White Outdoor ZT Zero 17 User manual

Service Manual
ZT Zero Turn Rider
MTD Products Inc. - Product Training and Education Department
FORM NUMBER - 769-01421
12/2004
NOTE: These materials are for use by trained technicians who are experienced in the service and repair of outdoor power
equipment of the kind described in this publication, and are not intended for use by untrained or inexperienced individuals.
These materials are intended to provide supplemental information to assist the trained technician. Untrained or inexperi-
enced individuals should seek the assistance of an experienced and trained professional. Read, understand, and follow all
instructions and use common sense when working on power equipment. This includes the contents of the product’s Oper-
ators Manual, supplied with the equipment. No liability can be accepted for any inaccuracies or omission in this publication,
although care has been taken to make it as complete and accurate as possible at the time of publication. However, due to
the variety of outdoor power equipment and continuing product changes that occur over time, updates will be made tothese
instructions from time to time. Therefore, it may be necessary to obtain the latest materials before servicing or repairing a
product. The company reserves the right to make changes at any time to this publication without prior notice and without
incurring an obligation to make such changes to previously published versions. Instructions, photographs and illustrations
used in this publication are for reference use only and may not depict actual model and component parts.
© Copyright 2005 MTD Products Inc. All Rights Reserved
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TABLE OF CONTENTS
General Information .............................................................................................................. 1
deck leveling ......................................................................................................................... 1
PTO/Deck Belt Replacement ............................................................................................... 2
Deck Removal ...................................................................................................................... 2
Blade Drive Belt Removal .................................................................................................... 2
Idler Arm Removal ................................................................................................................ 2
Blade Spindle Removal ........................................................................................................ 3
Drive Belt Replacement ........................................................................................................ 3
Servicing Electric PTO Clutch .............................................................................................. 3
Transmission Replacement .................................................................................................. 4
Steering Linkage: Adjustment .............................................................................................. 6
Pivot Bar ............................................................................................................................... 9
Seat Removal ..................................................................................................................... 10
Console Removal ............................................................................................................... 11
Battery Removal ................................................................................................................. 13
Fuel Tank Removal ............................................................................................................ 14
Control Shaft Replacement ................................................................................................ 15
Deck Lift Shaft Replacement .............................................................................................. 16
Electrical System Components .......................................................................................... 19
Relays ................................................................................................................................ 21
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1
17AA5A4G790
1E154G20133
GENERAL INFORMATION
2004 is the first year for the ZT. There are two models
ZT17 and ZT22. New for the ‘05 model year is a Kohler
Command 19 HP model with a 50” cutting deck.
This series of riders has the unique feature of not hav-
ing to reset the PTO switch if the end user tries to mow
in reverse. Once one lapbar is moved in to neutral or
forward the PTO will turn back on.
The “ZT 17” has a 17 HP Briggs & Stratton Intek which
is a single cylinder engine with full pressure lubrication.
The engine drives the dual Hydro-gear Hydrostatic
transmissions and the electric PTO. The PTO runs the
3-in-1blades on the 42” twin blade stamped deck. On
the front of the stamped frame is a large pivoting front
axle.
The “ZT 22” is very similar to the ZT 17 except for the
twin cylinder, 22 HP Briggs & Stratton Intek. There are
also 4 wheels, instead of 2, on the 50” triple blade
stamped deck.
1. DECK LEVELING
1.1. To adjust the deck pitch, front to back, loosen or
tighten the jam nuts located on the front stabi-
lizer bracket using a 15/16” socket and a 15/16”
wrench. The correct deck pitch should be 1/8” to
1/4” lower in the front than in the back, as mea-
sured from the blade tips. See Figure 1.1.
1.2. To level the deck, side to side, loosen the screw
on the left side adjustment gear using a 1/2”
socket. Using a 3/4” wrench, run the gear up or
down as necessary until each outside blade tip
is the same distance from the ground.
See Figure 1.2.
Figure 1.1
Front deck stabilizer bracket
Jam Nuts
Figure 1.2
Deck adjustment gear
Deck hanger rod
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2. PTO / DECK BELT REPLACEMENT
2.1. Insert a 1/2” breaker bar into the square hole in
the tensioner arm located on top of the deck.
See Figure 2.1.
2.2. Pivot the tensioner arm and pulley to slacken the
belt.
2.3. Remove the belt from the two stationary idler
pulleys and spindle pulleys.
NOTE: The spindle covers do not need to be
removed.
2.4. Remove the belt from the clutch.
3. DECK REMOVAL
3.1. Release the deck J pins from the rear hanger
arms. See Figure 3.1.
