Snapper ZF5201M, ZF2501KH, ZF6101M User Manual

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Page 1

Safety Instructions & Operator’s Manual for

OUT FRONT Z-RIDER

ZERO TURNING

HYDRO DRIVE

SERIES 1

POWER UNIT MODELS

ZF2501KH

MOWER UNIT MODELS

ZF5201M ZF6101M

MODEL NUMBER EXPLANATION

Z F 25 01 KH

DRIVE SYSTEM TYPE ENGINE TYPE MOWER ORIENTATION SERIES DESIGNATION

ENGINE HP

POWER UNIT

Z – Zero Turning – Hydro Drive 25– Engine Horse Power 01 – Series Designation KH – Kohler Engine F – Out Front Mower

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 Z-RIDER, 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!

MANUAL No. 7-3699 (REV. 2, 8/29/01)

Page 2

IMPORTANT SAFETY INSTRUCTIONS

WARNING: This powerful cuttin g machine is capable of amputat ing hands and feet and can throw objects that can cause injury and damage! Failure to comply with th e follow ing SAFETY instructio ns 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 t he 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 th e 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 BL ADES. 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 ext ra 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 o n slopes exceeding 15 degrees (27% grade).

2. Exercise EXTREME CAUTION on slopes ab ove 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 sl owly and with caution.

8. Use weights or a w eighted 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.

PREPARA TION

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 mach ine 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 in struction 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 pe ople 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 inju ry if t hro wn by blades or interfere with mowing.

7. Evaluate the terrain to det ermine 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 w ire. 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.

MAINTENA NCE

1. DO NOT store machine or fuel container inside where fumes may reach an open flame, spark or pilot lig ht such as in a water heater, furn ace, 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 eng ine, 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 ope n flame.

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

5. Keep all bolt s, nu ts an d 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

MAINTENA NCE

(Continued From Previous Page)

7. Disconnect battery before performing maintenance or service. Cranking engine could cause injury. Disconnect negative (black) cable from b attery 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 adjustment s w ith 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 c ould ignite gas exiting engine.

14. Carefully release pressure from components with stored energy.

15. Have machine serviced by an auth oriz ed 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 .................................... 10-13

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

Starting & Stopping Engine, Blades & Parking Brake.....................................11-12

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

Parking Brake ...................................................................................................... 12

Cutting Height Adjustment .................................................................................. .12

Driving & Stopping Machine................................................................................. 13

SECTION 4 - MAINTENANCE INSTRUCTIONS .............................. 14-17

Change Engine Oil............................................................................................... 14

Check Mower Blade............................................................................................. 14

Check Mower Drive Belt ...................................................................................... 15

Check Belt Tension.............................................................................................. 15

Service - After every 25 Hours (Engine).............................................................. 15

Service – After every 25 Hours (Mower Components) ........................................ 15

Mower Blade Spindle Lubrication ..................................................................... 15

Mower Deck Linkage Lubrication...................................................................... 15

Front Wheel Bearings Lubrication.................................................................... 16

Transaxle Lubrication ....................................................................................... 16

Power Transfer Shaft Lubrication ..................................................................... 16

Other Lubrication .............................................................................................. 16

Before Operating Machine...................................................................................16

Annually - End Of Season...............................................................................16-17

Fuel Filter Replacement....................................................................................... 17

Deck Removal...................................................................................................... 17

Power Transfer Shaft Removal............................................................................ 17

SECTION 5 - ADJUSTMENTS AND REPAIR.................................... 18-23

Neutral Position Adjustments............................................................................... 18

Mower Deck & Component Adjustments.............................................................18

Mower Deck Adjustment (Levelness) ............................................................. 18-19

Parking Brake Adjustment................................................................................... 19

Engine Adjustments & Repair..............................................................................19

Mower Blade Replacement.................................................................................. 20

Blade Sharpening................................................................................................. 20

Mower Drive Belt & Engine Belt Removal & Replacement.............................20-21

