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117592

toc-1

REV C

Table of Contents

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-1

Service Program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-1

Maintenance Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-1

Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-1

Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-1

Safe Servicing Practices  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-1

Pre-Operation Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-1

Operation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-2

Operate Machine Safely. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-2

General Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . .  2-2

Maintenance Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-2

Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-1

Standard Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-1

Special Torques   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-1

Power Unit Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-1

Steering Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-1

Park brake adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-4

Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-5

Hydraulic Pump Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . .  4-5

Hydraulic system  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-6

Test Procedure for DDC20 Pump  . . . . . . . . . . . . . . . . . . . . . . .  4-7

New or Rebuilt DDC20 Pump Startup Procedure  . . . . . . . . . . .  4-8

Warner Clutch Re-gap Adjustment Procedures . . . . . . . . . . . .  4-11

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-12

Engine Maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-1

General Engine Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . .  5-1

Engine Oil and Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-1

Engine Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-1

Carbon canister  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-3

Fuel evaporation system filter  . . . . . . . . . . . . . . . . . . . . . . . . . .  5-3

Fuel & evaporative system line routings. . . . . . . . . . . . . . . . . . .  5-3

Engine RPM Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-5

Deck Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-1

Deck Leveling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-1

Blades  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-3

Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-4

Deck Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-4

60”, 66” & 72” Side Discharge Deck Belt Routing & Tensioning   6-6

60” Rear Discharge Deck Belt Routing & Tensioning  . . . . . . . .  6-7

Содержание Super Z HD

Страница 1: ...117592 REV C Super Z HD General Service Manual 200 South Ridge Road Hesston Kansas 67062...

Страница 2: ...contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm NOTICE OF REQUIREMENT OF SPARK ARRESTER MUFFLER This equipment may create sparks that can...

Страница 3: ...ment 4 4 Belts 4 5 Hydraulic Pump Belt Adjustment 4 5 Hydraulic system 4 6 Test Procedure for DDC20 Pump 4 7 New or Rebuilt DDC20 Pump Startup Procedure 4 8 Warner Clutch Re gap Adjustment Procedures...

Страница 4: ...oning 6 8 Electrical 7 1 Electrical Schematic Kawasaki 7 1 Electrical Schematic Kawasaki 7 2 Electrical Schematic Kawasaki DFI 7 3 Electrical Schematic Briggs Stratton 7 4 Maintenance 8 1 Maintenance...

Страница 5: ...grease oil and dirt especially in the engine compartment and under the seat platform areas minute dust particles are abrasive to close tolerance engine and hydraulic assemblies Daily inspect mower for...

Страница 6: ...REV C 1 2 117592...

Страница 7: ...ts or plastic truck bed liners Always place fuel containers on the ground away from your vehicle before filling When practical remove gas or diesel fuel powered equipment from the truck or trailer and...

Страница 8: ...der the deck make certain engine cannot be accidentally started Shut engine off remove ignition switch key and disconnect negative bat tery cable for maximum safety Except when changing or checking be...

Страница 9: ...te may overflow and damage paint wiring or structure When cleaning the battery use soap and water Be careful not to get soap and water into the bat tery Clean the battery terminals with a solution of...

Страница 10: ...REV C 2 4 117592...

Страница 11: ...l this fastener SIZE FT LBS N M SIZE FT LBS N M 10 32 4 IN LBS 3 6 M3 12 IN LBS 1 3 250 98 4 IN LBS 11 1 M4 26 4 IN LBS 3 312 204 IN LBS 23 M5 54 IN LBS 6 1 375 30 40 M6 92 4 IN LBS 10 4 438 48 65 M8...

Страница 12: ...REV C 3 2 117592...

Страница 13: ...ble for this mower On one seat you will disconnect the mower harness directly from the set switch as shown in Figure 4 1 On the other seat you will disconnect the wire harness from the two connectors...

Страница 14: ...make the first adjustment the mower engine must not be running 2 Check to make sure the steering control levers are against the stops before the pumps are bottomed out internally 3 To do this gently a...

Страница 15: ...ers in the park brake position disengage deck clutch remove ignition switch key and disconnect negative battery cable before doing any adjustments 2 Place the steering control lever in the neutral pos...

Страница 16: ...half to one revolution Figure 4 12 6 Try and rotate the tire by hand The tire should rotate Remember hydraulic oil resistance will prevent the tire from rotating freely even with the bypass valves op...

Страница 17: ...run against the bottom of the groove Replace the pulley when this is the case otherwise the belt will lose power and slip excessively Never pry a belt to get it on a pulley as this will cut or damage...

Страница 18: ...he threads are right hand Hydraulic oil heat exchanger The Super Z HD is equipped with a hydraulic oil heat exchanger The heat exchanger coils must be kept clean to insure that the hydraulic oil is op...

Страница 19: ...il supply lines from the motor and loosen supply lines at the pump One wheel motor fitting may need to be removed to assist with test line installation Cap the wheel motor ports or fittings 6 Test pro...

Страница 20: ...seat switch This must be completed so that the safety circuit is functioning properly Figure 4 1 2 Remove Hustler Pressure Test Gauge Kit 3 After all repairs are completed check to make sure all tool...

Страница 21: ...rs in the neutral position 9 Set engine throttle to the half throttle position 10 Start engine Run at idle for 30 seconds 11 Stroke steering control lever to the forward position NOTE If wheel motor d...

