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ZTR 800X Series

Snapper ZTR 800X Series, 5901236, 5900658, 5900654, 5900656 Dealer Setup & Adjustment Instructions Manual

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Not for
Reproduction
800X Series Zero-Turn Rider - 61” & 72” Mower Deck
Dealer Setup & Adjustment Instructions
800X Series Zero-Turn Rider • 61” & 72” Mower Deck
This Dealer Setup Instruction covers the following products:
Model No. Description Model No. Description
5900654 S800XB31 5901236 F800XB31
5900658 S800XKAV28
ZTR
5900656 S800X/61 5901237 F800X/61
5900875 S800X/72 5901238 F800X/72
Mower
Deck
ATTENTION SETUP PERSONNEL:
The safety warnings provided in this guide and in the operator’s manual included with the unit contain important information that must be obeyed when assembling, setting-up, operating,
servicing, transporting, or storing the unit.
These warnings are highlighted by the safety alert triangle symbol shown above, which signifies that an important safety message is being provided.
You must read, understand, and follow these warnings and instructions, and use safe shop and work practices at all times while working on or around this unit and all other outdoor power equipment.
A Quick Setup List is provided on page 2 of this booklet to help you identify and check that the items have been performed.
Additional information concerning functional tests, general adjustment procedures, and the location of normal lubrication points are included in these instructions.
Although all required lubrication and normal adjustments on factory-assembled components are done at the factory, this additional information is provided to assist you in ensuring that each unit is delivered to the customer in proper working order.
TABLE OF CONTENTS:
SETUP PROCEDURES
Quick Setup List..................................................2
Uncrating ..........................................................3
Connect the Battery..............................................3
Tractor Assembly ................................................4
Ground Speed Control Lever Assembly ...........................4
Seat Assembly ..................................................................4
Roll Bar Assembly ...............................................5
Check Fluid levels ...............................................7
Check Engine Oil Level .....................................................7
Check Hydraulic Oil Level .................................................7
Check Tire Pressure .............................................7
Mower Assembly.................................................8
Check Torque - Mower Blades .........................................8
Check Deck Drive Belt ..........................................9
Check the Mower Belt Idler Tensioning Spring
Length (72” Models Only) ................................................9
Adjust the Mower Belt Idler Tensioning Spring
Length (72” Models Only) ................................................9
Install the Mower Deck .......................................10
Adjust Deck Lift Rod Timing .................................12
Check & Level the Mower Deck .............................13
Deck Lift Spring ................................................ 14
Lubrication ...................................................... 15
Adding Fuel ..................................................... 17
Starting The Engine ........................................... 17
Perform Safety Checks ........................................ 18
Functional Tests .............................................................18
Safety Interlock System .................................................18
ADJUSTMENT PROCEDURES
Seat Adjustment ............................................... 19
Ground Speed Control Lever Adjustment ..................20
Speed Balancing Adjustment ................................20
Neutral Adjustment ............................................ 21
Return-To-Neutral Adjustment ............................... 22
Parking Brake Adjustment .................................... 23
5101742
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Rev. J
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Not for
Reproduction
800X Series Zero-Turn Rider - 61” & 72” Mower Deck
Setup Procedures
Quick Setup List
Page Setup Procedure Steps to Perform
3 Uncrating
3 Connect Battery Cables
4 Tractor Assembly
5 Roll Bar Assembly
7 Check Fluid Levels
8 Check Mower Assembly
10 Install the Mower Deck
15 Lubrication &
Fuel Preparation
18 SAFETY CHECK
Register Product
Remove Crate & Banding.
Loosen Hydraulic Release Valves.
Release Parking Brake and Roll Tractor forward off skid.
Tighten Hydraulic Release Valves
Connect Battery Cables.
Assemble the Ground Speed Control Levers.
Assemble the Seat.
Assemble the Retainer Pins.
Assemble the Top Loop.
Install the Roll Bar.
Check Engine Oil Level.
Check Hydraulic Oil Level.
Check Tire Pressure.
Check Blade Bolt Torque.
Check Deck Drive Belt.
Install the Mower Deck.
Positioning the Mower Deck for Operation.
Check Deck Lift Rod Timing Adjustment.
Check & Level the Mower Deck.
Lubricate all grease & oil points.
Add fuel.
Start the Engine.
Check for loose hardware.
Check all operator controls.
Perform safety interlock system check.
To register the product: log onto www.thepowerportal.
com, select the appropriate brand, click “My Resources,” select the “Product Registration and Rebate” icon and then the “New Product Registration / Rebate” tab. Fill out and submit the online product registration form.