Battery Removal................................................................................................... 21

Battery Installation................................................................................................ 21

Battery Service & Charging............................................................................. 21-22

Battery Testing..................................................................................................... 22

New Battery Preparation...................................................................................... 22

Mower Spindles (Field Serviceable Spindles) Bearing Replacement..................23

TROUBLESHOOTING....................................................................... 24-25

SERVICE SCHEDULE.............................................................................26

Maintenance/Replacement Parts......................................................................... 26

WARRANTY.............................................................................................27

PRIMARY MAINTENANCE................................................................ 28-31

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 Struct ures may be required by local ordinances. Discuss your mowing application and ordinances with your local Snapper Dealer.

Page 6

Section 1 - FAMILIARIZATION

OPERATOR’S SEAT

CONTROL PANEL

AMP METER

KEYSWITCH

HOUR METER

FUEL TANK

BLADE SWITCH

DECK LIFT SWITCH

LIGHT SWITCH

MOTION CONTROL (JOYSTICK)

CONTROL PANEL (SEE INSET)

DECK HEIGHT OF CUT DECAL

DISCHARGE DEFLECTOR

CHOKE CONTROL

ENGINE SPEED CONTROL

PARKING BRAKE

DECK COVER

CASTER WHEEL BRACKET

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

FIGURE 1.1

1.1 INTRODUCTION

This manual has been prepared f or 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 Pages 2 thru 4 of this m anual 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.

1.2 NOMENCLATURE

The nomenclature inform ation above, F igure 1.1, s hows the essential parts of the SNAPPER OUT FRONT ZRIDER. It is recommended that all operator’s of this equipment become thoroughly fam iliar with the c ontrols , 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. F or 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.

Page 7

Section 2 – SAFETY MESSAGES AND SYMBOLS

CHOKE

“ON”

CHOKE

“OFF”

RABBIT “FAST”

ENGINE SPEED

AND CHOKE

CONTROLS

TURTLE “SLOW”

Page 8

Section 2 – SAFETY MESSAGES AND SYMBOLS

“START” ENGAGE “ON”

“RUN”

“STOP”

KEY SWITCH

MOTION CONTROL

MULTI-DIRECTIONAL

HOUR METE

BLADE

DISENGAGE “OFF”

LIGHT SWITCH

“ON”

“

”

Page 9

Section 2 – SAFETY MESSAGES AND SYMBOLS

DANGER! ROTATING BLADES

KEEP CHILDREN AND OTHERS OUT OF 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 releas e air as needed to bring pressure in drive tires to: 12 psi (Turf Type Tires), 5 psi (All T errain T ype Tires) and 25 psi in rear caster tire. Pressure in front deck caster wheels should be 25 psi.

3.1.2. Check guards, deflector s 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

IMPORTANT: This Out Front Z-Rider is equipped with hydrostatic drive. The forward and rearward movement of the mower is contro lled 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 th e pressu re. Rotate lever counter clockwise and secure in that position. See Figure 3.3.

PRESSURE RELEASE LEVER

FIGURE 3.1

3.1.4. Check Blade switch to insure it works freely.

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

3.1.5. Clean exterior surfaces of cutting deck and engine of any accumulation of dirt, grass, oil, etc. Keep engine air intake screen and cooling fins c lear at all times.

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

PULL UP TO ENGAGE BLADE. PUSH DOWN TO DISENGAGE BLADE.

BLADE SWITCH

LEVER IS IN POSITION FOR PROPELLING RIDER UNDER ITS OWN POWER (RIDER WILL NOT ROLL WITH LEVER IN THIS POSITION

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 3.3

IMPORTANT: This machine is equipped with a

WARNING beeper . The beeper will sound when engine oil pressure is low or engine tem perature 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 ver ified (with engine stopped) by turning key to “RUN” position.