Страница 22: ...27 14 Check to make sure all tools or obstructions are removed Figure 4 25 Prefill pump here Right side pump Prefill pump here Left side pump WARNING Do not operate the mower without plugging the mowe...

Страница 23: ...an 070 then follow the troubleshooting procedure outlined in Warner Electric P1177 installation troubleshooting guide available on Warner Electric s web site www Warnerelectric com If the air gap is o...

Страница 24: ...bleshooting guide available on Warner Electric s web site www Warnerelectric com and consult owner s manual Tires It is important for level mowing that the tires have the same amount of air pressure T...

Страница 25: ...minutes for engine oil to adequately drain 4 After oil is drained close the valve by twisting it clockwise 5 Clean up any spilled oil IMPORTANT All oil drips or spills must be cleaned off of the exha...

Страница 26: ...any manner because the condition of the filter after servicing is completely out of the filter manufacturer s control Therefore on a dust ingested engine failure there will be no warranty considerati...

Страница 27: ...tings There are two rubber hoses that are connected to the fuel tanks One is the fuel hose that is part of the fuel system The other is the vapor line that is part of the fuel evaporative system The f...

Страница 28: ...REV C 5 4 117592 Figure 5 9 Fuel evaporation system filter Vapor line Fuel tank Fuel tank Carbon canister Carbon canister...

Страница 29: ...le 922222 no extension 922222 EX 922222 CE 922222 US Kawasaki FX850 FX1000 ENGINE SPEED MODEL NO ENDING WITH HIGH IDLE MODEL NO WITHOUT EXTENSION 3600 RPM MODEL NO WITH EX EXTENSION 3600 RPM MODEL NO...

Страница 30: ...REV C 5 6 117592...

Страница 31: ...against the stop handle Rear Discharge Decks all Place the height stop in the 3 25 82 6mm hole with the plate side of the height adjusting stop against the stop handle 5 Clamp the height adjusting sto...

Страница 32: ...ake sure that there is still slack in the chain If not loosen the two nuts on the block holding the threaded rod until there is slack in the deck lift chain 21 Tighten the appropriate nut until the ch...

Страница 33: ...eplace any distorted blade Do not re use spindle bolts which have stripped worn or undercut threads Torque bolts on spindles to 118 foot pounds 160 0 N m when reinstalling blades Properly compressed c...

Страница 34: ...means of a tension idler and spring The spring tension should be such that the belt does not slip under normal operating load conditions assuming the belt is not excessively worn or damaged As the bel...

Страница 35: ...117592 6 5 REV C Figure 6 13 Figure 6 14 Spring chain Spring chain anchor point Idler spring 60 Rear Discharge Deck Spring chain Spring chain anchor point Idler spring 72 Rear Discharge Deck...

Страница 36: ...he different decks shown 1 Spring length after tensioning new belt Measured from outside of hook to outside of hook with deck set at 3 8 2 6mm cut height 2 Route belt as shown 60 66 72 Side Discharge...

Страница 37: ...117592 6 7 REV C 60 Rear Discharge Deck Belt Routing Tensioning Figure 6 16 9 3 10 3 23 6 26 2cm 9 3 10 3 236 262mm...

Страница 38: ...REV C 6 8 117592 72 Rear Discharge Deck Belt Routing Tensioning Figure 6 17 9 3 10 3 236 262mm 9 3 10 3 236 262mm...

Страница 39: ...12122104 NOTE If replacing this harness with the updated version the six pin connector pigtail that is attached to the engine will need to be removed The updated version has individual connections fo...

Страница 40: ...REV C 7 2 117592 Electrical Schematic Kawasaki Mowers with serial number 12122104 and later...

Страница 41: ...117592 7 3 REV C Electrical Schematic Kawasaki DFI...

Страница 42: ...REV C 7 4 117592 Electrical Schematic Briggs Stratton...

Страница 43: ...ed parts Prior to each use Visually inspect tires Prior to each use Check oil level engine 1 Prior to each use or every 4 hours Clean oil heat exchanger 8 Prior to each use or every 4 hours Clean air...

Страница 44: ...ation and then after every 500 hours of operation or yearly whichever comes first REFERENCES A Refer to engine owner s manual for engine service information NOTE After completing maintenance cycle 500...

Страница 45: ...Engine Oil Filter 11 Deck Height Pivot Zerks 4 12 Park Brake Switch 13 Drive Tires 14 Pump Idler Zerk 1 15 Pump Belt 16 Deck Pusher Arm Zerks 2 17 Deck Belt 18 Spindle Housing Zerk 3 19 Blades 20 Fuel...

Страница 46: ...Maintenance Service Performed Dealer Hour Meter Reading Date Maintenance Service Performed Dealer Hour Meter Reading Date Maintenance Service Performed Dealer Hour Meter Reading Date Maintenance Serv...

Страница 47: ...broken Install a new traction drive belt Air in system Check filter and fittings For additional causes See engine manual Low engine oil pressure Low oil level Add oil Oil diluted or too light Change o...

Страница 48: ...the Deck leveling and height adjustment section of the General Service Manual An anti scalp wheel is not set correctly Adjust the height of the anti scalp wheel The underside of the deck is dirty Clea...

Страница 49: ...ance precautions 2 2 Hydraulic pump belt adjustment 4 5 Hydraulic system 4 6 Maintenance introduction 1 1 Maintenance precautions 2 2 Maintenance schedule 8 1 Mower blade maintenance 6 3 Mower blade r...

Страница 50: ...INDEX PAGE PAGE REV C 1 2 117592...

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