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800X Series Zero-Turn Rider - 61” & 72” Mower Deck
Uncrating
1. Using a reciprocating utility saw or equivalent, cut the crate away from the bottom skid. Remove the crate. Remove the shrink-wrap plastic.
2. Cut the nylon banding that secures the unit to the crate.
NOTICE
When cutting the crate from the bottom skid, use caution around the tires and the mower rollers.
3. Locate the hydraulic release valves (A, Figure 1) on the bottom side of the hydraulic pumps.
4. Open the hydraulic release valves. To open the release valves, turn the release valve counter-clockwise two (2) full turns MAXIMUM See Figure 1 for valve location.
5. Push down on the parking brake lever (A, Figure 2) to release the parking brake.
6. Be sure there are no nails or sharp objects on the bottom skid to puncture the machine’s tires. Roll the machine forward off the bottom skid.
7. After moving the tractor, re-engage the pumps (drive position) by turning the release valves clockwise and tighten to 80-120 in/lbs (9-13.5 Nm). See Figure 1 for valve location.
Connect Battery Cables
A
Figure 1. Hydraulic System By-Pass A. Hydraulic Release Valve (right-hand pump shown)
A
Figure 2. Disengaging the Parking Brake (lever shown in disengaged position) A. Parking Brake Lever
WARNING
Battery acid can cause severe burns. Wear protective gear when handling the battery.
Open flames and sparks can cause the battery to explode.
BATTERY SAFETY RULES:
• Battery acid causes severe burns. Avoid contact with skin.
• Wear eye protection when handling the battery.
• To avoid an explosion, keep flames and sparks away from battery, especially while charging.
• When installing the battery cables, CONNECT THE POSITIVE (+) CABLE FIRST and negative (-) cable last. If not done in this order, the positive terminal can be shorted to the frame by a tool.
1. Connect the red positive battery cable (B, Figure 3) to
the positive battery post.
2. Connect the black negative battery cable (A) to the
negative battery post.
A
B
Figure 3. Battery Compartment A. Positive Battery Cable B. Negative Battery Cable
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800X Series Zero-Turn Rider - 61” & 72” Mower Deck
Tractor Assembly
Ground Speed Control Lever Assembly
1. Remove the ground speed control lever and mounting hardware from the handle bar box.
NOTE: There is a LEFT-HAND and a RIGHT-HAND ground speed control lever . When assembled to the control lever mount, the control lever base should be pointing towards the rear of the machine as shown in Figure 4.
2. Install the ground speed control levers (A, Figure 4) onto the control lever mount (C) using the 5/16-18 x 1” bolts, 5/16” lock washers and 5/16” flat washers (B). Prior to tightening the bolts, align the levers with each other (see Ground Speed Control Lever Adjustment).
Seat Assembly
1. Unpack the seat.
2. Install the seat onto the seat mount plate and secure with the 5/16-18” nylock flange nuts (A, Figure 5).
A
B
C
Figure 4. Ground Speed Control Lever Installation A. Ground Speed Control Lever B. 5/16-18 x 1” Bolt(s), 5/16” Lock Washer(s) & 5/16” Flat Washer(s) C. Control Lever Mount
A
4
A
Figure 5. Install the Seat & Connect the Harness A. 5/16-18” Nylock Flange Nuts
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800X Series Zero-Turn Rider - 61” & 72” Mower Deck
Roll Bar Assembly
Assemble Retainer Pins
1. Unpack the roll bar and hardware from the box.
2. Assemble the foam ring (A, Figure 6) onto the retainer pin (B).
3. Loop the snap end of the lanyard (C) through the retainer pin handle and snap together.
4. Install the lanyard anchor (D) onto the lanyard.
5. Install the clevis pin (E) onto the loop end of the lanyard as shown in Figure 6.
Assemble the Top Loop
1. Install the plastic cap (B, Figure 7) into the end of the top loop tube (A). Repeat for other end of tube.
2. Make sure the rubber stop (C) is properly seated against the inside of the pivot mount. See Figure 7.
C
Snap End
B
Figure 6. Assemble the Retainer Pins A. Foam Ring B. Retainer Pin C. Lanyard D. Lanyard Anchor E. Clevis Pin
A
D
A
Loop End
E
B
C
Install the Roll Bar
1. Make sure the roll bar sockets (A, Figure 8) are clear of any obstructions, wires, foreign objects, etc.
2. Install the roll bar upright tubes (B) into the sockets. Loosely Install the 1/2-13 X 3-1/4” hex head bolts and 1/2-13 hex side lock nuts (C).
3. Repeat steps 1 and 2 for the other side of the machine.
Figure 7. Assemble the Top Loop A. Top Loop Tube B. Plastic Cap C. Rubber Stop
B A C
Rear View
B
Figure 8. Install the Upright Tubes A. Roll Bar Sockets B. Upright Tube C. 1/2” x 3-1/4” Bolt, 1/2” Flat Washer & 1/2” Nylock Flange Nut (not shown)
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800X Series Zero-Turn Rider - 61” & 72” Mower Deck
4. Install the top loop (A, Figure 10) onto the upright tubes (B). From the outside, install the 1/2” x 3-1/4” bolt (C) through the retainer pin assembly (D), then through the top loop and upright tube and shown in FIgure 10. Loosely install the 1/2” side lock nut (E). Repeat for other side.
5. Tighten the hardware securing the upright tubes to the frame (see Figure 8). Torque the hardware to 75 ft. lbs. (102 Nm).
6. Tighten the 1/2” x 3-1/4” bolts and hex side lock nuts (C & E) securing the top loop (A) to the upright tubes (B). Do not over-tighten. The top loop should pivot snugly with the retainer pins removed.
7. Raise the top loop (A) until the rubber stops (F) contact the upright tubes.
8. Push or pull the top of the roll bar forward against the rubber stops and install the retainer pins and hair pin clips to secure the roll bar in the raised position.
Figure 9. Upright Tube Orientation
A
F
B
Figure 10. Install Top Loop A. Top Loop B. Upright Tube C. 1/2” x 3-1/4” Bolt GD.5 D. Retainer Pin Assembly E. 1/2” Side Lock Nut F. Rubber Stop
C
A
D
D
C
D
E
B
E
B
C
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800X Series Zero-Turn Rider - 61” & 72” Mower Deck
Check Fluid Levels
Check Engine Oil Level
1. Raise the hood to gain access to the engine oil dipstick.
2. Use the engine oil dipstick (A, Figure 11) to check the engine oil level. If necessary add engine oil through the crankcase oil fill (B). Check the engine manufacturer’s owner’s manual for oil recommendations.
Check Hydraulic Oil Level
1. Raise the hood to gain access to the hydraulic oil reservoir.
2. Before removing the reservoir cap, make sure the area around the reservoir cap and the fill neck of the reservoir is free of dust, dirt, or other debris.
3. Unscrew the reservoir cap (B, Figure 12).
4. Look down the filler neck of the hydraulic oil reservoir (A) and observe the oil level. When cold, the oil level should be approximately 4” (10 cm) below the top of the filler neck.
5. If necessary, add either Mobil 1™, 15W-50 synthetic oil or Castrol Syntec™ 5W-50 oil. DO NOT use conventional oils.
6. Reinstall the reservoir cap.
B
A
Figure 11. Check Engine Oil Level (Unit Shown With Hood Raised) A. Engine Oil Dipstick B. Crankcase Oil Fill
B
A
Check Tire Pressures
Tire pressure should be checked periodically, and maintained at the levels shown in the chart. Note that these pressures may differ slightly from the “Max Inflation” stamped on the side-wall of the tires. The pressures shown provide proper traction, improve cut quality, and extend tire life.
Tire
Deck Caster Tires 25 psi (1,03 bar)
Drive Tires 10 psi (0,69 bar)
Tractor Caster Tires
Pressure
25 psi (1,03 bar)
Figure 12. Checking Hydraulic Oil Level A. Hydraulic Oil Reservoir B. Reservoir Cap
Figure 13. Checking Tire Pressure
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800X Series Zero-Turn Rider - 61” & 72” Mower Deck
Check Mower Assembly
Check Torque - Mower Blades
WARNING
Avoid injury! Mower blades are sharp.
• Mower blades are sharp. For your personnal safety, do NOT handle mower blades with bare hands.
• Careless or improper handling of blades may result in serious injury.
• Blade mounting bolts must each be installed with a flat washer then securely tightened. Torque blade mounting bolts to 120 ft.lbs (163 Nm).
1. Check that blades are installed with the tabs pointing up towards the deck as shown in Figure 14. Torque bolts to 120 ft.lbs. (63 Nm).
B
A
D
TIGHTEN
Figure 14. Tightening the Mower Blade for Installation A. Mower Blade Mounting Bolt B. Flat Washer C. Mower Blade Air Lift (Points Up) D. 4 X 4 Wooden Block
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