FIGURE 3.2

Page 11

Section 3 - OPERATING INSTRUCTIONS

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. Moving the joystick farther fr om the neutral position will cause the speed of motion to inc rease. T o 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 "ENG AGED" and the blade switch is in the “DISENGAGED” position! Be seated on the Out Front Z-Rider before attempting to start the engine with the key switch.

4. Move engine speed control to a medium speed setting. See Figure 3.5.

5. Move engine choke control to the choke position to start a cold engine. After starting, choke control m us t be moved to "OFF" no c hoke position.

ENGINE SPEED CONTROL

CHOKE CONTROL

CHOKE POSITION

FAST POSITION

FIGURE 3.5

6. Turn key to the start position until engine

starts. See Figure 3.6.

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

ENGAGED

DISENGAGED

FIGURE 3.4

NOTE: If after 5 seconds of cranking the engine does

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

PULL UP TO ENGAGE BLADE. PUSH DOWN TO DISENGAGE BLADE.

BLADE

SWITCH START POSITION

RUN POSITION

STOP POSITION

IGNITION KEY

FIGURE 3.6

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

engine runs smooth. Move the choke control to the “OFF” or no choke position.

Page 12

Section 3 - OPERATING INSTRUCTIONS

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 3.6.

WARNING

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

3.2.2. STARTING MOWER BLADES

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 power unit to move instantly. Move joystick carefully and slowly.

WARNING

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

3.2.3. STOPPING MOWER BLADES

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 NO T CONT INUE to operate mower if blades fail to stop in 7 seconds.

3.2.4. PARKING BRAKE

1. Engage parking brake by pulling the parking

brake lever back to the “ON” position. See Figure 3.4.

2. Release parking brake by moving brake lever down to the “OFF” position. See Figure. 3.8.

PARKING BRAKE DISENGAGED “OFF” 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 3.9. Observe the height of cut decal loc ated on the upper right top side of the deck to place deck at the correct height of cut. See Figure 3.9. NOTE: The engine does not have to be running to adjust cutting height, but key switch must be in the “ON” position.

WARNING

DO NOT park the machine on slopes.

DECK LIFT SWITCH

DECK HEIGHT OF CUT DECAL

FIGURE 3.9

Page 13

Section 3 - OPERATING INSTRUCTIONS

3.3 OPERATION – MOTION CONTROL

3.3.1 DRIVING MACHINE IMPORTANT: The joystick lever has to be m anually

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 park ing 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 3.10.

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

NEUTRAL POSITION

LEFT TURN

FORWARD MOVEMENT

FIGURE 3.10

Page 14

Section 4 – MAINTENANCE

4.1 INTRODUCTION

To retain the quality of the SNAPPER Out Front ZRider, 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 ZRider, always mention the model and serial number. SNAPPER recommends returning the Out Front ZRider 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 MOWERS. 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 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. Change engine oil as follows: a. Place a 4 quart minimum capacity

container under the end of the oil drain. b. Rotate counter cloc kwise and pull out to open the drain plug. See Figure 4.1.

d. Fill engine c rankcase with new oil. Refer to your engine owner’s manual for oil specifications. e. 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

crank engine. Raise mower deck to highest setting, using deck lift switch located to the right of operator as viewed from the operator’s position. Turn key to “OFF” position and 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.

As necessary, torque to 70 to 80 ft. lbs. See Figure 4.2.

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

7. Check blade for straightness.

ROTATE PLUG COU N TER CLOCKWISE THEN PULL OUT TO

FIGURE 4.1

c. After all the oil has dr ained, close the

drain by pushing in and rotating clockwise to close. W ipe up any oil that may have spilled. Dispose of drained oil properly. See Figure 4.1.

(4) BLADE SPACERS

MOUNTING BOLT

AIR LIFT

BLADE

BEVELED WASHER

TIGHTEN TO 70-80 FOOT POUNDS

FIGURE 4.2

Page 15

Section 4 – MAINTENANCE

4.2.3. CHECK MOWER DRIVE BELT

1. Drive Belt Cover Removal

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

deck cover. See Figure 4.3. c. Remove cover to gain ac c es s to dec k belt.

