P ARTS MANUAL - Mower Parts Web
Contents
1. 21 KAW 1 OBTAIN LOCALLY 92 64152 46 SCREW SLT HH 10 24X112 2 5 4138859 7 BRACKET RELAY MNTG 1 53 64025 15 NUT HEX 10 24 KEPS 2 6 2186211 5 HYD RESERVOIR W LABS 1 54 64229 08 LOCKNUT NYLON 5 16 24 2 f 64263 013 BLT FLG HD M10 1 5 X 30 55 64025 33 5 16 24 LH 2 8 64197 016 BLT TDFM 3 8 16 1 2 96 64263 002 BLT FLG HD M6 1 0 X 16 4 9 64268 03 LOCKNUT 3 8 16 57 4118507 7 BRKT MUFFLER LH 1 10 831861 BOLT BENT BATT HOOK 4118508 7 BRKT MUFFLER 1 11 64141 4 NUT WLF 3 8 16 12 64237 03 LOCKNUT NYLON M10 1 5 13 4118430 14 38369 02 END BALL JOINT LH 15 2188140 TURNBUCKLE 16 64205 003 BLT MET M8 1 25X30 17 64229 02 LOCKNUT NYLON 5 16 18 18 2182405 7 BRKT REVERSE RETURN 19 A1104057 BOLT M10 1 50X25 20 64246 03 NUT WHIZ 10 1 50 21 64123 205 BLT HEX 5 16 24 4 22 2188145 BEARING 75IDSELF ALIGN 23 38020N CLEVIS YOKE 5 16 PLATE 24 64188 02 PIN CLEVIS 5 16X1 25 64168 2 08 1 19 26 64025 03 NUT HEX 5 16 24 27 2188139 SPRING COMPRESSION 28 2121246 DAMPENER 29 4112105 7 VVLDMT MOTION CTRL RH 4112104 WLDMT MOTION CTRL LH 58 2120607 ENGINE KAWASAKI 19 1 4114746 S AIR FILTER PRIMARY 1 4114747 S AIR FILTER SAFETY 1 2122214 FILTER OIL 1 38666 FILTER FUEL 1 ITEMS 39 46 56 amp 59 62 FOR USE WITH KAWASAKI ENGINES ONLY 59 64263 007 BLT FLG HD M8 1 25 X20 2 60 64266 02 NUT FL LOCK 8 1 25 2 61 2188226 ASSY MUFFLER 1 62 3862. 40 ZT 200 Series ITEM HYDROGEAR PART NO 1 70516 2 10517 3 50641 4 50969 5 51232 6 2513027 7 50273 8 9004101 1340 10 50095 15 2513030 18 10521 19 50315 20 51161 21 50951 22 50329 25 70331 29 2003014 30 2003017 31 51246 32 2003087 34 50551 37 2003005 38 2000015 42A 70743 42 70741 44 70403 49 2513043 56 9005110 4400 66 9005110 3100 100 10525 CGC INC PART NO 2121615 01 2121615 02 38345 06 38345 07 38345 08 38345 10 2121615 09 188059 11 2121615 11 188059 15 2121615 13 4121354 4121355 2121615 16 2121615 17 2121615 18 HYDROGEAR PUMP DESCRIPTION HOUSING KIT END CAP KIT STRAIGHT HEADLESS PIN FLANGE BOLT M8 1 25 X 60 HOUSING O RING CHARGE PUMP KIT STD GEROTOR ASSEMBLY O RING SOCKET SCREW M6 1 0 x 20 BYPASS VALVE KIT BLANK PUMP SHAFT KIT BALL BEARING 17 X 40 X 12 LIP SEAL 17 x 40 x 12 SPACER RETAINING RING CYLINDER BLOCK KIT BLOCK SPRING BLOCK THRUST WASHER VALVE PLATE SWASH PLATE BALL THRUST BEARING ARM TRUNION SLOT GUIDE SHOCK VALVE KIT 031 SHOCK VALVE KIT BLANK CHARGE RELIEF VALVE KIT TRUNNION SEAL RETAIN KIT STRAIGHT THREAD PLUG 9 16 SAE PLUG OVERHAUL SEAL KIT QTY LA ee X IX X a N NO E FIGURE 8 41 KOHLER WIRE HARNESS ZT 200 Series FIGURE 9 CLUTCH ELECTRIC 13 4 12 WIRE COLORS ENGINE FE WHITE W BLACK STRIPE PURPIF ORANGE BATTERY BATTERY ORANGE WI B
3. MAN 4163279 Rev A 01 2008 OPERATOR S MANUAL 4163280 942220E ZT219 19HP KAW W 48 SIDE DISCHARGE 942221E ZT219 19HP KAW W 52 SIDE DISCHARGE 942233E ZT225 25HP KAW W 61 SIDE DISCHARGE 942244E ZT225 25HP KAW W 52 SIDE DISCHARGE 942237 21227 27HP W 61 SIDE DISCHARGE 942248E ZT221 21HP KAW W 52 SIDE DISCHARGE 942249E ZT227 27HP KAW W 61 SIDE DISCHARGE Commercial Grounds Care Inc PARTS MANUAL CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Californie Proposition 65 Avert issement Les echappements des moteurs diesel et certains de leurs composes sont reconnus par l Etat de Californie pour tre canc rig nes provoquer des d fauts cong nitaux et d autres dangers en matiere de reproduction de la Proposicion 65 El estado de California hace saber que los gases de escape de los mo tores diesel y algunos de sus com ponentes producen c ncer defectos de nacimiento y otros danos en el proceso de reproducci n humana WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm AVERTISSEMENT L mission du moteur de ce materiel contient des produits chimiques que l Etat de Californie consid re tre cancerigenes provoquer
