Textron BOB-CAT ZT 220D Series User manual

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

1
ZT 200
Series
TABLEOFCONTENTS PAGE
Safety .............................................................................................................................................................................. 2
Assembly & Setup........................................................................................................................................................ 3-5
Maintenance Chart.......................................................................................................................................................... 6
Maintenance Record....................................................................................................................................................... 7
Maintenance...............................................................................................................................................................8-14
Troubleshooting.......................................................................................................................................................15-16
Adjustments.............................................................................................................................................................17-21
Belt Replacement .................................................................................................................................................... 22,22
Specifications ..........................................................................................................................................................23-26
Fastener Torques ......................................................................................................................................................... 27
Upper engine deck assembly.................................................................................................................................. 28,29
Lower engine deck assembly/Clutch....................................................................................................................... 30,31
Cradle assembly ..................................................................................................................................................... 32,33
Decals...................................................................................................................................................................... 34,35
Bumper .................................................................................................................................................................... 36,37
Brakes/Rear wheel .................................................................................................................................................. 38,39
Hydraulics ................................................................................................................................................................ 40,41
Hydrogear pump ...................................................................................................................................................... 42,43
Yanmar Wire harness.............................................................................................................................................. 44,45
Fuel tanks/Control panel.......................................................................................................................................... 46,47
Radiator Screen & Air Filter...................................................................................................................................... 48,49
Oil Cooler & Radiator ............................................................................................................................................... 50,51
Seat assembly & ROPS ........................................................................................................................................... 52,53
Steering/Deck Lift..................................................................................................................................................... 54,55
Cradle & Caster Assembly ...................................................................................................................................... 56,57
52" & 61" Side Discharge......................................................................................................................................... 58,59
Belts......................................................................................................................................................................... 60,61
Decals-Cutterdecks ................................................................................................................................................. 62,63
Cross Reference .....................................................................................................................................................64-68
IMPORTANT MESSAGE
ThankyouforpurchasingthisBob-Catproduct. Youhavepurchasedaworldclassmowingproduct,oneofthebest
designedandbuiltanywhere.
ThismachinecomeswithanOperationandSafetyManualandaseparateSetup,PartsandMaintenanceManual.
Theusefullifeandgoodserviceyoureceivefromthismachinedependstoalargeextentonhowwellyoureadand
understand these manuals. Treat your machine properly, lubricate and adjust it as instructed, and it will give you
many years of reliable service.
Yoursafeuseofthis Bob-Cat product is one of our prime design objectives. Many safety features are built in, but
wealsorelyonyourgoodsenseandcaretoachieveaccident-freeoperation. Forbestprotection,studythemanuals
thoroughly. Learn the proper operation of all controls. Observe all safety precautions. Follow all instructions and
warningscompletely. Donotremoveordefeatanysafetyfeatures. Makesurethosewhooperatethismachineare
as well informed and careful in its use as you are.
SeeaBob-Catdealerforanyserviceorpartsneeded. Bob-Catserviceensuresthatyoucontinuetoreceive thebest
resultspossiblefromBob-Cat’sproducts. YoucantrustBob-Catreplacementpartsbecausetheyaremanufactured
with the same high precision and quality as the original parts.
Bob-Catdesignsandbuildsits equipment to serve many years in a safe and productive manner. Forlongestlife,
usethismachineonlyasdirectedinthemanuals,keepitingoodrepairandfollowsafetywarningsandinstructions.
You'll always be glad you did. Textron Turf Care And Specialty Products
One Bob Cat Lane
Johnson Creek, WI 53038-0469
8-2000-TTCSP
CONTENTS