3.2. Slide the deck forward until the front stabilizer
bar can be lifted away from the front mounting
bracket.
3.3. Slide the deck out from underneath the unit.
4. BLADE DRIVE BELT REMOVAL
4.1. Remove the deck from the unit.
4.2. Remove both belt covers. These belt covers are
identical and interchangeable. See Figure 4.2.
4.3. Remove the belt from around the pulleys.
4.4. Install the new belt. A belt routing diagram label
is adhered to the deck housing.
5. IDLER ARM REMOVAL
Figure 2.1
1/2” Breaker bar
Idler arm
Figure 3.1
“J” Pin
Deck hanger rod
Figure 4.2
Belt Covers
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5.1. Remove the cutting deck from the unit.
5.2. Remove the shoulder screw and hex lock nut
securing the idler to the deck housing. See Fig-
ure 5.2.
5.3. Remove the idler and inspect for wear or dam-
age.
6. BLADE SPINDLE REMOVAL
6.1. Remove the deck from the unit.
6.2. Remove the spindle covers and blade drive belt.
6.3. Using an impact wrench, remove the hex flange
nut securing the blade to the spindle assembly.
See Figure 6.3.
6.4. Remove the four hex washer head tapp screws
securing the spindle assembly to the deck hous-
ing.
7. DRIVE BELT REPLACEMENT
Figure 5.2
Idler
Figure 6.3
Hex Flange Lock Nut
7.1. Insert a 3/8” breaker bar into the square hole on
the tensioner arm.
7.2. Pull the breaker bar to the right until it can be
braced in position at the pivot point of the ten-
sioner arm. See Figure 7.2.
7.3. Remove the belt from the transmission pulleys,
tensioner pulley and the crankshaft pulley. Belt
is part number 754-04043
8. SERVICING ELECTRIC PTO CLUTCH
8.1. Using a small flat blade screwdriver, unplug the
electrical connector on the PTO clutch.
8.2. Using a 5/8” socket and an impact wrench,
remove the clutch bolt. See Figure 8.2.
8.3. Lower the clutch off of the crankshaft.
8.4. Remove the crankshaft key.
Figure 7.2
Idler arm
Figure 8.2
Clutch Bolt
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8.5. Remove the crankshaft pulley. See Figure 8.5.
8.6. Use a 9/16” socket to adjust the air gap on the
clutch to between.010” and.015”.
See Figure 8.6.
NOTE: Clutch adjustment can be done with the
clutch in the unit. If a new clutch is being put in
the adjustment can be done on the bench.
9. TRANSMISSION REPLACEMENT
9.1. Insert a 1/2” breaker bar into the square hole on
the tensioner arm.
9.2. Pull the breaker bar to the right until it can be
braced in position at the pivot point of the ten-
sioner arm.
9.3. Remove the belt from the transmission pulleys,
tensioner pulley and the crankshaft pulley.
9.4. Using a 3/4” socket and impact wrench, remove
the four lug nuts securing the rear wheel to the
axle hub.
NOTE: Insure the lap bar control rods and brake
rods are not rubbing against the frame.
9.5. Remove the cotter pin securing the bypass rod
to the transmission bypass arm. Remove the
bypass rod. See Figure 9.5.
9.6. Mark the lap bar control rod threads near the fer-
rule. See Figure 9.6.
Figure 8.5
Key
Crankshaft pulley
Figure 8.6
.012 Feeler gage
Figure 9.5
Bypass rod
Cotter Pin
Figure 9.6
Control Rod
Ferrule
Marking Paint
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9.7. Remove the hairpin securing the lap bar control
rod ferrule to the transmission return assem-
bly. See Figure 9.7.
9.8. Disconnect the brake return spring from the
brake arm. See Figure 9.8.
Figure 9.7
Hairpin
Figure 9.8
Brake Return Spring
9.9. Remove the bolt securing the brake arm to the
transmission using a 7/16” socket.
See Figure 9.9.
NOTE: A spacer is located between the brake
arm and transmission housing.
NOTE: During installation, the bottom ridge of
the brake arm needs to be below the emboss-
ment on the transmission housing. Improper
installation will prevent the brake from engaging.
9.10. Remove both bolts securing the tubular trans-
mission brace using a 5/8” socket.
NOTE: When installing the brace bolts use loc-
tite 242.
9.11. Remove the front transmission mounting bolt
using a 1/2” wrench and a 1/2” socket.
NOTE: Secure the transmission or use another
technician to support the transmission while per-
forming the next step.
Figure 9.9
Brake Arm Bolt
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9.12. Remove both transmission mounting bolts
securing the transmission to the mounting
bracket using two 1/2” wrenches.