4. Adjust the clevis yoke by turning the head of the bolt until the clevis pin just makes contact with the rear of the slot in the lever it connects with Tighten jam nut Repeat steps 2 and 3 for the opposite side NOTE Aslight creep in reverse is acceptable provided the wheel does not turn and the hydrostat pump does not whine when the parking brake is on 18 ZT 200 Series Right side adjustments wiring harness and seat rod removed for clarity ZT 200 BELT REPLACEMENT Series Note Always use CGC Inc replacement belts not general purpose belts CGC Inc belts are specially designed for use on commercial mowers and will normally last longer ENGINE CUTTERDECK PTO BELT 1 Set the cutterdeck in the lowest height of cut position Attach a short extension to a 3 8 drive ratchet Insert the ratchet extension into the square hole in 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 cutterdeck pulley Push belt back under engine deck Disconnect the electric clutch from the wire har ness at plug P Remove the carriage bolts securing torque re straint Q to clutch R Remove torque restraint Remove old belt from the machine Install a new belt by performing the these steps In reverse order 19 BELT REPLACEMENT ZT 200 Series CUTTERDECK BELT 1 Set the cutterdeck the lowest height of cut pos
5. BRAKING Parker brakes Spring applied for overload protection SEAT High back foam padded full suspension seat with standard armrests Fore and aft adjusters hinged for easy tilt up access to pumps and battery Internally mounted seat switch SPECIFICATIONS 7T 200 Series ENGINES MODEL 942220E 942233E NUMBERS 942221 942244 942237 942248 942249 MODEL FHV19 FHV25 CV740 FHV21 FX751 2 96 X 2 99 2 96 X 2 99 3 27 X 2 64 2 96 X 2 99 3 33 X 2 99 PORE On 75 2 X 76 mm 75 2 X 76 mm 83 X 67mm 75 2 X 76 mm 184 5 76mm 41 2 cu in 41 2 cu in 44 cu in 41 2 Cu in 52 0 cu in DISPLACEMENT 675 cc 675 cc 725cc 675cc 852cc 19 hp 14 2 kw 25 hp 18 6 kw 27hp 20 1kw 21hp 15 6 1kw 27hp 20 1 kw DE 3600 rpm 3600 rpm 3600 rpm 3600 rpm 3600 rpm 37 0 ft lb 50 2 41 3 ft lb 56 0 42 7 ft lb 57 9 OUTPUT TORQUE J J J 2500 rpm 2400 rpm 3000 rpm FULL FULL FULL FULL FULL Eon PRESSURE PRESSURE PRESSURE PRESSURE PRESSURE AIR CLEANER Duabelerent Heavy duly Heavy duty Dual element Dual element cyclonic cyclonic CHARGING 15 amp 15 amp 15 amp 15 amp 15 amp SYSTEM regulated regulated regulated regulated regulated BATTERY group U1 group U1 group U1 group U1 BCI group U1 Two 20 amp Two 20 amp Two 20 amp Two 20 amp Two 20 amp blade blade blade blade blade FUEL CONSUMPTION 1 7 gal hr 2 3 gal hr 2 2 gal hr MAX LOAD 6 5 Uhr 8 8 8 3 S
6. Repeat steps 2 7 on opposite side of machine Replace wheels and tighten wheel nuts This adjustment will cause the brake springs to stretch 3 8 when the parking brake is in the ON posi NOTE Parking brake must be in the OFF position to tion providing the correct parking brake force without properly seat brake drums overloading the brake arm Parking brake assembly tire and deck not shown for clarity brake in ON position 17 ADJUSTMENTS HYDROSTAT ADJUSTMENTS A turnbuckle style hydrostat neutral adjustment is provided Neutral 1 Support the machine with the rear wheels off the ground Use jackstands or equivalent sup port Do not rely only on mechanical or hydraulic jacks Move the traction levers out into the neutral lock position and raise the seat Disconnect the seat switch wire K and temporarily connect the two terminals with jumper wire J as shown Start the engine and run at low speed Loosen jam nuts T at both ends of the turnbuckle Rotate 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 Repeat steps 5 and 6 for the opposite side Remove the jumper wire and reconnect the seat switch Reverse Return 1 4 Move traction levers out to the neutral lock posi tion and raise the seat Locknut U should be run on the bolt as far as it will go Loosen jam nut Y
7. Tighten cables securely to battery terminals and apply a light coat of silicone dielectric grease to terminals and cable ends to prevent corrosion Keep terminal covers in place Read Operation and Safety Manual before starting Run engine at full RPM for 5 minutes before engaging blades to allow the engine to be fully lubricated before load is 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 MAINTENANCE CHART ZT 200 nn Series Maintenance is an ongoing job These intervals are maximum times between maintenance operations Perform more often under severe conditions MAINTENANCE OPERATION FIRST 5 d EVERY HOURS DAILY 50 HOURS ENGINE Consult the engine manual for additional information and instructions Check Top Off Engine Coolant Level Where Applicable Check Top Off Oil Level Check For Leaks For Leaks E Air Intake Screen Clean Air Cleaner Clean Air Element Clean Cooling Fins Change Oil And Filter Check Replace Spark Plugs N A IF EQUIPPED WITH HEAVY DUTY CYCLONIC AIR CLEANER IF EQUIPPED WITH HEAVY DUTY CYCLONIC AIR CLEANER HYDRAULICS ELLE op Off O
8. 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 fit 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 Install assembly on the blade spindle Torque the blade bolt to 70 ft lbs ks SED puse 9 1 ZT 200 Series DECK LEVELING a Park the machine on a smooth level surface Raise the deck to the transport position b Lower the deck onto a set of equal height blocks A under the rear corners of the deck Place an other set of blocks B under the front of the deck so that the deck top is pitched forward 1 8 NOTE The front and rear of the deck are at different heights c Measure the height of the blade cutting edge above the ground Remove pin C and set the height of cut lever D to that height d Loosen nuts lat all four corners of the deck NOTE This will relieve tension on chains H e Loosen the jam nuts E on the height of cut clips F and adjusting screws G Turn the adjusting screws G until the play is taken ou
9. amp 17 9 8 128010 KEY SWITCH 9 9 2722325 RELAY 40AMP SEALED 9 10 2188154 MODULE DELAY 9 11 2721505 SWITCH PTO 9 12 2721337 CLUTCH ELECTRIC INCLUDES 2720949 WIRE ASSY 9 13 2720949 ASSY CLUTCH WIRE 9 14 108208 SWITCH DBL POLE 9 15 2188156 5 DBL POLE 9 16 112386 BOOT BAT TERM POS 9 17 2308095 COVER TERMINAL 9 18 4142266 12 a o 43 KAWASAKI WIRE HARNESS ZT 200 FIGURE 10 Series CLUTCH gt 12 WIRE COLORS WHITE 20 WHITE Wl BLACK STRIPE ORANGE BATTERY BATTERY ORANGE Wi BLACK STRIPE PURPLE W GRANGE STRIPE E 2317 DRANGE W PURPLE STRIPE DARK BLUE RED BLACK BLACK efern _ 1 1 PR RED ENGINE BLOCK SOLENOID YE wm A E BR BROWN I BROWN VI YELLOW STRIFE e 10 VO bl TO ENGINE BLOCK GROUND DELAY MODULE CARB SOLENOID MAGNET 4 PACKARD 9 02962793 2 gt VOLTAGE 19 REGULATOR Too RELAY 1 TO SOLENOID 4 12279 P 21 4 9 E 18 RED TO SOLENOID 3 Y STARTER RELAY U U U 24 8 TO SOLENOID 2 15 SWITCH 4 87A NC 30 87 85 86 RELAY SCHEMATIC 5 14 y 5 TRACTION 4 Q a 6 de 2 gt al zs 2 G u qe gt 16 mL NP o 9 AUXILLARY ELECTRICAL CONNECTION i pls CLUTCH SWITCH RELAY E
10. 16X3 4 25 64141 4 NUT WLF 3 8 16 26 64207 07 M12 1 75 2 64168 2 08 1 19 28 64025 03 NUT HEX 5 16 24 29 64006 05 LOCKWSHR HELICAL 1 2 30 4159242 WLDMT PRK BRAKE ROD 31 450767 CAPSCREW 12 1 75X110 32 64164 08 S KEY FOR WHEEL MOTOR 2 33 64025 31 NUT 1 20 UNSLOTTED TRW 2 34 99 B34 WASHER 1 OQ NN Q NOT ILLUSTRATED 35 OIL COOLER ZT 200 Series FIGURE 6 36 ZT 200 OIL COOLER Series FIGURE 6 ITEM PART NO DESCRIPTION QTY ITEM PART DESCRIPTION QTY 4136780 S ENGINE DECK W LABS 1 4139443 7 BRKT COOLER FRONT 1 64263 002 BLT FLG HD M6 1 0 X 16 4 2720891 7 SCREEN OIL COOLER 1 2188173 COOLER OIL 1 2186211 5 RSRVR W LABS 1 O 69053 05 IS A SERVICEABLE LENGTH OF 55 TA 69053 05 3 8 HIGH TEMP HOSE 26 1 7B 69053 05 318 HIGH TEMP HOSE 22 1 8 48228 2A CABLE CLIP 3 4 W INSTN 9 88042 04 CLAMP 3 4 CLIP 10 58026 01 WAY CONNECTOR 3 8 11 2722296 ARM BUMPER 12 64237 02 LOCKNUT NYLON M6 1 00 13 4139367 7 BRACKET REAR COOLER 14 64265 05 NYL LOCK M10 1 5 15 64263 013 BLT FLG HD M10 1 5 X 30 16 4162890 7 BRACKET REAR COOLER 17 4162889 7 BRACKET FRONT COOLER 1 ITEMS 16 amp 17 USED ON 942249E ONLY MOON N KNN 37 ZT 200 Series HYDRAULICS FIGURE 7 38 ZT 200 HYDRAULICS Series FIGURE 7 ITEM PARTNO DESCRIPTION QTY 1 2186211 SHYD RESERVOIR VVILAB 1 2 02720398 FILTER2
11. 18 BOLT CARRIAGE 3 8 16X2 17 2302125 7 GUIDE BELT 18 48393 PULLEY VIDLER 19 38297 IDLER 5 0 OD FLNGD 20 2228034 PULLEY 5 25 DEEP GRV 21 64209 03 SPRING WSHR 67 ID 22 64164 12 1 4 1 4 1 SQ END KEY 23 128169 PULLEY IDLER 5 50 24 4115849 S ASSYSPNDL ZT200 CNTR 1 63 64018 30 BOLT CRG 3 8 16 X 4 1 2 1 INCLUDES ITEMS 57 61 64 4149017 7 HINGE CHUTE RUBBER 1 65 64262 013 BLT FLG HD 3 8 16 X 1 1 2 2 25 4129075 ASSY DECK IDLER 48 52 1 66 4163030 7 VVLDMT IDLER PIN 1 INCLUDES ITEMS 41 51 53 4 63 47 64163 64 WSHR 1 015X1 500X14 1 48 64229 01 LOCKNUT 1 4 20 NYLON 4 49 4134336 7 BAFFLE FRONT CTR 48 1 8 50 4120175 7 BAFFLE 48 FRONT 1 51 4127999 SEAL 1 2 1 2 N O KON gt 52 4163155 INNER RING 53 4163014 SPACER 64144 40 SNAP RING 95 64268 03 NYLN LOCK 3 8 16 9 56 4120208 7 BAFFLE DISCHARGE 32 48 1 8 57 38348 01 BEARING SPINDLE SEALED 6 58 2121096 HOUSING SPINDLE 6 HOLE 59 64144 38 SNAP RING 3 60 38315 NUT SPINDLE 3 61 2183070 01SHAFT SPINDLE LONG 1 USED ON 4115849 CENTER SPINDLE ONLY 62 2183070 02SHAFT SPINDLE 2 USED ON 4115850 OUTER SPINDLE ONLY 4 0 AQ C gt 26 4115850 S ASSYSPNDL ZT200 OUTR 2 INCLUDES ITEMS 57 60 4 62 2 64270 02 BOLTI HEXM10 1 5x30ISO CL10 9 2 28 4133155 7 WLDMT PUSHBAR 2 29 64006 05 LOCKWSHR HELICAL 1 2 1 30 64123 05 BLT HEX 1 2 20 1 1 2 1 31 64163 46 WASHER 383 393X 88X7 4 32 2186125 WLD
12. 30 64205 052 10 1 5 50 1 31 85010N ZERK 1 4 28 STR SELF TH 1 32 64221 04 E RING 875 1 33 64175 05 NUT PUSH 1 2 1 34 64188 36 CLEVIS 7 16 1 1 4 2 35 2188143 GRIP 1 36 2183071 03 SPACER 15 88X10 32X24 2 37 64265 05 NUT FL NYL LOCK M10 1 5 4 38 2120544 SPRING COMPRESSION 1 39 4159284 ROD LIFT STOP 1 40 64163 65 WSHR 890X1 375X18GA 3 41 2120742 LBL ZT200 HT CUT OUTER 1 42 2120743 LBL ZT200 HT CUT INNER 1 43 64163 29 WASHER 21 64 X 1 X 11GA 2 NOT ILLUSTRATED 51 CRADLE ASSEMBLY ZT 200 Series FIGURE 14 LLI lt l lt lt 0 14 gt 77 DA 52 ZT 200 CRADLE ASSEMBLY Series FIGURE 14 ITEM PART DESCRIPTION QTY ITEM PARTNO DESCRIPTION QTY 1 4118843 LABEL WARNING 1 2 2182356 7 BRACKET SHAFT HANGER 4 3 2188127 CHAIN 6 35 250 5 LINKS 4 4 4139065 MAT FOOT PLATE LOWER 1 5 4129955 MAT FOOT PLATE MIDDLE 1 6 2721861 PLATE UPPER 1 7 4157861 LABEL PROCAT 1 8 4109780 S FOOT PLATE BOBCAT 1 INCLUDES ITEMS 4 7 9 64163 65 WASHER 890X1 375X18GA 10 64221 04 E RING 875 11 4159283 7 WLDMT DECK LIFT FRONT 12 2722559 7 VVLDMT DECK LIFT REAR 13 2122630 HEIGHT ADJ 14 2122119 SPRING DECK LIFT NOT USED ON 48 DECKS Nba 15 4159920 7 WLDMT CRADLE 1 16 64265 05 NUT FL NYLN LCK M10 1 5 1 17 4109960 WLDMT DECK LIFT ROD 2 18 4111842 7 BRKT SPRING ANCHOR LH 1 19 4139785 MAT FOOT LIFT 1 20
13. 4113682 ROD SPRING MOUNT 2 21 64141 2 NUT WLF 1 4 20 4 22 64141 4 NUT WLF 3 8 16 4 ITEMS 18 19 20 amp 22 NOT USED ON 48 DECKS 23 64197 020 BLT TDFM 1 4 20X1 1 2 4 24 64205 007 BLT MET M10 1 50X20 2 29 64205 029 12 1 75 40 4 26 64205 060 BOLT MET 12 1 75 50 4 2 64263 013 BLT FLG HD M10 15X30 15 28 64246 04 NUT WHIZ M12 1 75 16 29 85010N ZERK 1 4 28 STR SLFTHRD 1 30 85051 ZERK 1 8 PIPE 6 31 64237 03 LOCKNUT NYLON M10 1 5 2 USED ON 48 ONLY NOT ILLUSTRATED 53 CRADLE amp CASTER ASSEMBLY ZT 200 Series FIGURE 15 222 gt 94 ZT 200 CRADLE amp CASTER ASSEMBLY Series FIGURE 15 ITEM PART NO DESCRIPTION QTY ITEM PART DESCRIPTION QTY 1 48043 03C CUP OUTER BEARING 4 27 2722401 7 WLDMT CASTER ARM 48 LH1 2 2721306 7 WLDMT CASTER YOKE 2 28 2722400 7 WLDMT CASTER ARM 48 RH1 3 DECK W LABS USED WITH 48 DECKS 4 64123 215 BOLT HEX 3 4 10X7 1 2 2 5 2122228 WHEEL 13X5 00 6 ASSY 2 29 64123 223 BOLT 3 4 10 X 10 2 INCLUDES ITEMS 6 6 30 2122326 02 RIM ASM VVIVALVE STEM 2 USED ON 48 amp 52 DECKS ONLY 31 2122326 01 TIRE 13X6 50 6 SMOOTH 2 33 2122326 ASSY WHL 13X6 5 6 2 6 2720475 01 13 5 00 6 SMOOTH 1 INCLUDES ITEMS 7 31 amp 32 7 2722228 03BEARING 2 8 2122228 01RIM 13 ASSY W VALVE 1 33 2722230 03 SPANNER 2 9 2722231 5 4 34 2122452 22 WLDMT CASTER YOKE 2 10 64163 26 WASHER 2 ITEMS 29 34 USED ON 61 DECKS 11 64229 07 LO
14. E clips Y Secure seat wire W on the bottom of the seat plate with clip C and a 1 4 20 X 318 thread forming screw Connect the tractor harness to the seat wire Bottom of seat plate Z showing clip C 3 Set tire pressures to 14 Ibs in 1 0 kg cm Tires are overinflated for shipping ASSEMBLY AND SETUP ZT 200 Series 4 TRACTION LEVERS a Loosen bolt A and remove bolt B b Rotate traction lever D into position and secure with bolts A and B Repeat for the other lever c Tighten all fasteners d Siton the machine Levers may be adjusted in bracket C for a more comfortable reach or moved to upper set of holes for a better operator fit 5 DECK LEVELING a Park the machine on a smooth level surface Raise the deck to the transport position b Lower the deck onto a set of equal height blocks A under the rear corners of the deck Place an other set of blocks B under the front of the deck so that the deck top is pitched forward 1 8 NOTE The front and rear of the deck are at different heights c Measure the height of the blade cutting edge above the ground Remove pin C and set the height of cut lever D to that height d Loosen nuts lat all four corners of the deck NOTE This will relieve tension on chains H e Loosen the jam nuts E on the height of cut clips F and adjusting screws G Turn the adjusting screws G until the play is taken out of the chains H at all four corners Tighten the
15. des d fauts cong nitaux et d autres dangers en matiere de reproduction ADVERTENCIA El estado de California hace saber que los gases de escape de este producto contienen productos quimi cos que producen c ncer defectos de nacimiento y otros danos en el proceso de reproducci n humana CALIFORNIA Proposition 65 Warning Battery posts terminals wiring insulation and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm WASH HANDS AFTER HANDLING ZT 200 Series IMPORTANT MESSAGE Thank you for purchasing this CGC Inc product You have purchased a world class mowing product one of the best designed and built anywhere This machine comes with an Operation and Safety Manual and a separate Setup Parts and Maintenance Manual The useful life and good service you receive from this machine depends to a large extent on how well you read 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 CGC Inc product is one of our prime design objectives Many safety features are built in but we also rely on your good sense and care to achieve accident free operation For best protection study the manuals thoroughly Learn the proper operation of all controls Observe all safety precautions Follow all instruc
16. 14 64262 012 BLT FLG HD 3 8 16 X 1 1 4 18 57 4115864 7 BAFFLE DISCHARGE 15 4163028 ASSY IDLER ARM PTO 58 38348 01 BEARING SPINDLE SEALED 6 16 64018 18 BOLT CARRIAGE 3 8 16X2 59 2121096 HOUSING SPINDLE 6 HOLE 17 2302125 7 GUIDE BELT 60 64144 38 SNAP RING 3 18 48393 PULLEY V IDLER 61 38315 NUT SPINDLE 3 19 38297 IDLER 5 0 OD FLNGD 62 2183070 01SHAFT SPINDLE LONG 1 20 2228034 PULLEY 5 25 DEEP GRV 21 64209 03 SPRING WSHR 67 ID 22 64164 12 1 4 1 4 1 SQ END KEY 23 128169 PULLEY IDLER 5 50 24 4115849 S ASSYSPNDL ZT200 CNTR INCLUDES ITEMS 58 62 64 64018 30 BOLT CRG 3 8 16 X 4 1 2 3 65 64018 5 3 8 16X1 3 4 1 25 4129075 55 IDLER 48 52 1 66 64262 013 BLT FLG HD 3 8 16 X 1 1 2 2 1 1 CO YO Hh 5 USED ON 4115849 CENTER SPINDLE ONLY 63 2183070 02SHAFT SPINDLE 2 USED ON 4115850 OUTER SPINDLE ONLY INCLUDES ITEMS 41 51 43 amp 54 67 4163030 7 WLDMT IDLER PIN 68 64123 217 BLT HEX 3 8 16X4 1 4 CTR 26 4115850 S ASSYSPNDL ZT200 2 INCLUDES ITEMS 58 61 amp 63 NOT ILLUSTRATED 27 64270 02 BOLTHEXM10 1 5x30ISOCL109 28 4133155 7 VVLDMT PUSHBAR 29 64006 05 LOCKVVSHR HELICAL 112 30 64123 05 BLT HEX 1 2 20X1 1 2 31 64163 46 VVASHER 3831 393X 88X7 32 2186125 VVLDMT LOCK PUSHBAR 33 85010 ZERK 1 4 28 STR SLF THD 34 64123 152 BLT HEX 5 8 11X5 35 64123 50 BOLT HEX 3 8 16 1 36 64229 02 LOCKNUT NYLON 5 16 18 37 4118314 SPACER BLADE 16MM 38 64229 06 LOC
17. 3 1 2722296 ARM BUMPER 2 3 2 4136780 SENG DECK W LABS 1 3 3 2721324 7 WLDMT BUMPER 1 3 4 64263 013 BLT FLG HD 10 1 5 X30 10 3 5 64265 05 NUT FL NYL LOCK M10 1 5 10 3 6 2721932 7 BRACE VERTICAL 1 31 FUEL TANKS CONTROL PANEL ZT 200 Series FIGURE 4 15 2 2 l LLI IL TO ENGINE 32 Series FIGURE 4 ITEM PART NO DESCRIPTION QTY ITEM PART DESCRIPTION QTY 1 4162990 TANK FUEL LH 1 INCLUDES ITEMS 18 amp 19 2 4162991 TANK FUEL RH 1 INCLUDES ITEMS 18 amp 19 3 4159162 5 PANEL 4 4136780 SENG DECK W LABS 9 4160281 S DOC TUBE VVILABEL 6 4130320 CAP FUEL GASOLINE 3 5 7 4110023 PLUG SWITCH HOLE 8 64205 007 BLT MET M10 1 50X20 9 38061A VINYL CAP 10 2188178 SWITCH RETAINER 11 64263 001 BLT FLG HD M6 1 0 X 12 12 88042N HOSE CLAMP 13 128010 KEY SWITCH 14 118020 16 CONTROL THROTTLE 48 19 2121505 SWITCH PTO 16 64025 15 NUT HEX 10 24 KEPS 17 64152 46 SCR SLT HH 10 24X1 2 18 4132325 GROMMET FUEL TANK 19 4162997 001 TUBE FUEL LINE 20 800488 LOCKWASHER M10 21 64251 004 WASHER M10 22 2188161 VALVE TANK SELECTOR 23 4162977 016 HOSE 251DX 500D X 48 24 4142266 CONNECTOR 12V RECEPT 1 29 4162977 009 HOSE 25IDX 500D X 24 1 Oo PP a oO NY NYO 26 38666 FILTER FUEL B amp S 1 2 128010 01 S KEY SWITCH NYLON NUT 1 28 128010 03 S COVERED KEY 1 29 4158086 7 PLATE KICK 1 30 48228 2A C
18. 5MICRON i 3 69216 7 CAP RESERVOIR 1 PARA 4 4160243 PLUG HYDRAULIC TANK 1 NUMBER THREAD SIZE AS 568 5 158058 04 FTG 90 BRB 9 16 18X 38 2 6 108205 03 ELBOW MALE 45 37 ORB 4 158061 10 69053 05 IS A SERVICEABLE LENGTH OF 55 TA 69053 05 318 HIGH TEMP HSE 18 7B 69053 05 3 8 HIGH TEMP HSE 15 158061 12 1 1 7 69053 05 3 8 HIGH TEMP HSE 19 1 7D 69053 05 318 HIGH TEMP HSE 12 1 1 1 1 158061 11 3 4 16 908 69053 05 3 8 HIGH TEMP HSE 22 m TF 69053 05 3 8 HIGH TEMP HSE 26 7G 69053 05 3 8 HIGH TEMP HSE 5 158061 16 8 2188157 01HOSE HYD ORB 37 22 38 2 158061 03 USE QTY 1 ON 19HP amp 25HP KAW USE QTY 2 ON 27HP KLR 9 2188157 02 5 HYD ORB 37 25 00 USE QTY 1 ON 25HP amp 27HP KAW USE QTY 2 ON 19HP KAW amp 27 KLR 10 4159280 MOTOR PARKER 2 11 2690030 01F TG 9 16 18 ORB X 3 8 2 12 58026 01 WAY CONNECTOR 3 8 2 13 88042 04 CLAMP HOSE 5 8 14 14 4137278 PUMP HYDRO 12cc 2 15 2120320 02HOSE 112 37 45 37 1 USE ON LH SIDE OF 27HP KAW ONLY 16 2188173 OIL COOLER 1 17 48089 03 FTG STRGHT 8 ORB X 8 JIC USE QTY 1 ON 19HP KAW USE QTY 2 ON 25HP KAW 18 2120320 01HOSE 112 37 45 37 26 25 1 USED ON 19HP 25 8 27HP KAW ONLY USE QTY 2ON 27HP KAW 19 64123 60 BOLT 1 4 20X2 HEX 2 20 64229 01 LOCKNUT NYL 1 4 20 2 39 ZT 200 Series 32 t x lt o lt X Lu gt O GROUP A HYDROGEAR PUMP FIGURE 8 E
19. 6 26 4115850 27 64270 02 28 4133155 7 29 64006 05 30 64123 05 31 64163 46 32 2186125 33 85010N 34 64123 152 35 64123 50 36 64229 02 37 4118314 38 64229 06 39 64123 187 40 64123 208 41 4128004 42 4134344 7 BOLT HEX M10 1 5X30 ISOCL109 WLDMT PUSHBAR LOCKWSHR HELICAL 1 2 BLT HEX 1 2 20X1 1 2 WSHR 383 393X 88X7 WLDMT LOCK PUSHBAR ZERK 1 4 28 STR SLF THD BLT HEX 5 8 11X5 BOLT HEX 3 8 16X1 LOCKNUT NYLON 5 16 18 SPACER BLADE 16MM LOCKNUT NYLON 5 8 11 BLT HEX 5 8 18X3 75 BLT HEX 5 8 18X1 5 BEARING BAFFLE RIGHT FRONT 00 00 00 AN Q N N FIGURE 18 ITEM PARTNO DESCRIPTION QTY 43 4128002 END 2 44 2188131 SPRING EXTENSION 2 45 64163 73 WSHR 625IDX1 120DX 06A R 46 64018 2 1 4 20X3 4 47 64018 5 3 8 16 1 3 4 48 64229 01 LOCKNUT 1 4 20 NYLON 49 4134340 7 BAFFLE FRONT CTR 61 50 4117663 7 BAFFLE FRONT LH 51 4127999 SEAL 92 4163016 VALVE IN LINE FUEL FILTER 1 53 64268 03 NUT FL NYLN LOCK 3 8 16 10 54 4163155 INNER RING 2 55 64144 40 SNAP RING 2 56 64018 3 BOLT 3 8 16X1 CARRIAGE 1 57 38348 01 BEARING SPINDLE SEALED 6 58 2121096 HOUSING SPINDLE 6 HOLE nh 99 64144 38 SNAP RING 3 60 38315 NUT SPINDLE 3 61 2183070 01 SHAFT SPINDLE LONG 1 USED ON 4115849 CENTER SPINDLE ONLY 62 2183070 02 SHAFT SPINDLE 2 USED ON 4115850 OUTER SPINDLE ONLY 63 64123 217 3 8 16 4 1 4 64 64262 013 BLT FLG HD 3 8 16 X 1 1 2 65 4149017 7 HINGE CHUTE
20. 65 SOLENOID 1 63 4123374 ENGINE KOHLER 7405 1 SERVICE MANUAL KOHLER TP 2475 A 4114746 S AIR FILTER PRIMARY 4114747 S AIR FILTER SAFETY 842502 FILTER OIL 38666 FILTER FUEL N JN SN N N N KNN EN SN NN O O N 30 64237 05 LOCKNUT NYLON M8 1 25 8 64 48024 17A NIPPLE PIPE 3 8 X 5 1 31 38369 01 ROD END BALL JOINTRH 2 65 2690033 01 ELBOW 3 8 PIPE 90 DEG 1 32 2182427 7 HOLDDOWN BATTERY 1 66 690501 PLUG PIPE 3 8 1 33 64192 06 SETSCR SQHD 5 16 18 3 4 2 67 4163086 ENGINE KAW FX751 1 34 112386 BOOT BAT TERM POS 1 4152953 S AIR FILTER PRIMARY 35 108208 SWITCH DBL POLE 2 4152954 s AIR FILTER SAFETY 36 2188156 SWITCH NONO DBL POLE 1 68 4163089 ASSY MUFFLER 1 37 64197 015 BLT TDFM 10 32X1 2 TORX 8 69 4163124 7 BRACKET MUFFLER RH 1 38 2188154 MODULE DELAY 1 4163123 7 BRACKET MUFFLER LH 1 39 11060 9016GASKET MUFFLER 2 70 64263 001 BLT FLG HD M8 1 25X 20 4 AVAILABLE THROUGH KAWASAKI DEALER ITEMS 67 70 USED ON 942249E ONLY 40 2308095 COVER TERMINAL 1 41 4158086 7 PLATE KICK 42 64263 011 BLT FLG HD M10 1 5 X20 4 NOTILLUSTRATED 27 LOWER ENGINE DECK ASSY CLUTCH ZT 200 Series FIGURE 2 BELT DETAIL e SUNDSTRAND HYDROGEAR PUMP N N CH SUNDSTRAND HYDROGEAR PUMP LO q O 2 VC 0 664 EM 20 TORQUE TO 50 5 10 28 LOWER ENGINE DECK ASSY CLUTCH Series FIGURE 2 ITEM PART D
21. 79 SEAT SUSPENSION 1 INCLUDES ITEMS 2 15 2 4122479 01CUSHION SEAT BACK 3 4122479 02CUSHION SEAT BOTTOM 4 4122479 03SLIDE RAIL ADJUSTER 9 4122479 04SLIDE RAIL SLAVE 6 4122479 05SKIRT SEAT ASSY 7 4122479 06CLIP SMALL XMAS TREE 8 4122479 07CLIP LARGE XMAS TREE 9 4122479 08ASSY CABLE 10 4122479 09BACK PANEL SEAT 11 4124009 SWITCH SEAT 12 4122481 ARMREST RH 19 4122480 ARMREST LH 14 64123 68 BOLT HEX 5116 18X1 15 64123 54 BOLT 5 16 18X3 4 HEX 16 4121386 7 PLATE SEAT 17 64141 6 NUT WLF 5 16 18 18 4143068 JUMPER SEAT SWITCH 19 33138 09 PIN CLEVIS 20 64144 30 SNAP RING 21 38371 01 BRG NYLINER 3 8 22 48228A CABLE CLIP INSULATED 23 64152 23 SCREW 1 4 20X3 8 N N N N N a I a A X X X x 6 x X X OPTIONAL ROPS 24 970162 ATT ROPS INCLUDES ITEM 22 25 2208260 S SEAT BELT 26 2720975 07 SPACER NYLON 3 8 2 2720975 09 SPACER NYLON 1 4 28 970363 KIT SPRING 8 SADDLE na NNa NOT ILLUSTRATED 47 FOLDING ROPS KIT 970354 ZT 200 Series FIGURE 12 48 ZT 200 Series ITEM PART NO 1 4162879 2 64123 31 3 64151 7 4 4162880 5 4162882 6 4160347 7 64163 19 8 64123 28 9 64006 06 10 64151 11 11 64163 31 12 64006 03 13 64123 16 14 64025 05 15 64168 1 16 4160343 17 4160344 18 4160348 19 4162878 FOLDING ROPS KIT 970354 DESCRIPTION PIN HITCH 1 2 BOLT 1 2 13 X 3 LOCKNUT 1 2 13 LANYARD NYLON SEATBELT LABEL WARNING ROPS WASHER FLAT 7 16 BOLT 7 16 X 1 1 4 LOC
22. BEL LH TRACTION LABEL HT CUT OUTER LABEL HT CUT INNER LABEL WARNING LABEL FUEL LABEL MADE IN USA DECAL CAUTION SPANISH LABEL DURADECK LABEL 19HP LABEL 21HP LABEL 25HP LABEL 27HP LABEL DECK SIZE 52 LABEL DECK SIZE 61 LABEL DECK SIZE 48 NJ X a 1 ITEM PART NO FIGURE 20 DESCRIPTION QTY 65 Series FIGURE 21 ITEM PARTNO DESCRIPTION QTY ITEM PARTNO DESCRIPTION QTY 21 1 2000572 LABEL WARNING BLADES 1 21 2 2000577 LABEL WARNING 2 21 3 2000696 LABEL BLADE INSTALL 1 21 4 2000677 LABEL DANGER WARNING 2 67 COMMERCIAL GROUNDS CARE INC ONE BOB CAT LANE P O BOX 469 JOHNSON CREEK WI 53038 920 699 2000 www cgcequip com BOB CAT BUNTON RYAN STEINER
23. CKNUT NYLON 3 4 10 2 12 85010N ZERK 1 4 28 STRSLF THD 2 13 2122230 02SPANNER 13 WHEEL 2 USED ON 48 amp 52 DECKS ONLY 14 2188135 DUST COVER 2 15 48043 04C CONE OUTERBEARING 4 16 64205 029 12 1 75 40 4 17 64246 04 NUT WHIZ M12 1 75 8 18 48480 SEAL CR 12411 2 19 64140 5 COTTER PIN 2 20 2 22399 7 WLDMT CSTR ARM 52L 1 USED WITH 52 DECKS 21 2722398 7 WLDMT CSTR ARM 52R 61L 1 22 64025 20 3 4 16 SLOT U 2 23 4159920 7 WLDMT CRADLE 1 24 A1105061 BOLT M12 1 75X30 8 25 64237 06 LOCKNUT NYLON M12 1 75 8 26 4113902 7 WLDMT CASTER ARM 1 USED WITH 61 DECKS 95 48 SIDE DISCHARGE ZT 200 Series FIGURE 16 40 21 22 21 39 TORQUE TO 70 FT LBS 55 49 5 56 ZT 200 48 SIDE DISCHARGE FIGURE 16 ITEM PART NO DESCRIPTION QTY ITEM PART DESCRIPTION QTY 4154060 S 48INCH DECK W LABELS 1 44 2188131 SPRING EXTENSION Z 4127853 2 COVER BELT RH 48 45 64163 73 WSHR 6251DX1 120DX 06 4127852 2 COVER BELT LH 48 46 64018 2 BLT CRG 1 4 20X3 4 4 38524 KNOB 4 PRONG 3 8 16 4147115 ASSY 64018 5 3 8 16X1 3 4 64229 03 LOCKNUT NYLON 3 8 16 64123 173 BLT HEX 3 8 16 4 1 2 2121512 ROLLER 5X2 75 CENTERED 10 64123 68 BOLT 5 16 18 X 1 HEX 11 2308140 PULLEY ENGINE 12 112111 01 BLADE 16 25 OFFST HLFT 13 2120685 SPACER ROLLER 14 64262 012 BLT FLG HD 3 8 16 X 1 1 4 15 4163028 ASSY IDLER ARM PTO 16 64018