REMOVE DECK COVER

FIGURE 4.3

REMOVE FOUR KNOBS

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 , rem oving 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. Check 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.

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 “MOWER BLADE REPLACEMENT”.

3. Mower Deck Levelness

Check mower deck f or proper levelnes s. Adj us t as required. Refer to Sec tion “MOW ER DECK ADJUSTMENT – LEVELNESS”.

4. Cleaning Mower Deck a. Remove key from ignition switch. b. Remove spark plug wire(s) and

secure away from spark plug(s).

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

Page 16

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

FRONT WHEEL

FIGURE 4.5

2. Transaxle

Check the level of fluid in both of the fluid reservoirs. W ipe away all dirt and debris from around reservoir cap before removing. Oil must remain absolutely clean! Check with machine 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 c an 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

FIGURE 4.7

4. OTHER LUBRICATION POINTS

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

4.4 BEFORE OPERATING MACHINE

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 air intake screen.

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

4.5 ANNUALLY (END OF EACH SEASON)

Perform all maintenance as described in SERVICE SCHEDULE section of this manual.

HYDRAULIC OIL RESERVOIR

4.5.1. ENGINE

Service engine according to engine owner’s manual.

(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 17

Section 4 – MAINTENANCE

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

4.5.2. FUEL FILTER

Service fuel filter as instructed below. Turn key to “OFF” position. Engine MUST be stopped and MUST be cold before removing filter. Clamp fuel line to prevent fuel spillage or perform filter change when fuel tank and fuel line are empty.

1. Remove hose clamps from fuel filter.

2. Remove fuel lines from filter. Discard filter.

3. Install new fuel filter . Reinstall hose clamps. See

Figure 4.8.

FUEL FILTER

DIRECTION OF FUEL

FUEL HOSE

REINSTALL CLAMPS AS SHOWN

FIGURE 4.8

4.6 DECK REMOVAL

Move power unit/mower deck 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 shafts moved down to the lowest position and both locking pins inserted.

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 ar m into position. See Figure 4.9.

HITCH LATCH PIN SHOWN IN LATCHED OR LOCKED

DECK LIFT ARM

HITCH LATCH PIN

POSITION

4. Rotate spring loaded hitch latch pins (Loc ated on

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

HITCH LATCH PIN SHOWN IN UNLATCHED POSITION

HITCH PLATE

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

HITCH LATCH PIN

FIGURE 4.10

5. Move deck lif t 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.

LOCK COLLAR

POWER TAKE OFF SHAFT

POWER TRANSFER SHAFT

PULL LOCK COLLAR BACKWARDS

HITCH PLATE

FIGURE 4.9

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.

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. Refer to Figure 4.11.

Page 18

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 movem ent and stopping of the machine. Move the joystick to the center or neutral position to stop machine. IMPORTANT: Alwa ys re t u rn t h e j oystick with hand assistanc e to the neutral position. If machine does not come to a complete stop or has any movem ent when joystick is moved to the neutral position, adjustment must be made.

1. Turn key to “OFF” position.

2. Raise both drive wheels off the ground. Wheels

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

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

4. Engage parking brake lever. NOTE: Engaging parking brake without brake r od c onnected will lock joystick in center or neutral position.

5. Turn key to start position and start unit.

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 counterclockwise, until wheel(s) stop rotating. See Figure

5.1.

8. With wheels in neutral, (not rotating) stop engine and readjust control rods until they fit into the c ross shaft arms with no wheel creep.

9. Reconnect park brake rod.

5.2 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.

5.2.1. 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 and 25 psi in rear caster tire. Pressure in front dec k c as ter wheels should be 25 psi. If tires are properly inflated and m owing 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. T his allows the lift arm to settle down into hitch brackets.

