Assembly

Bag of Parts

Parking Safely

1. Stop machine on a level surface, not on a slope.

2. Move motion control levers out to the neutral lock position.

3. Disengage mower blades.

4. Lower attachments to the ground.

5. Lock the park brake.

6. Stop the engine.

7. Remove the key.

8. Wait for engine and all moving parts to stop before you leave the operator's seat.

9. Close fuel shut-off valve, if your machine is equipped.

10. Disconnect the negative battery cable or remove the spark plug wire (for gasoline engines) before servicing the machine.

Install Rear Drive Wheels

c CAUTION: Avoid injury! The machine may fall or slip from an unsafe lifting device or supports, injuring anyone beneath it. · Remove key before raising machine. · Use a safe lifting device rated for the load to be lifted. · Lower machine onto stable supports or jack stands and block wheels before servicing.

1. Lift rear of machine using a safe lifting device.

2. Check drive wheel tire inflation pressures:

· Keep tires inflated to 69-97 kPa (10-14 psi).

MX20890

3. Attach one wheel to each hub (A) using four lug nuts provided.

· Mount each wheel with the valve stem facing to the outside.

MX10287

· Tighten lug nuts in numbered sequence shown. Tighten alternately until recommended torque value is reached.

· Tighten lug nuts to 100 N·m (75 lb-ft).

Install ROPS

MX21268

1. Remove rear grille.

· Loosen retainer (A).

· Lift rear grille up slightly at the rear and slide back to remove.

2. Fold ROPS to the upright operating position and install pins.

MX21269

3. Attach ROPS using four M12 carriage bolts (B) and flange locknuts on each side. Tighten to 120 N·m (90 lb-ft).

4. Install M12 carriage bolt (C), with washer and locknut installed on underside of frame on each side. Tighten to 120 N·m (90 lb-ft).

5. Install rear grille. Tighten lower retainer (A) securely.

Checking Tire Pressure

c CAUTION: Avoid injury! Explosive separation of tire and rim parts is possible when they are serviced incorrectly: · Do not attempt to mount a tire without the proper equipment and experience to perform the job. · Do not inflate the tires above the recommended pressure. · Do not weld or heat a wheel and tire assembly. Heat can cause an increase in air pressure resulting in an explosion. Welding can structurally weaken or deform the wheel. · Do not stand in front or over the tire assembly when inflating. Use a clip-on chuck and extension hose long enough to allow you to stand to one side.

1. Check tires for damage.

NOTE: Refer to the SPECIFICATIONS section for tire pressures.

2. Check tire pressure with an accurate gauge.

3. Add or remove air, if necessary.

Connect Battery

c CAUTION: Avoid injury! The battery produces a flammable and explosive gas. The battery may explode: · Do not smoke or have open flame near battery. · Wear eye protection and gloves. · Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. · Do not jump start or charge a frozen battery. Warm battery to 16°C (60°F).

MX20891

1. Connect positive (red) cable to positive battery terminal using M6 cap screws and nuts supplied.

· Install red terminal cover (A).

2. Connect negative (black) cable (B) to negative battery terminal.

3. Check that rubber hold-down strap (C) is secure.

Install Seat

1. Move the motion control levers to the swing-out neutral lock position.

MX20896

2. Remove seat prop rod (A) from seat and pass through hole (B) in frame.

3. Attach prop rod to seat frame using cotter pin (C) supplied.

4. Lower seat to operating position. If seat latch does not engage, weight of operator will engage latch.

Checking and Adjusting Motion Control Linkages

c CAUTION: Avoid injury! Do not attempt this adjustment unless you are a qualified and properly trained technician. Improper adjustment can result in an unsafe machine.

Checking Motion Control Linkages

NOTE: Check and adjust motion control linkages with the machine parked on a hard, level surface.

c CAUTION: Avoid injury! Engine exhaust fumes contain carbon monoxide and can cause serious illness or death. Move the machine to an outside area before running the engine. Do not run an engine in an enclosed area without adequate ventilation. · Connect a pipe extension to the engine exhaust pipe to direct the exhaust fumes out of the area. · Allow fresh outside air into the work area to clear the exhaust fumes out.

1. Sit on operator's seat and place both motion control levers in the neutral lock position.

2. Start engine.

3. Set throttle lever to the fast position.

4. Unlock park brake.

5. If the rear drive wheels begin to creep, an adjustment is required.

Adjusting Motion Control Linkages

1. Stop engine and lock park brake.

MX18075

2. Move both motion control levers (A) to the neutral lock position.

3. Lift and secure operator seat in the raised position.

MX18904

4. Activate operator seat safety switch (A).

· Clamp a wooden block to machine frame and across seat switch to activate seat switch.

5. Start engine.

6. Set throttle to the fast position.

c CAUTION: Avoid injury! Prevent entanglement when performing this service procedure by keeping hands, feet and clothing away from rotating tires.