2
ZT 200
Series
SAFETY
NOTICE!!!
Unauthorized modifications may present extreme
safetyhazardstooperatorsandbystandersandcould
alsoresult in product damage.
Textron Turf Care And Specialty Products strongly
warns against, rejects and disclaims any modifica-
tions,add-onaccessoriesorproductalterationsthat
arenotdesigned,developed,testedandapprovedby
TextronTurfCareAndSpecialtyProductsEngineer-
ingDepartment. AnyTextronTurfCareAndSpecialty
Productsproductthatisaltered,modifiedorchanged
inanymannernotspecificallyauthorizedafteroriginal
manufacture–includingtheadditionof“after-market”
accessoriesor component parts not specifically ap-
provedbyTextronTurfCareAndSpecialtyProducts–
will result in the Textron Turf Care And Specialty
ProductsWarrantybeingvoided.
Anyandallliabilityforpersonalinjuryand/orproperty
damagecausedbyanyunauthorizedmodifications,
add-on accessories or products not approved by
Textron Turf Care And Specialty Products will be
considered the responsibility of the individual(s) or
company designing and/or making such changes.
TextronTurfCareAndSpecialtyProductswillvigor-
ouslypursuefullindemnificationandcostsfromany
partyresponsibleforsuchunauthorizedpost-manu-
facturemodificationsand/oraccessoriesshouldper-
sonalinjuryand/orpropertydamageresult.
This symbol means:
ATTENTION!
BECOME ALERT!
Yoursafety and the safety ofothersisinvolved.
Signal word definitions:
Thesignalwordsbelowareusedtoidentifylevelsof
hazard seriousness. These words appear in this
manualandonthesafetylabelsattachedtoBob-Cat
machines. For your safety and the safety of others,
readandfollowtheinformationgivenwiththesesignal
wordsand/orthesymbolshownabove.
DANGERindicatesanimminentlyhazardoussituation
which,ifnotavoided,WILLresultindeathorserious
injury.
WARNINGindicatesapotentiallyhazardoussituation
which, if not avoided, COULD result in death or
seriousinjury.
CAUTIONindicatesapotentiallyhazardoussituation
which,ifnotavoided,MAYresultinminorormoderate
injury. It may also be used to alert against unsafe
practicesorpropertydamage.
CAUTION used without the safety alert symbol
indicates a potentially hazardous situation which, if
notavoided,MAYresultinpropertydamage
MODELNUMBER: Thisnumberappearson
sales literature, technical manuals and price lists.
SERIALNUMBER: Thisnumberappearsonlyon
yourmower. It contains the model number
followedconsecutivelybytheserialnumber. Use
thisnumberwhenorderingpartsorseeking
warrantyinformation.
SERIAL TAG

3
ZT 200
Series ASSEMBLY AND SETUP
TOOLSREQUIREDFORASSEMBLY
– Wreckingbar
– Clawhammer
– Ratchets: 3/8"
– Sockets: 3/8", 1/2", 17 mm, 19 mm
– Wrenches: two 15/16" (or adjustable), 13 mm, 17 mm, 19 mm
– Level
– Straightedge
– Tirepressuregauge
NOTE: All references below to the "right" or "left" are with respect to an operator at the controls.
1. INSTALLSEAT
a) Position seat over seat plate and route seat wire
Wthrough hole Hin seat plate. Drop seat mount-
ing studs through seat plate holes. Secure studs
withfour 5/16-18 whiz nuts and tighten securely.
b) Leaveenoughseatwirebetweentheseatandseat
plateto allow full fore and aft travel of the seat.
Secure seat wire on the bottom of the seat plate
withclip Cand a 1/4-20x3/8 thread formingscrew.
c) Connect the tractor harness to the seat wire.
Bottom of seat plate P showing clip C

4
ZT 200
Series
ASSEMBLY AND SETUP
2. Settirepressuresto14 psi. Tiresareoverinflated for shipping.
3. LEVELCUTTERDECKANDADJUSTCOUNTER-
BALANCESPRINGS
– Side Discharge: The frontof a side discharge
deck should be slightly lower than the rear.
– Mulching: The front of a mulching deck should
be slightly higher than the rear.
To level deck:
a) Park themachine on a smooth, level surface. The
deck may be set to any cutting height.
b) Place 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
placethe level on the straightedge.
c) Laya 1/8"spacerbeneath the front of the level for
theside dischargeandunder the rearformulch-
ing.
d) Adjust nuts Muntil the level's bubble is centered.
Repeat for the other side of the deck.
AdjustCounterbalancesprings:(52"&61"DECKSONLY)
The counterbalance springs are adjusted to a length of 13-1/4" with the deck raised all the way. The springs
maybetightenedorloosenedfromthisprintwithnutNaccordingtopersonalpreference

5
ZT 200
Series
4.TRACTIONLEVERS
a) RemoveboltA.
b) Rotate traction leverBintoposition
and secure with bolt A. Repeat for
the other lever.
c) Tighten all fasteners.
d) Sit on the machine. If the levers
are too long, bracket Cmay be
removed to make them shorter.
Ä
...
5.FINALPREPARATIONS
– Check the engine and hydraulic oil levels. Top up with the correct oil if necessary. See engine manufactur-
ers manual for recommended grade of oil. Use fresh, clean 15W40 or 20W50 motor oil or 15W50 synthetic
motor oil for the hydraulic system.
– Remove the battery from themachineandtrickle charge for several hours. Replace the battery in the
machineandmakethe connections, red to positive first, then black (ground)tonegative.
– ReadOperationandSafetyManualbeforestarting.
– If fuel tanks have been completely emptied, refer to the bleeding the fuel system on Page 11 of this manual.
– Runengine at full RPM for 5minutesbeforeengagingblades to allow the engine tobefullylubricatedbefore
loadis applied.
– Check the hydrostat neutral adjustment. Neutral is set at the factory but may require readjustment if air
trapped during the initial oil fill has worked out of the system. See adjustments section later in this manual.
– Do not use the machine without an approved grass collector, the grass discharge chute or mulching plates
correctly fitted.
ASSEMBLY AND SETUP

6
ZT 200
Series
MAINTENANCE CHART
ECNANETNIAM NOITAREPO
neewtebsemitmumixameraslavretniesehT.bojgniognonasiecnanetniaM .snoitidnocerevesrednunetfoerommrofreP.snoitarepoecnanetniam
5TSRIF SRUOH YLIAD YREVE 52 SRUOH
YREVE 05 SRUOH YREVE 001 SRUOH YREVE 002 SRUOH YREVE 005 SRUOH
ENIGNE snoitcurtsnidnanoitamrofnilanoitiddaroflaunamenigneehttlusnoC
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renaelCriAnaelC renaelcerP X
renaelCriAnaelC tnemelE X
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dnaliOegnahC retliF XX
SCILUARDYH
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dnaliOegnahC retliF XX
ENIHCAM
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pupoT/kcehC yrettaB yrettaB"eerFecnanetniaM"delaeS
stnioPllAetacirbuLX

7
ZT 200
Series
NOTES
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________________________________________________________________________
_______________________________________________________________
____________________________________________________________
____________________________________________________
________________________________________________________________________
_______________________________________________________________
____________________________________________________________
_______________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
MAINTENANCE RECORD
LARENEG
ETAD SRH ETAD SRH ETAD SRH ETAD SRH ETAD SRH ETAD SRH
serusserperitkcehC
stniopllaetacirbuL
stlob&stunkcehC
ENIGNE
levelliokcehC
lioegnahC
naelC tnemelerenaelcria
snifgniloocnaelC
ecalpeR tnemelerenaelcria
.sretlifhtobdnaliociluardyh,lioenigneecalpernoitarepofosruoh5tsrifretfA:ETON

8
ZT 200
Series
MAINTENANCE
CHECK DAILY
Operator Presence Interlock System - Start Operation
For the engine to crank, the parking brake must be on, the PTO (blades) off and traction levers in the neutral
lock position. Sit in the seat and check, one by one, if the engine will crank with the parking brake off, the
bladeson, and either traction lever out of neutral lock.
Operator Presence Interlock System - Run Operation
Theoperator must be in the seat for the engine to run with the parking brake off, the traction levers moved out of
the neutral lock position, or the blades on. To check:
1. Start the engine and run at 1/2 throttle with the operator on the machine but raised off the seat.
2. One by one: move the parking brake to the “OFF” position, traction levers out of the neutral lock position
(check each independently), and turn the blades on. Each check should kill the engine after 1/2 second.
(A 1/2 second delay is built into the system to prevent engine cutout when traversing rough terrain.)
Repair machine before using if the Operator Presence Interlock System does not operate correctly in start or
run.ContactyourauthorizedBob-Catdealer.
Hardware
Tighten any nuts and bolts found loose. Replace any broken or missing cotter pins. Repair any other problems
beforeoperating.
Tirepressure
Tires should be kept inflated at 14 lbs/in2(1.0kg/cm2).Improper tire inflation can cause rapid tire wear and poor
traction. Uneveninflationcancauseunevencutting.
Fuel System
Checkfilterbulbforwateraccumulation.
Radiator and Oil Cooler
Check for debris build up and clean if necessary
Battery
Battery acid is very caustic and
fumesareexplosiveandcancause serious injury or
death.
Always use insulated tools, wear protective glasses or
gogglesandprotectiveclothingwhenworkingwith
batteries. You must read and obey all of the battery
manufacturer’sinstructions.
Make absolutely certain the ignition switch is “OFF”
andthekeyhasbeenremovedbeforeservicingthe
battery.
NOTE: The battery included from the factory is of the
sealed type.
1. Verifybatterypolaritybeforeconnectingor
disconnecting the battery cables.
2. When installing the battery, always assemble the
RED, positive ( + ) battery cable first and the
ground, BLACK, negative ( - ) cable last.
3. Whenremovingthebattery,alwaysremovethe
ground,negative( - ) cable first and the red,
positive ( + ) cable last.
4. Checktheelectrolytelevelevery100hoursof
operation.
5. Clean the cable ends and battery posts with steel
wool. Use a solution of baking soda and water to
clean the battery. Do not allow the solution to
enter into the battery cells.
6. Tighten cables securely to battery terminals and
apply a light coat of silicone dielectric grease to
terminalsandcableendstopreventcorrosion.
Keepterminalcoversinplace.

9
ZT 200
Series
LUBRICATION
Every 50 hours of operation, lubricate the following points with grease:
1. Casterwheelpivots(2points)
2. Casterwheelbearings(2points)
3. Deckidlerpivotbearings(2points)
4. Deck lift pivots (6 points)
5. Hydrobelttensioner(1pointunder enginedeck)
6. Brakeleverpivot(1point)
7. Push arms (2 points located at rear of cutter deck under each fuel tank)
8. Deck lift rockshaft (1 point)
NOTE ON BLADE SPINDLES -The blade spindles on these machines use
a superior sealed bearing that does not require relubrication.
4
3
6
44
2
1
7
5
8
44
2
1
7
MAINTENANCE

10
ZT 200
Series
MAINTENANCE
HYDRAULIC SYSTEM
Afterthe first 5 hours of operation, fluidlevel in the
hydraulicsystem should be checked every100 hours
or when a leak has occurred. If the fluid is low, check
all components for leaks.
Tocheck,removereservoircapM.Thefluidlevel
should be at the bottom of the filler tube. If low, top up
(donot overfill). Use oneof the oils listed below:
–SAE 15W40 motor oil
–SAE 20W50 motor oil
–15W50 synthetic motor oil
AFTERFIRSTFIVE(5)HOURS
1. RemoveplugNtodrainhydraulicreservoir.
Dispose of used oil in accordance with local
requirements.
2. Cleanandreplacetheplug.
3. Changehydraulicoilfilter G.
4. Fill the reservoir with fresh oil to the bottom of the
reservoirfiller tube,usingan oilfrom thelistabove.
Donotoverfill.
PERIODICOILCHANGES
Changethehydraulicfluidandhydraulicfilterafter
each500hoursofoperationusingthesameprocedure
givenabove.
View from right side
View from below machine
NOTES:
Before servicing the hydraulic system, stop the engine anddisengage the PTO.
–After any hydraulic line is opened, plug or cap it promptly to reduce the risk of contamination.
–Do not use teflon tape on hydraulic pipe fittings. Use a liquid sealant that will dissolve into the system.
–Make sure all hydraulic connections are tight and hydraulic hoses and lines are in good condition before
applying pressure to system.
The machine's hydraulic system operates under high pressure. When checking for leaks, do not use your
hands to attempt to find a leak. Instead, use cardboard or paper. Escaping hydraulic fluid can be under suffi-
cient pressure to penetrate skin and cause serious injury. If hydraulic fluid is injected into the skin, it must be
promptly removed by a doctor familiar with this form of injury or gangrene may result.

11
ZT 200
Series MAINTENANCE
ENGINE OIL
Donotperformenginemaintenancewithouttheengine
offandPTOdisengaged.
AFTERFIRSTFIVE(5)HOURS
While the engine is warm:
1. RemovedrainplugDanddrainthecrankcase.
Dispose of used oil in accordance with local
requirements.
2. Cleanand replacetheplug D.
3. Change oil filter F. See Engine Manual
4. Remove cap Cand fill the crankcase with fresh oil
to the full mark on the dipstick. Do not overfill. See
enginemanualforoilspecifications.
DAILY
1. Check oil level with the dipstick.
2. Ifoilis needed, add fresh oilof proper viscosity
andgrade.Seeenginemanualforoilspecifica-
tions.Donotoverfill.
3. Replacedipstickbeforestartingengine.
PERIODICOILCHANGES
1. Seeenginemanualfor oilandfilterchange
intervalsafterthebreak-inperiod.
2. Followinstructionsforfirstoilchange,above.
FUEL FILTER
An in-line fuel filter S is located at the right side of the
engine. Inspect at every oil change to make sure fuel
filter is clean an unobstructed. Replace if dirty or after
400hours of use.

12
ZT 200
Series
MAINTENANCE
BLEEDING AIR OUT OF FUEL SYSTEM
If fuel tanks are run dry, it may be necessary to bleed
off air from the fuel system.
–Follow the instructions on the fuel line bleed decal
located on the tractor.
AIR CLEANER
The air cleaner with this engine has a high density
paperair cleanercartridge. Itshouldbe inspected
regularlyandmaintained. Unevenrunning,lackof
power or black exhaust fumes may indicate a dirty air
cleaner.
Tocleanorreplace dieselengine aircleanerelement:
1. UnclampendcoverYandremoveelementZ.
2. Insertnewelementandreplaceendcoverby
clamping in position as shown on the cover.
Every100hours(moreoftenunderverydustyordirty
conditions),check the paper cartridge.
–Cleanbytappinggently.
–Do not wash the cartridge or use compressed air
whichcan cause damage.
–Replacewhen cartridge is dirty, bentordamaged.

13
ZT 200
Series
ENGINE COOLING
Continuedoperationwithacloggedcoolingsystemwill
causesevereoverheatingandcanresultinengine
damage.
Performthe followingstepsdaily or whenfinsbecome
clogged.
DAILY
1. Clean air intake screen S.
2. Cleanoil cooler and radiator fins by opening latch
Landrotating screenSforward.
3. Wipeorbrushoffaccumulateddebris.
4. Unclampand raise radiator by opening latch H.
Usingcompressed air,blowdebris fromfins
directingairawayfromthe engine.
NOTE:Donotusepressurizedwaterorother
liquid.
5. Whencompleted, clamp the radiator and screen
back into place.
NOTE: Engine will not crank unless radiator is se-
curely clamped into place.
MAINTENANCE

14
ZT 200
Series
BLADE REMOVAL
Follow these instructions to prevent injury during
blade removal:
1. Loosen with a box wrench or a socket and long
breaker bar. To gain additional leverage, slip a
long pipe or thick-walled tube over breaker bar or
wrench.
2. Insert wood block Aas shown, with grain perpen-
dicular to blade, to prevent blade from turning
when loosening.
3. Wear thickly padded gloves. Keep hands clear of
blade path. Blades may rotate when bolt releases.
SHARPENING
Bladesmay sharpenedbyfiling orgrinding.
–Inspectbladesbeforesharpening.
–Replace bent or cracked blades.
–Replace blades when the lift portion has worn
thin.
–Maintain cut angle at 30o.
–Do not overheat blades when sharpening.
–Always use 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, wear, and shortened life of
most components of the machine.
To balance a blade:
1. Sharpen blade first.
2. Balance the blade at the center.
3. Attach a 1/8 oz (3.9 g) weight at a distance 5"
(127 mm) from center on the light end. This
should make the light end the heavy end:
–If it does, the blade is balanced.
–If does not, file or grind the heavy end until
the addition of the weight makes the light end
the heavy end.
BLADE INSTALLATION
1. Wear thickly padded gloves to prevent cuts from
the sharp blade.
2. Insert the blade bolt, in order, through the conical
washer (cup side toward the blade, as shown),
the blade, and the blade spacer.
3. Install assembly on the blade spindle.
4. Torque the blade bolt to 70 ft-lbs.
MAINTENANCE

15
ZT 200
Series
SYMPTOMS
Engine will not start.
PROBABLECAUSE
Safetyinterlock not activated.
Battery discharged. (See
Page8forcharging
instructions.)
SOLUTION
Latch clamps.
ShutoffPTO.
Engageparking
brakeor adjust
parkingbrake
switch.
Placeleversin
neutral lock
positionor adjust
tractioncontrol
switch.
Cleanandtighten
cableterminal
fasteners.
Removeand
checkcharge
relayswitching.
Replacerelayif
necessary.
Repairas
necessary.
CHECKFOR
Radiatormountingclamploose.
PTOSwitchengaged.
Parkingbrakedisengaged.
Position of traction control
levers.
Looseorcorrodedcable
terminals.
Chargerrelayfunction.
Electrical continuity.
Engine cranks but will
not start. Coldambienttemp.
Nofuel.
Fuelsolenoidnotactivated.
Useglow plugs
per
recommendations.
Addcleanfresh
fuel.
Directlevertoward
tankcontaining
fuel.
Purgeairfromfuel
line. (See decal
orPage 12.)
Checkandtighten
all terminals as
required.
Checkfuel
solenoidrelay.
Replacerelayif
necessary.
Replacefuse.
determinecause
forburnedfuse
andrepairas
required.
Glow plug chart. (See chart on
Page23.)
No fuel in tanks.
Leverpositionofshutoff/tank
selectvalve.
Air in fuel line. Air must be
purgedfromfuellineafter
runningoutoffuel.
Electrical continuity. (Solenoid
should "click" when keyswitch
is turned on.)
Blown 30 Amp fuse.
TROUBLESHOOTING

16
ZT 200
Series
SYMPTOMS
Engine starts but runs
unevenly.
PROBABLECAUSE
Fuelline not bled after
runningoutoffuel.
Waterin fuel orpluggedfuel
filter.
Engine air intake restricted.
SOLUTION
Purgeairfromfuel
line. (See decal
orPage 12.)
Replacefuelfilter.
Cleanorreplace
airfilter.
CHECKFOR
Air in fuel line.
Water in fuel bowl. Dirty fuel
filter.
Dirty air filter.
Engineoverheating Airflowthroughradiator
restricted.
Lowcoolant.
Cleanscreen.
Cleanradiator
core. (See
instructions on
Page13.)
Seeengine
manual.
Repairas
required.
Replacehose.
Pluggedairscreen.
Pluggedradiatorcore.
Coolantlevel insurgetank.
Collapsedorleakinghose
betweensurgetankand
radiator.
Damagedradiatorhose.
Cutterdeckshutsdown
withoutbeingturnedoff. Engineoverheating.
Openwiringcircuit.
Seeengine
overheatingof
troubleshooting
section.
Replacefuse/
determinecause
forburnedfuse
andrepairas
required.
Seeengineoverheatingof
troubleshootingsection.
Blown 20 Amp fuse.
Engineshutsdown
immediatelywhen
operatorraisesfrom seat.
Gauges/Indicatorsnot
functioning.
Timedelaymodule,fuelshut
offtimer.
Openwiringcircuit.
Checkandtighten
allterminals/delay
module/timer.
Checkandtighten
all terminals.
Replacefuse/
determinecause
forburnedfuse
andrepairas
required.
Replacebulbs
Loosewireharnessterminals/
module/timer.
Loosewiringterminalsor
damagedelectricalwiring.
Blown10 amp fuse.
Burnedoutbulbs.
Tractordoesnotrespond
tomovementofcontrol
levers.
Hydraulicoilbypassing
pumps.
Lowlevelofhydraulicoil.
Closetowvalves.
Add hydraulic oil/
Determinecause
for oil loss.
Opentowvalve(s).
Levelof hydraulic oil in
reservoir.
TROUBLESHOOTING

17
ZT 200
Series
REAR DECK ROLLERS
The rear outside deck rollers are adjustable up and
down to provide improved deck flotation and scalping
protection at various heights of cut. They are not
intended to ride continuously on the ground. Adjust
no closer than 3/8" (10mm) to the ground.
Height of cut ranges for roller 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 position.
2. Move pin Nto the selected hole.
3. Lower the deck until the lift lever is stopped by
the pin.
NOTES:
–Height of cut may vary due to the amount of tread
on the tires, tire diameter or inflation pressure.
–For best results, adjust the rear deck rollers for
the height of cut to be used (see below).
ADJUSTMENTS

18
ZT 200
Series
PUSH ARMS
The push arm rod ends must be adjusted evenly to:
–locate the deck perpendicular to the front-to-rear
axis of the machine; and
–so the notch at the front 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 additional adjustment is required, adjust both
rod ends so the same number of threads show.
BELTS
All belts are tensioned by spring loaded idlers. No adjustment is required.
ADJUSTMENTS

19
ZT 200
Series
Parking brake assembly (fuel tank, tire and deck
not shown for clarity - brake in ON position).
PARKING BRAKE
Start with parking brake Nin the OFF position.
1. Adjust the parking brake rod to provide a distance
of 14-3/16”between pin K and pin L
2. Disconnect one end of rods M(at brakes on both
sides of the machine).
3. Move the parking brake lever to the ON position.
4. Adjust rods Mon each brake to be 3/4”short of
connecting to the spring when all the slack is
taken out of the brake linkage and brake lever N.
5. Move the parking brake to the OFF position and
reconnect rods M.
This adjustment will cause the brake springs to
stretch 3/4”when the brake is in the ON position to
provide the correct parking brake force without
overloading 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 slightly higher than the rear.
To level deck:
1. Park the machine on a smooth, level surface.
The deck may be set to any cutting height.
2. Place 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.
3. Lay a 1/8" spacer beneath the front of the level
for the side discharge and under the rear for
mulching.
4. Adjust nuts Muntil the level's bubble is centered.
Repeat for the other side of the deck.
Adjust Counterbalance springs:
Raise the cutterdeck all the way. Adjust the spring with nut Nto a length of 13-1/4 inches (335 mm). The
springs may be tightened or loosened from this point according to personal preference.
ADJUSTMENTS