under the heading, ENGINES - gasoline.

Section 2 - OPERATING INSTRUCTIONS

TANK

2.1 PRE-START CHECK LIST

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

2.1.1. Check tires and add or release air as needed to bring pressure in drive tires to: 12 ps i (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.

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

2.1.3. Check engine oil and add oil as needed to bring level up to the FULL mark . Ref er to engine owner’s manual for oil specifications. See Figure 2.1.

FULL MARK

AIR FILTER ASSEMBLY IS SHOWN REMOVED

2.1.5. 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.

2.1.6. 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.

2.1.7. 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 2.3.

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

WARNING

OIL DIP STICK

FIGURE 2.1

2.1.4. Check Blade s witch to ins ure it works fr eely. Switch

is pulled “OUT” for blade engagement or pushed back “IN” for blade disengagement. See Figure 2.2. IMPORTANT: Disengagement stops blades.

IGNITION SWITCH

AMP METER

HOUR METER

BLADE SWITCH

LIGHT SWITCH

DECK LIFT SWITCH

PULL “OUT” TO ENGAGE BLADE.

PUSH “IN” TO DISENGAGE BLADE.

BLADE SWITCH:

FIGURE 2.2

FULL COOLANT MARK

LOW COOLANT MARK (COOLANT SHOULD BE ADDED)

COOLANT RESERVE

FIGURE 2.3

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

the “ON” position See Figure 3.8.

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 func tion can be verified (with engine stopped) by turning key to “RUN” position.

Section 2 - 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 in stantly. 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 pressu re. Rotate lever counter clockwise and secure in that position . See Figure 2.4.

PRESSURE RELEASE LEVER

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

2.2.1. STARTING ENGINE

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.

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 2.2.

PARKING BRAKE

PRESSURE RELEASE LEVER

LEVER IS ROTATED COUNTER CLOCKWISE AND LATCHED IN A SECURED POSITION FOR ROLLING RIDER (RIDER WIL L NOT PROP EL ITSELF WITH LEVER IN THIS POSITION)

FIGURE 2.4

2.2 STARTING & STOPPING – ENGINE, BLADES & PARKING BRA KE

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 2.5

4. Move engine speed control to a medium

speed setting. See Figure 2.6.

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.

Section 2 - OPERATING INSTRUCTIONS

POSITION

GAS ENGINE SWITCH POSITION

DIESEL ENGINE SWITCH POSITION

POSITION

2.2.1. STARTING ENGINE (Continued from previous page )

FAST ENGINE SPEED POSITION

SLOW ENGINE SPEED POSITION

ENGINE SPEED CONTROL SHOWN IN “FAST” POSITION

FIGURE 2.6

6. IM PORTANT: (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 2.7.

7. Rotate key clock wise to the start pos ition until engine starts. See Figure 2.7.

: If after 5 s econds of cranking the engine does

NOTE

not start, release the k ey and attempt star ting again after waiting for approximately 20 seconds.

STOP

GLOW PLUG

PRE-HEAT

POSITION

OFF

STOP

POSITION

OFF

POSITION

RUN

START

RUN

POSITION

START

FIGURE 2.7

2.2 STOPPING - ENGINE

2.2.1. ENGINE

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

2.2.2. STARTING MOWER BLADE

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

2.2.3. STOPPING MOWER BLADE

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 CONT INUE to operate mower if blades fail to stop in 7 seconds.

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

engine runs smooth.

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 2.7.

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 m achine to move instantly. Move joystick carefully and slowly.

1. Push the blade switch in to “ OFF” position to disengage or stop the mower blades. See Figure

2.2.

WARNING

Section 2 - OPERATING INSTRUCTIONS

POSITION

2.2.4. PARKING BRAKE

1. Engage parking brake by pulling the parking

brake lever back to the “ON” position. See Figure 2.8.

2. Release park ing brake by moving brak e lever down to the “OFF” position. See Figure. 2.9.

JOYSTICK IN NEUTRAL POSITION

PARKING BRAKE LEVER IN ENGAGED “ON” POSITION

FIGURE 2.8

PARKING BRAKE DISENGAGED “OFF”

2.2.5. CUTTING HEIGHT ADJUSTMENT

1. Adjust cutting height as desired to any

position, using deck lift s witch. When in desired height of cut, release switch. See Figure 2.10. 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 2.10. 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

DECK LIFT SWITCH

FIGURE 2.10

WARNING

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

FIGURE 2.9

Section 2 - OPERATING INSTRUCTIONS

2.3 OPERATION – MOTION CONTROL

2.3.1. DRIVING MACHINE IMPORTANT: T he j oystick lever has to be manually

moved to propel machine. Always return the joystick with hand assistance to the neutral pos ition 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 2.11.

REARWARD MOVEMENT

RIGHT TURN

LEFT TURN

FORWARD MOVEMENT

FIGURE 2.11

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.

WARNING

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