LEVELING BRACKET

TRANSMISSION ROD

LOOSEN NUTS

TURN ADJUSTING BOLTS

FIGURE 5.2

5. Retighten leveling bracket bolts.

6. Remove both bolts (one fr om each side)

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

DETAIL

FIGURE 5.1

Page 19

Section 5 - ADJUSTMENTS & REPAIR

5.2.1. MOWER DECK ADJUSTMENT (Continued)

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 tips 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.

ROTATE BALL JOINT IN OR OUT TO ALIGN WITH HOLE IN CASTER WHEEL BRACKET

CASTER WHEEL BRACKET

5.3 PARKING BRAKE ADJUSTMENT

5.3.1. The park brake can be adjus ted by removing the

park brake rod from the park brake lever and rotating clockwise to increase brake tension. See Figure 5.4. 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.

ROTATE ROD CLOCKWISE TO TIGHTEN BRAKE

REMOVE BOLT

FIGURE 5.3

WARNING

PARKING BRAKE LEVER

PARKING BRAKE ROD

FIGURE 5.4

5.4 ENGINE ADJUSTMENTS & REPAIR

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

Page 20

Section 5 - ADJUSTMENTS & REPAIR

5.5 MOWER BLADE REPAIR/REPLACEMENT

5.5.1. BLADE WEAR LIMITS

1. Inspect blade frequently for signs of

excessive wear or damage. See Figure 5.5.

NEW BLADE

WEAR LIMIT (NOTCH STARTS)

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

FIGURE 5.5

2. Inspect condition of blade.

See Figure 5.5.

3. If blade is in good condition, sharpen at 22 to

28 degrees. DO NOT sharpen beyond existing cutting edge. See Figure 5.7.

WARNING

22º TO 28º

BLADE

BLADE TIP

ORIGINAL CUTTING EDGE

WARNING

DO NOT use a cutting blade that shows signs of excessive wear or damage. See 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.

AIR LIFT

(4) BLADE SPACERS

BLADE

BEVELED WASHER

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 recom mended range of 70 to 80 ft. lbs.

5.6 MOWER DRIVE BELT REPLACEMENT

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

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 fro m 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.

MOUNTING BOLT

5.6.1. ENGINE BELT REMOVAL

1. Remove mower drive belt cover.

2. Remove old belt.

FIGURE 5.6

Page 21

Section 5 - ADJUSTMENTS & REPAIR

5.6.2. ENGINE BELT REPLACEMENT

1. Route belt around blade pulleys and idler

pulley in same the 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.

BELT ROUTING

FIGURE 5.8

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 5.9.

4. Disconnect c ables from battery terminals, disconnecting BLACK (Negative) cable first, then disconnect RED (Positive) last. Retain mounting bolts and nuts.

BATTERY REMOVAL: DISCONNECT BLACK CABLE (NEGATIVE) FIRST, DISCONNECT RED CABLE (POSITIVE) LAST.

BATTERY INSTALLATION: CONNECT RED CABLE (POSITIVE) FIRST, CONNECT BLACK CABLE (NEGATIVE) LAST.

POSITIVE TERMINAL

TERMINAL

NEGATIVE TER MINAL

TERMINAL COVER MUST SHIELD POSITIVE TERMINAL AFTER INSTALLATION

FIGURE 5.9

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.

WARNING

Cables must be connected to batt ery terminals in t he proper position. RED (Positive) cable must go to the ( + ) terminal. BLACK (Negative) cable must go to the ( - ) terminal. If battery is removed, DO NOT operate engine without insulating Positive ( + ) battery cable terminal with electrical tape, or sparking from the battery cables can result.

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 terminal cover.

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)

Page 22

Section 5 - ADJUSTMENTS & REPAIR

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 chart on the next page shows the charge level as measured by syringe float hydrometer, digital voltmeter and five ball hydrometer.

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 p rev ent s metal f rom 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.