7. Unlock park brake.

MX18893

8. Locate left and right motion control linkages (D).

9. Be sure the right motion control lever is in the neutral lock position.

· The right drive wheel must not turn. If it does turn, adjust the motion control linkage:

a. Loosen hex nuts on each end of the turnbuckle (E).

b. Adjust turnbuckle (E) until the wheel stops rotating completely.

c. Tighten hex nuts.

10. Move the right motion control lever completely rearward in the slot and release lever. The lever should return back to the neutral position (completely centered in the slot).

· The drive wheels must stop completely. If the drive wheel does not completely stop rotating, a damper mount adjustment is necessary:

· Adjust damper in slot as necessary; tighten nut to 20 N·m (15 ft-lb).

11. Move the right motion control lever completely forward and rearward in the slot and then back to the neutral lock position.

· The drive wheels must stop completely. If the drive wheel does not completely stop rotating, repeat steps12 and 13.

12. Repeat procedure to adjust the left motion control linkage (F). Loosen jam nuts on both ends of linkage and turn linkage to adjust.

13. Stop engine.

14. Move both motion control levers to the neutral lock position.

15. Remove wooden block that is activating seat switch.

16. Lower machine.

17. Lower seat.

Check Fluid Levels

· Check engine oil level.

· Check hydraulic oil level.

Leveling Mower Deck

c CAUTION: Avoid injury! Rotating blades are dangerous. Before adjusting or servicing mower: · Disconnect spark plug wire(s) or battery negative (-) cable to prevent engine from starting accidently. · Always wear gloves when handling mower blades or working near blades.

NOTE: Mower deck anti-scalp wheels should not contact the ground.

1. Park machine safely. (See Parking Safely in the Safety section.)

2. Inflate tires to the correct pressure.

3. Step on deck lift pedal and turn height-of-cut knob to the transport position.

· The transport position is the 127 mm (5 in.) cutting height position.

4. Inspect mower blades for:

· Blade sharpness.

· Blade damage.

· Bent blades.

Checking Level (Side-to-Side)

NOTE: Mower deck anti-scalp wheels should not contact the ground.

1. Step on deck lift pedal and turn height-of-cut knob to the 76 mm (3 in.) cutting height position.

NOTE: Discharge chute raised to illustrate photo clarity.

2. Position left mower blade in the sideways (left to right) position.

NOTE: Use a short ruler or a leveling gauge to check the mower blade level.

3. Measure from outside blade tip to the ground.

Mx10371

4. Position right mower blade (A) (discharge side) in the side-to-side position.

5. Measure from outside blade tip to the ground.

· The difference between both measurements should be no greater than 3 mm (1/8 in.).

6. If side-to-side level is not within the given tolerance, an adjustment is necessary.

Adjusting Level (Side-to-Side)

1. Step on deck lift pedal and turn height-of-cut knob to the transport position.

· The transport position is the 127 mm (5 in.) cutting height position.

MX10369 MX10370 MIF

2. Place 76 mm (3 in.) wood blocks (B) under each side of the mower deck.

· The wood block placed under the left side of the mower deck must be positioned to the rear of the raised portion of the deck wall.

NOTE: The right front anti-scalp wheel must not rest on the wood block.

· The wood block placed under the right side of the mower deck must be positioned under the right front anti-scalp wheel bracket (C).

3. Lower mower deck down onto the wood blocks.

4. Step on deck lift pedal and turn height-of-cut knob to the 83 mm (3-1/4 in.) cutting height position.

5. Remove mule belt from clutch.

MX10327

6. Loosen lift assist springs (D) on each side of machine to allow deck to sit flat.

7. Verify that cam follower located on rear lift shaft is in contact with height adjustment cam on lift system.

8. Adjust front and rear chain lengths (E) on each side of machine so there is no slack in links and deck is freely supported by the 76 mm (3 in.) wood blocks.

9. Step on deck lift pedal and turn height-of-cut knob to the transport position.

· The transport position is the 127 mm (5 in.) cutting height position.

10. Remove wood blocks from under both sides of the mower deck.

11. Step on deck lift pedal and turn height-of-cut knob to the 76 mm (3 in.) cutting height position.

12. Check side-to-side mower level. Repeat adjustment as needed.

Checking Level (Front-to-Rear)

1. Step on deck lift pedal and turn height-of-cut knob to the 76 mm (3 in.) cutting height position.

2. Position right mower blade (discharge side) in the straight forward (front-to-rear) position.

3. Measure from the right front blade tip to the ground.

4. Turn blade 180° and measure from right rear blade tip to the ground.

M40137

· The height (F) of the rear blade tip should be between 3 - 6 mm (1/8 - 1/4 in.) higher than the front blade tip.

5. If the front-to-rear level is not within the given tolerance, an adjustment is necessary.

Adjusting Level (Front-to-Rear)

NOTE: Adjust side-to-side mower level before adjusting front-to-rear level.

Adjust both sides of the mower deck equally.

MX10327

1. Loosen jam nut (G) on each deck lift assist rod.

2. While positioned in front of the machine, adjust mower level:

· Turn hex nut (H) clockwise to lower front of mower deck.

· Turn hex nut (H) counterclockwise to raise front of mower deck.

3. Verify that the adjustment on right and left sides is equal.

4. Tighten jam nuts.

5. Check front-to-rear mower level.

6. Install mule belt when all adjustments are made.

Mulch-On-Demand Mower Deck - Adjusting Linkage

NOTE: Clean mower deck to allow free movement of baffles.

1. Move deck mode lever into the side discharge position. See Operating Mulch-On-Demand Mower Deck.

MX20357

MX20357

A - Baffle Link

B - Slider Bushing Bolt

C - Jam Nut

D - Left Outer Baffle Arm

E - Left Inner Baffle Arm

F - Cotter Pin

G - Nut

H - Right Outer Baffle Arm

I - Discharge Gate Link

J - Extension Spring

K - Discharge Gate

L - Handle Link

M - Deck Mode Lever Arm

N - Right Inner Baffle Arm

O - Deck Mode Lever

2. Disconnect the extension spring (J) connected to the right outer baffle arm (H).

3. Loosen the five jam nuts (C) on links (A, I and L), and disconnect them from their respective arms at the rod end side.

MX20355

4. Loosen the slider bushing bolt (B). Adjust the right inner baffle arm (N) until it makes contact with its stop point. Adjust the right outer baffle arm (H) until the right outer baffle makes contact with the right inner baffle. Tighten the slider bushing bolt (B).

5. Adjust the left outer baffle arm (D) until it makes contact with its stop point. Adjust the baffle link (A) to fit the left outer baffle arm. Secure baffle link (A) to left outer baffle arm (D) with the appropriate hardware and tighten the jam nut.

6. Adjust the left inner baffle arm (E) until it makes contact with the left outer baffle. Adjust the baffle link (A) to fit the left inner baffle arm. Secure baffle link (A) to left inner baffle arm (E) with the appropriate hardware and tighten the jam nut.

MX22703

7. Adjust the discharge gate link (I) so that the discharge gate (K) is fully closed. Secure discharge gate link to discharge gate with the appropriate hardware and tighten the jam nut.

· With discharge gate in the mulch position (rear most gate) turn the right spindle to insure that the blade does not contact the gate (K). If the blade contacts the gate, move the washer, which is located under the M6 flange nut, to the position under the head of the M6 carriage bolt (P) and readjust the gate link. Verify that the blade clears the gate in this new position.

8. Install the handle link (L) on right outer baffle arm (H) and move the deck mode lever (O) to the side-discharge position.

9. Attach extension spring (J).

10. Move deck mode lever (O) into the mulch position Adjust handle link (L) so that the baffles and discharge gate are fully closed when the deck mode lever is latched into the rear most gate. Tighten the jam nuts on handle link (L).

11. Cycle the deck mode lever several times to make sure the baffles move freely and fully from mulch mode to side discharge mode. If baffles need further adjusting, adjust appropriate linkage.

Testing Safety Systems

c CAUTION: Avoid injury! Engine exhaust fumes contain carbon monoxide and can cause serious illness or death. Move the machine to an outside area before running the engine. Do not run an engine in an enclosed area without adequate ventilation. · Connect a pipe extension to the engine exhaust pipe to direct the exhaust fumes out of the area. · Allow fresh outside air into the work area to clear the exhaust fumes out.

The safety systems installed on your machine should be checked before each machine use. Be sure you have read the machine operator manual and are completely familiar with the operation of the machine before performing these safety system checks.

Use the following checkout procedures to check for normal operation of machine.

If there is a malfunction during one of these procedures, do not operate machine. See your authorized dealer for service.

Perform these tests in a clear open area. Keep bystanders away.

Testing PTO Switch

MX21193

1. Sit on the operator seat with the motion control levers (A) in the neutral lock position.

2. Lock the park brake.

3. Pull PTO knob (B) up to engage mower deck.

4. Turn key switch to the start position.

Testing Park Brake Switch

MX21193

1. Sit on the operator seat with the motion control levers (A) in the neutral lock position.

2. Push PTO knob (B) down to disengage.

3. Unlock park brake (C).

4. Turn key switch to the start position.

Testing Neutral Start Switch

NOTE: Do not sit on the seat during this test.

MX21195

1. Move motion control lever(s) (A) inward to the neutral position.

2. Lock the park brake (B).

3. Push PTO knob (C) down to disengage.

4. Turn key switch to the start position.

Testing Seat Switch

1. Start the engine.

2. Unlock park brake.

c CAUTION: Avoid injury! Before engaging attachment, make sure that area is clear of bystanders, especially children.

3. Pull PTO knob up to engage.

4. Rise slightly off the seat.

Testing the Park Brake

ztrak-m653dROPS

1. Stop machine on a 17° slope (30% grade). Stop the engine and lock the park brake.

Break In PTO Clutch

1. Start engine and move machine to flat level surface.

2. Push throttle to full-throttle position.

3. Engage PTO and allow mower deck to run for 10 seconds.

4. Disengage PTO and wait 10 seconds.

5. Repeat steps 3 and 4 for 12-15 cycles.