See Figure 9.12.
9.13. Rotate the transmission out and down until the
fan is clear of the front transmission mounting
bracket, and remove it from the frame.
9.14. Installation notes:
• Lift transmission into place and start all threaded
fasteners before tightening any individual fasten-
ers.
• Install the axle horn bolts from the top down,
tighten nuts to a torque of 90-120 in-lbs.
• Install the torque bracket bolt from the bottom
up, and tighten the nut to a torque of 90-120 in-
lbs.
• Install the bolts in the tubular transmission
braces and tighten them to a torque of 90-120 in-
lbs.
• The remainder of the installation process con-
sists of reversing the removal process.
• Tighten the lug nuts to a torque of 350-500 in-
lbs.
• Tighten the center wheel hub nut to 100-160 Ft.
Lbs.
10. STEERING LINKAGE: ADJUSTMENT
10.1. Begin to adjust the steering by confirming that
both hydros are correctly adjusted for neutral
control. See Figure 10.1.
10.2. Lift and safely support the rear of the mower.
10.3. Disconnect the ferrule at the hydro end of each
lap bar control rod from the neutral return
assembly on each of the hydros. The ferrules
are secured to the neutral return assemblies with
hairpin clips. See Figure 10.3.
NOTE: In the course of normal service, it is very
unusual for the neutral return assemblies to
require adjustment unless someone has previ-
ously tampered with it. It is necessary to check
the adjustment because the rest of the proce-
Figure 9.12
Transmission Mounting Bolts
Figure 10.1
Neutral Return Assembly
Figure 10.3
Ferrule
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dure counts on the neutral control being cor-
rectly adjusted.
10.4. Start the engine. With the control rods discon-
nected, the hydro should self-center to neutral.
The wheels should not rotate. If either wheel
rotates, the neutral return assembly on the hydro
that drives that wheel needs to be adjusted.
10.5. To adjust the neutral return assembly, loosen
the socket head cap screw that holds the center-
ing bracket in position on the housing using a
1/4” allen wrench. See Figure 10.5.
10.6. Rotate the assembly in whichever direction
causes the wheels to stop rotating. The point
where the wheels do not rotate with the engine
at full throttle is true neutral. Tighten the socket
head cap screw at true neutral. When making
this adjustment, the transmission should be
warm.
Figure 10.5
Socket Head Cap Screw
10.7. Align the post on the ferrule with the hole that it
seats into on the neutral return assembly.
Thread the ferrule up or down the length of the
control rod to center the lap bar in the neutral
recess in the control console. See Figure 10.7.
10.8. When each ferrule is in the correct position,
secure it to the neutral control assembly with a
hairpin clip.
10.9. Lower the machine to the ground. Test the oper-
ation of the hydros in a safe space.
10.10.Adjust the stop bolts so that it tracks as straight
as possible with both lap bars pushed to the full
forward position. See Figure 10.10.
Figure 10.7
Lap bar centered in console
Figure 10.10
Stop Bolt
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10.11.The socket head cap screws that secure the
neutral return assemblies to the hydros act as a
travel stop at the hydro end of the linkage. The
lap bar pivot brackets should contact the stop
screws before the socket head cap screw con-
tacts the end of the slot on the neutral bracket.
See Figure 10.11.
10.12.If the lap bars are not aligned with each-other,
they may be adjusted using the slotted mounting
where they connect to the lap bar pivot brackets.
See Figure 10.12
10.13.After final adjustment, test the operation of the
reverse safety switches. They should turn the
PTO clutch off whenever both lap bars are in the
reverse position.
NOTE: With one lap bar in the reverse position,
and the PTO turned on, the PTO clutch should
turn off as soon as the second lap bar crosses
the threshold from neutral into reverse. Repeat
test for each side.
NOTE: When at least one lap bar is in the neu-
tral or forward position, the PTO clutch will oper-
ate. There is not a relay to re-set by cycling the
PTO switch off and on again, as is the case with
MTD front engine residential equipment.
10.14.If the reverse safety switch adjustment is not
correct, loosen the reverse safety switch bracket
using a 3/8” wrench. Pivot the bracket and
switch to a position that results in correct opera-
tion, then tighten the bracket. See Figure 10.14.
NOTE: It is not necessary to remove either con-
trol console to reach the reversesafety switches,
but it may be necessary to temporarily discon-
nect the blue wires in order to reach the mount-
ing screws for the brackets.
Figure 10.11
Travel Stop
Figure 10.12
Figure 10.14
Reverse Safety Switch Bracket
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