5.7.5. NEW BATTERY PREPA RA TION

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 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 recom mended 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, c heck 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 term inal (+) 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.

10. Install battery retainer and terminal cover.

Page 23

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

5.10.

REMOVE NUT

REMOVE BELT FROM SPINDLE

REMOVE BLADE BOLT

FIGURE 5.10

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.

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 5.11

Page 24

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

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 fuel.

4. Engine needs choking. 4. Move choke control to “CHOKE” position.

5. Spark plug wire disconnected. 5. Place spark plug wire onto spark plug.

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. Choke control in the “CHOKE” position. 2. Move choke control to “OFF” position.

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

4. Engine air pre-cleaner and or air cleaner dirty. 4. Clean free of all debris.

5. Spark plug defective or gap set improperly. 5. Service spark plug.

6. Fuel filter stopped up. 6. Replace fuel filter.

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. Engine cooling fins & air intake screen excessively dirty. 4. Clean cooling fins, air intake screen of all debris.

5. Spark plug faulty. 5. Service spark plug.

6. Water, debris or stale fuel in fuel system. 6. Drain and clean fuel system.

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

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.

4. Contact authorized SNAPPER dealer.

7. Contact authorized SNAPPER dealer.

idle. Then, turn key to “OFF”.

(Trouble Shooting Continued on Next Page)

Page 25

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 26

SERVICE SCHEDULE

ITEM SERVICE PERFORMED REF. EACH

Engine Oil

Air Pre-Cleaner

Air Cleaner Spark Plug Fuel Filter Engine Cooling

System Battery

Tires

Check Oil Level Page 10 Initial Oil Change Page 14

Periodic Oil Change Page 14-15 Clean Sponge Element Engine Manual Clean or Replace Engine Manual

Replace Engine Manual Replace Page 17 Clean Shroud & Fins Engine Manual

& Page 16

Check Electrolyte Page 21 & 22 Charge Battery Page 21

Testing Battery Page 22 Check Pressures Page 10

100

USE5HRS25HRS50HRS

X**

XXX

HRS

X**

EACH

SEASON

X 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

Check For Wear And Tension Check For Wear, Damage & Replacement Clean Debris Accumulation Clean Outside and Underside Grease or Oil Pages 15-16

Check Oil Level Page 16 Replace Filter Page 16 First Change at 200 Hours.

Page 15 Page 20 Page 15 Page 15

Thereafter every 500 Hours.

MAINTENANCE PARTS

4.8.1. MAINTENANCE/REPLACEMENT PARTS

MAINTENANCE PARTS

Mower Blades (52” Deck, Standard Lift) 2-9246 Mower Blades (52” Deck, Low Lift) 7-3395 Mower Deck Belt (52” Deck) 4-2776 Mower Blades (61” Deck, Standard Lift) 2-9251 Mower Blades (61” Deck, Low Lift) 7-3396 Mower Deck Belt (61” Deck) 3-5542 Upper Drive Shaft To Hydro Pump Belt 3-5544 (2) Deck Drive Shaft To Electric Clutch -Belt 3-5543 (2) Battery 3-5610

Page 27

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 f or 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 commer cial equipment have a three (3) year limited warranty against defec ts in material or workmanship or both.

All transportation costs incurr ed 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 requir ed during the first ninety (90) days from the original purc hase 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 p ermitted 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 damag es, so th e abo v e limitat ion o r 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 Registra tion Center, P.O. Box 1379, McDonough, Georgia. 30253

Page 28

PRIMARY MAINTENANCE

Page 29

PRIMARY MAINTENANCE

Page 30

PRIMARY MAINTENANCE

Page 31

PRIMARY MAINTENANCE

Page 32

Safety Instructions & Operator’s Manual for

OUT FRONT Z-RIDER ZERO TURNING 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).

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.

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.

WARNING

MANUAL No. 7-3699 (REV. 2, 8/29/01)

Snapper ZF5201M, ZF2501KH, ZF6101M User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual