Textron BOB-CAT 942208 Setup, Parts & Maintenance Manual Download Page 1 | Manualshive

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WARNING: If incorrectly used this machine can cause severe injury. Those who
use and maintain this machine should be trained in its proper use, warned of its
dangers and should read the entire manual before attempting to set up, operate,
adjust or service the machine.

2721543 REV00

SETUP, PARTS & MAINTENANCE
MANUAL ZT 220D SERIES

MODELS: 942208 ZT 220D 52" SIDE DISCHARGE

942209 ZT 220D 61" SIDE DISCHARGE

Operation & Safety Manual: 2721542

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Summary of Contents for BOB-CAT 942208

Page 1: ...trained in its proper use warned of its dangers and should read the entire manual before attempting to set up operate adjust or service the machine 2721543 REV00 SETUP PARTS MAINTENANCE MANUAL ZT 220...

Page 2: ...d and understand these manuals Treat your machine properly lubricate and adjust it as instructed and it will give you many years of reliable service Your safe use of this Bob Cat product is one of our...

Page 3: ...rom any party responsible for such unauthorized post manu facturemodificationsand oraccessoriesshouldper sonal injury and or property damage result This symbol means ATTENTION BECOME ALERT Your safety...

Page 4: ...trols 1 INSTALLSEAT a Position seat over seat plate and route seat wire W through hole H in seat plate Drop seat mount ing studs through seat plate holes Secure studs with four 5 16 18 whiz nuts and t...

Page 5: ...ce a level on the deck from front to rear If the level is too short to reach all the way from front to rear lay a straight edge on the deck first then place the level on the straight edge c Lay a 1 8...

Page 6: ...e for several hours Replace the battery in the machine and make the connections red to positive first then black ground to negative Read Operation and Safety Manual before starting If fuel tanks have...

Page 7: ...a m r o f n i l a n o i t i d d a r o f l a u n a m e n i g n e e h t t l u s n o C p u p o T k c e l C l e v e L l i O X s k a e L r o f k c e h C X e k a t n I r i A n a e l C n e e r c S X r e n a...

Page 8: ..._ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ _______________...

Page 9: ...ure Tires should be kept inflated at 14 lbs in2 1 0 kg cm2 Improper tire inflation can cause rapid tire wear and poor traction Uneven inflation can cause uneven cutting Fuel System Check filter bulb f...

Page 10: ...ings 2 points 4 Deck lift pivots 6 points 5 Hydro belt tensioner 1 point under engine deck 6 Brakeleverpivot 1point 7 Push arms 2 points located at rear of cutter deck under each fuel tank 8 Deck lift...

Page 11: ...ange the hydraulic fluid and hydraulic filter after each 500 hours of operation using the same procedure givenabove View from right side View from below machine NOTES Before servicing the hydraulic sy...

Page 12: ...ipstick Do not overfill See engine manual for oil specifications DAILY 1 Check oil level with the dipstick 2 If oil is needed add fresh oil of proper viscosity and grade See engine manual for oil spec...

Page 13: ...ted regularly and maintained Uneven running lack of power or black exhaust fumes may indicate a dirty air cleaner To clean or replace diesel engine air cleaner element 1 Unclamp end cover Y and remove...

Page 14: ...an oil cooler and radiator fins by opening latch L and rotating screen S forward 3 Wipe or brush off accumulated debris 4 Unclamp and raise radiator by opening latch H Using compressed air blow debris...

Page 15: ...Bob Cat blades Use of another manufacturer sbladesmaybedangerous BLADE BALANCE Blade balance must be maintained at 5 8 oz in 19 4 g cm or less Failure to keep blades balanced causes excess vibration w...

Page 16: ...s Loose or corroded cable terminals Chargerrelayfunction Electrical continuity Engine cranks but will not start Cold ambient temp Nofuel Fuel solenoid not activated Use glow plugs per recommendations...

Page 17: ...ut being turned off Engineoverheating Open wiring circuit Seeengine overheatingof troubleshooting section Replacefuse determinecause forburnedfuse and repair as required Seeengineoverheatingof trouble...

Page 18: ...ller adjustment HEIGHT OF CUT The height of cut is set by moving height of cut pin N to the hole designated for the height of cut desired To change the height of cut 1 Lift the deck to the highest pos...

Page 19: ...of the engine deck clears the push arm bracket on the rear of the cutter deck when the cutterdeck is raised to the trans port position Adjust the rod end length to 1 7 16 37 mm to start If any additi...

Page 20: ...ding the brake DECK LEVELING AND COUNTERBALANCE SPRINGS Side Discharge The front of a side discharge deck should be slightly lower than the rear Mulching The front of a mulching deck should be slightl...

Page 21: ...the turnbuckle until the corresponding wheel stops turning Lock the turnbuckle jam nuts Run the engine up to high idle to check the adjustment Readjust if necessary 7 Repeat steps 5 and 6 for the oppo...

Page 22: ...the idler arm and use the ratchet to rotate the idler assembly enough to remove the belt Remove the belt from the idlers and center cutter deck pulley Push belt back under engine deck 3 Remove old bel...

Page 23: ...einstall engine cutterdeck belt see engine cutterdeck belt replacement CUTTERDECK BELT 1 Set the cutterdeck in the lowest height of cut position 2 Remove the engine cutterdeck belt from the deck idler...

Page 24: ...eutral lock position The operator may leave the seat with the engine running if the parking brake is on the PTO blades is off and the traction levers are in the neutral lock position A time delay elim...

Page 25: ...r D e v l a V r o t a u c a v E M E T S Y S G N I G R A H C d e t a l u g e r p m a 0 2 Y R E T T A B 1 U p u o r g I C B S E S U F 0 3 0 2 0 1 e e r h T e d a l b p m a L E U F N O I T P M U S N O C...

Page 26: ...25 ZT 200 Series SPECIFICATIONS...

Page 27: ...to without searching from operator position S K C E D R E T T U C R E B M U N L E D O M 8 0 2 2 4 9 9 0 2 2 4 9 E P Y T e g r a h c s i D e d i S e g r a h c s i D e d i S H T D I W G N I T T U C m c...

Page 28: ...m N s b l t f 0 4 2 1 2 9 0 5 6 1 2 2 1 0 4 7 1 9 2 1 0 3 3 2 2 7 1 8 2 4 1 m N s b l n i 6 9 5 8 3 1 1 5 1 1 5 3 1 0 2 1 4 8 1 3 6 1 1 1 8 5 m N s b l t f 0 3 5 1 3 1 1 0 4 0 2 1 5 1 0 5 1 2 9 5 1 0...

Page 29: ...7 9 45 29 22 20 12 8 12 9 11 30 12 6 44 44 48 46 5 50 41 37 20 42 53 4 2 48 9 7 2 WA RN ING 34 10 TRAY BATTERY 3 48 35 52 17 32 56 39 57 57 38 43 56 57 51 19 17 58 59 59 40 36 42 17 9 GROUND WIRE FRO...

Page 30: ...SPRING COMPRESSION 2 1 28 2721246 DAMPENER 2 1 29 2186168 7 WLDMT TRACTNCTRLRH 1 2186167 7 WLDMT TRACTNCTRLLH 1 1 30 64237 05 LOCKNUT NYLONM8 1 25 8 1 31 38369 01 RODENDBALLJOINT 2 1 32 2182427 7 HOLD...

Page 31: ...14 21 16 19 15 30 1 2 3 28 27 29 SUNDSTRAND HYDROGEAR PUMP 25 1 14 5 BELT DETAIL 1 9 7 6 34 36 35 33 37 38 37 36 37 39 37 40 10 32 28 41 42 5 4 26 12 11 TORQUE CRANKSHAFT BOLT 26 TO 50 FT LBS 10 8 31...

Page 32: ...18 GA 1 2 18 65103A BEARING BUSHING 1 2 19 33148 01 SPACER 1 2 20 38219 SPRING TENSION 1 2 21 64006 03 LCKWSHR HELICAL 3 8 1 2 22 64123 21 BLT HEX3 8 24X11 4 1 2 23 2720996 S ENGINE DECK W LABS 1 2 2...

Page 33: ...20D Series TO KICKPLATE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 6 6 6 2 14 6 2 7 19 7 3 7 19 6 3 8 20 5 20 19 19 7 7 20 21 25 22 23 25 25 19 19 7 7 27 28 FIGURE 3 CRADLE A...

Page 34: ...3 11 2183052 ROD LIFT 2 3 12 85010N ZERKSTRAIGHTFTTG 1 3 13 2188133 SPRING COMPRESSION 2 3 14 2188165 MAT ANGLE 2 3 15 2188164 MAT UPPER 1 3 16 2188228 MAT PLATFORM 1 3 17 32418 03 7 HANDLEW SLOT 1 3...

Page 35: ...startingandenginedamage transporting toprevent Closefuelvalvebefore IMPORTANT flooding bolt location Bracket Top Antiscalp Roller 2000699 higher 3 2 1 14 p s i 1kg cm Height of Cut Pressure Tire 2 1 2...

Page 36: ...ILL 1 4 6 2721060 LABEL CONTROLPANEL 1 4 7 2000693 LABEL PARK BRAKE 1 4 8 2000698 LABEL DBL FUEL LEAKS 2 4 9 2000705 LABEL TIRES 1 4 10 2000700 LABEL RHTRACTION 1 4 11 2000701 LABEL LHTRACTION 1 4 12...

Page 37: ...36 ZT 220D Series 4 4 4 7 5 5 4 7 5 4 5 5 5 4 1 3 6 2 FIGURE 5 BUMPER...

Page 38: ...0D Series 5 1 2721325 7 BUMPER UPPER 1 5 2 2720996 S ENG DECK W LABS 1 5 3 2721324 7 WLDMT BUMPER 1 5 4 A1104057 BLT METRICM10 1 5X25 14 5 5 64237 03 LOCKNUT NYLONM10 1 5 14 5 6 2182442 7 BRACE VERTIC...

Page 39: ...38 ZT 220D Series 31 17 32 175 FT LBS TORQUE 14 TO 19 10 34 33 14 3 23 24 1 11 27 5 29 30 18 29 27 22 28 26 26 27 28 10 2 17 16 19 25 21 27 7 12 8 6 4 20 9 13 15 FIGURE 6 BRAKES REAR WHEEL...

Page 40: ...8155 GRIP 1 4X1X41 2 1 6 19 2183063 01 SPACER 32MM LONG 8 6 20 2188149 HUB WHL DISC 2 6 21 85010N STRAIGHTZERKFITTING 1 6 22 64144 34 SNAP RING 50 1 6 23 2188145 BRG 75IDBRNZSLFALIGN 2 SERVICEPARTSFOR...

Page 41: ...40 ZT 220D Series 7 13 14 13 11 5 3 2 7 4 13 12 13 7 13 13 1 8 10 9 13 14 6 6 11 8 10 6 6 12 7 13 7 5 13 13 9 13 7 7 16 15 15 FIGURE 7 HYDRAULICS...

Page 42: ...HIGH TEMP HOSE 2 50 FT 7 8 2188157 01 HOSE HYD ORB 37 22 38 2 7 9 2188157 02 HOSE HYD ORB 37 25 00 2 7 10 2188126 01 MOTOR ASSYHYD 2 7 11 158058 07 FTG 90BARBADJ 2 7 12 58026 01 3 WAY CONNECTOR 3 8 2...

Page 43: ...42 ZT 220D Series FIGURE 8 HYDROGEAR PUMP...

Page 44: ...08GRTASY 1 8 8 38345 08 S SUN9004101 1340OR 1 8 10 38345 10 S SUN9007375 0035SHS 2 8 18 38345 09 S SUNJ1030673SHAFT 1 8 32 188059 11 SSWPLT VAR2003087 1 8 37 188059 15 SARMTRUNN2003005 1 8 38 188059 9...

Page 45: ...153 SWITCH CLUTCH 1 9 12 2721337 CLUTCH 1 INCLUDESITEM27 9 13 2188172 HARNESS JUMPER 2 9 14 108208 SWITCH DBLPOLE 3 9 15 2720886 TEMP GAUGE 1 9 16 2720887 TEMP SENDER 1 9 17 2198089 LAMPHOLDER 1 INCLU...

Page 46: ...16 ORG BLK 16 RED 16 RED 16 GRN BLK 16 YEL BLU 16 87A 85 87 86 TIMER BLK 16 BRN GRN 16 YEL 14 GRN BLK 16 BRN 16 BRN 16 BRN 16 BLK 16 BLK 16 RELAY STARTER 86 85 87 87A 85 30 86 87 87A 30 85 RELAY 86 SO...

Page 47: ...1 20 3 19 23 4 22 12 25 12 12 24 12 7 8 5 28 11 10 9 27 1 6 18 16 BLEEDING FUEL BASIN WHEN LINE FUEL RETURN TO CATCH SYSTEM FROM TO FUEL FILTER 9 17 16 41 43 42 38 29 39 40 29 39 26 33 12 12 32 31 33...

Page 48: ...004 WASHER M10 8 10 22 2188161 VALVE TANKSELECTOR 2 10 23 48016 11A HOSE1 4IDX1 2ODX24 0 1 10 24 48016 11A HOSE1 4IDX1 2ODX22 0 1 FIGURE 10 FUEL TANKS CONTROL PANEL 2721543 10 30 44 13 45 15 3 16 14 1...

Page 49: ...48 ZT 220D Series FIGURE 11 RADIATOR SCREEN AIR FILTER 2 1 3 5 6 7 8 8 9 9 10 11 12 13 12 10 16 14 15 17 18 19 20 19 21 22 23 4 24 8 8 25 26 27...

Page 50: ...PS 4 12 11 38382 SWITCH N O 1 12 12 64152 46 SCR SLTHH10 24X1 2 4 12 13 2721624 7 BRKT RADIATORSWITCH 1 12 14 2218076 LATCH OVERCENTER 2 12 15 64152 20 8 32X1 2MACHSCREW 4 12 16 64025 29 NUT HEX 8 32K...

Page 51: ...26 21 22 22 21 26 25 23 4 5 20 26 23 25 27 TO RESEVOIR 8 7 29 30 23 25 26 19 9 9 28 16 16 28 9 9 24 18 15 14 13 12 11 17 3 6 1 18 17 23 25 10 2 18 25 31 32 17 17 34 35 36 36 33 35 36 33 36 38 37 39 FI...

Page 52: ...12 18 64205 038 BLT METRICM6 1 00X20 6 12 19 2721570 7 PLATE RADIATORMTG 1 12 20 64229 01 LOCKNUT NYLON1 4 20 4 12 21 2721803 S COOLER BRKT W LABEL 2 INCLUDESITEM22 12 22 365956 LABEL WRNGRADIATOR 2...

Page 53: ...52 ZT 220D Series 5 14 2 3 1 4 6 7 8 9 10 11 12 13 TO REAR CROSSBAR ON ENGINE DECK WELDMENT BRACKET ON ENGINE DECK WELDMENT 15 17 18 19 17 17 16 20 FIGURE 13 SEAT ASSEMBLY ROPS...

Page 54: ...7 2720975 04 SLIDERAIL ADJ 1 13 8 2720975 03 SLIDERAIL SLAVE 1 13 9 158136 WIRE SEATSWITCH 1 13 10 2182391 7 PLATE SEAT 1 13 11 64141 6 NUT WLF5 16 18 4 13 12 2183069 ROD PROP 1 13 13 64168 2 HAIRPIN...

Page 55: ...T 220D Series FIGURE 14 STEERING DECK LIFT 8 5 15 7 6 14 18 16 16 12 15 13 9 10 1 15 11 3 2 35 27 15 30 38 30 17 33 39 21 23 29 37 21 31 22 34 26 21 18 14 32 40 18 4 20 41 25 36 24 15 42 15 36 15 4 28...

Page 56: ...04057 BLT METM10 1 5X25 3 14 19 2183073 SPACER 6 14 20 2721076 7 WLDMT CRADLE 1 14 21 64168 2 HAIRPINCOTTER 4 14 22 2720551 7 WLDMT DECKLIFTLEVER 1 14 23 2720511 7 WLDMT LVRSTOPLATCH 1 14 24 2720517 7...

Page 57: ...56 ZT 220D Series FIGURE 15 CRADLE CASTER ASSEMBLY 17 17 16 17 17 16 3 7 6 8 9 5 7 19 17 18 20 19 22 4 13 11 12 2 10 1 14 23 24 15 15 25...

Page 58: ...RIM 1 15 10 64163 64 WASHER 0 766IDX1 625 6 15 11 64229 07 LOCKNUT NYLON3 4 10 2 15 12 85010N ZERK 1 4 28 STR SLF THD 9 15 13 2720474 SPACER CASTERHUB 2 15 14 2721307 DUSTCOVER 2 15 15 48043 04C SCON...

Page 59: ...26 51 44 8 10 10 55 39 56 14 26 6 38 11 8 46 57 23 21 22 18 48 59 42 51 61 51 62 6 26 9 63 60 51 10 26 70 FT LBS TORQUE TO 45 21 12 43 11 9 31 20 47 7 14 27A 9 61 6 52 52 15 53 31 19 14 27 38 31 17 61...

Page 60: ...DL 1 INCLUDES ITEMS 33 37 16 27A 2186205 ASSY TOPMNTSPNDL 2 INCLUDES ITEMS 33 37 16 28 2186185 7 WLDMT PUSHBAR 2 16 29 64006 05 LCKWSHR HELICAL 1 2 1 16 30 64123 05 BLT HEX 1 2 20X1 1 2 1 16 31 64163...

Page 61: ...60 ZT 220D Series FIGURE 17 BELTS 4 2 3 1...

Page 62: ...ON QTY ITEM PARTNO DESCRIPTION QTY ZT 220D Series FIGURE 17 BELTS 2721543 17 17 1 2188176 BELT CUTTERDECK 54 1 17 2 2188134 BELT PTO 1 USE ON 54 SD DECK 17 3 128003 BELT CUTTERDECK 1 17 4 2720881 BELT...

Page 63: ...62 ZT 220D Series FIGURE 18 DECALS CUTTERDECKS 1 4 3 2...

Page 64: ...TION QTY ITEM PARTNO DESCRIPTION QTY ZT 220D Series FIGURE 18 DECALS CUTTERDECKS 2187164 18 1 2000572 LABEL WARNINGBLADES 1 18 2 2000577 LABEL WARNING 2 18 3 2000696 LBL BLADE INSTALL 1 18 4 2000677 L...

Page 65: ...ARNING 18 2 2000590 LABEL WARN BATTERY 4 4 2000677 LABEL DANGER WARNING 18 4 2000691 LBL HYDR OIL FILL 4 5 2000693 LBL PARK BRAKE 4 7 2000695 LBL WARN USING 3 27 2000695 LBL WARN USING 4 14 2000696 LB...

Page 66: ...SWITCH RETAINER 10 30 2188188 PULLEY 4 25 2 5 2188228 MAT PLATFORM 3 16 2191000 7 SPINDLE HOUSING 16 33 2198088 LENS BATTERY 9 23 2198089 LAMPHOLDER DUAL 9 17 2198092 CABLE BATTERYNEGATIVE 9 7 2198096...

Page 67: ...2721646 HINGE 50 8X470 12 13 2721661 7 PLATE BACKING 12 11 2721662 BARRIER AIR FLOW 12 12 2721803 S COOLER BRKT W LABEL 12 21 2721806 CAP FUEL DIESEL 3 5 10 6 2721894 CLUSTER WARNINGLIGHT 10 45 272193...

Page 68: ...5 16 45 64123 21 BLT HEX3 8 24X1 1 4 2 22 64123 215 BOLT HEX3 4 10X71 2 15 4 64123 50 BLT HEX3 8 16X1 16 40 64123 54 BLT HEX5 16 18X3 4 2 38 64123 89 BLT HEX1 4 20X3 4 12 23 64139 02 BLT WLF1 4 20X1...

Page 69: ...1 54 64237 02 LOCKNUT NYLONM6 1 00 2 42 64237 02 LOCKNUT NYLONM6 1 00 10 39 64237 02 LOCKNUT NYLONM6 1 00 12 17 64237 02 LOCKNUT NYLONM6 1 00 16 41 64237 03 LOCKNUT NYLONM10 1 5 1 12 64237 03 LOCKNUT...

Page 70: ...om this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm California Advertencia de la Proposicion 65 El estado de California hace sa...

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