24. DUAL ELEMENT AIR CLEANER Engines equipped vvith dual element air cleaners Air Cleaner have a paper air cleaner element with an oiled foam Cover precleaner element on the dirty side of the paper element Both should be inspected regularly and maintained Clean and re oil precleaner element every 25 hours more often under dusty conditions Disassemble air cleaner cover Remove precleaner by sliding it off the paper car tridge Wash precleaner in kerosene or liquid detergent QUT ds and water ESSEN Wrap precleaner in cloth and squeeze to remove cleaner Saturate precleaner in engine oil Squeeze to remove excess oil Element Re install precleaner over paper cartridge Reassemble air cleaner components and screw dys assembly down tight a J Rubber Every 100 hours more often under very dusty or lt Seai dirty conditions check the paper cartridge Clean by tapping gently Do not wash the cartridge or use compressed air which can cause damage Replace when cartridge is dirty bent or damaged Air Cleaner Base HEAVY DUTY CYCLONIC AIR CLEANER Clean and replace the air cleaner element as specified in the service chart Uneven running lack of power or black exhaust fumes may indicate a dirty air Cleaner To replace air cleaner elements 1 Unclamp end cover X and remove existing cleaner elements Insert new elements Y and Z and replace cover Ensure the breathing port A is pointing dow
25. ESCRIPTION QTY ITEM PART DESCRIPTION QTY 1 4158360 PULLEY PUMP 2 2 64044 18 SCREW SET 1 4 20 X 5 16 4 3 64238 03 KEY MET 5MM SQX28MM 2 4 64164 12 KEY 1 5 4157860 PULLEY 5 25 ENGINE 1 6 2721337 CLUTCH ELECTRIC 1 USED ON ALL MODELS EXCEPT 19HP INCLUDES ITEMS 29 amp 30 2722016 CLUTCH ELECTRIC 19HP 1 USED ON 19HP MODELS ONLY INCLUDES ITEMS 29 amp 30 2721338 7 WLDMT CLUTCH STOP 1 USED ON ALL MODELS EXCEPT 19HP 2721331 7 WLDMT CLUTCH STOP 1 USED ON 19HP MODELS ONLY 2186147 7 WLDMT CLUTCH BRACKET 1 38304 03 BEARING FLANGED PLSTC 1 64205 001 BLT MET M8 1 25X20 64197 005 BLT TDFM 3 8 16X1 1 4 64006 06 LCKWSHER HELICAL 7 16 64265 04 NUT FL NYL LOCK M8 1 25 2308000 PULLEY IDLER 4 00 EOD 4128923 S ASSY IDLER ARM PUMP INCLUDES ITEMS 16 18 amp 24 N gt P N 4127999 SEAL 64270 01 BOLT MET HEX M10 1 5X30 4128004 BEARING 33148 01 SPACER 0 379X0 750X0 25 2188131 SPRING EXTENSION 64006 03 WSHR 3 8 HELICAL LOCK 64123 21 BLT HEX 3 8 24 1 1 4 4136780 5 DECK W LABS 64144 40 SNAP RING 4162583 BELT TRACTION DRIVE 64123 155 BLT HEX 7 16 20X3 64205 013 BLT MET M6 1X12 64209 09 WASHER CONICAL SPRING 2 Na AS do do do doo 2120949 ASSY CLUTCH WIRE 1 4121560 KIT BRAKE POLE RPLCMNT 1 4128002 END 1 NOT ILLUSTRATED 29 BUMPER ZT 200 Series FIGURE 3 30 ZT 200 BUMPER Series FIGURE 3 ITEM PART NO DESCRIPTION QTY ITEM PART DESCRIPTION QTY
26. KNUT NYLON 5 8 11 39 64123 187 BLT HEX 5 8 18X3 75 40 64123 208 BLT HEX 5 8 18X1 5 41 4128004 BEARING 42 4134343 7 BAFFLE RT FRT 52 54 43 4128002 END CAP vn DS 59 61 SIDE DISCHARGE ZT 200 Series FIGURE 18 AM 3 YA Vig N LO ry 9 My N O O N N e LO 12 39 TORQUE TO 70 FT LBS 49 53 60 61 SIDE DISCHARGE DESCRIPTION QTY 5 61 DECK 1 BELT COVER RH 1 BELT COVER LH 1 KNOB 4 PRONG 3 8 16 2 CHUTE RUBBER ASSY 1 WSHR 1 015X1 500X14GA 3 LOCKNUT NYLON 3 8 16 3 BLT HEX 3 8 16X4 1 2 2 ROLLER 5X2 75 CENTERED 7 BOLT HEX 5 16 18 1 2 PULLEY ENGINE 4 BLADE 21 00 OFFST HLFT 3 SPACER ROLLER 7 BLT FLG HD 3 8 16 X 1 1 4 1 ASSY IDLER ARM PTO 1 BOLT CARRIAGE 3 8 16 2 1 GUIDE BELT 1 PULLEY V IDLER 1 IDLER 5 0 OD FLNGD 1 BAFFLE DISCHARGE 1 SPRING WSRR 67 ID 6 1 4X1 4X1 SQ END KEY 4 PULLEY IDLER 5 50 1 S ASSYSPNDL ZT200 CNTR 1 INCLUDES ITEMS 57 61 ASSY DECK IDLER 61 1 INCLUDES ITEMS 41 43 51 amp 55 S ASSYSPNDL ZT200 OUT 2 INCLUDES ITEMS 57 60 amp 62 ZT 200 Series ITEM PART NO 1 4145000 2 2182352 2 3 2182351 2 4 38524 5 4147399 6 64163 64 7 64229 03 8 64123 173 9 2 21512 10 64123 68 11 2308140 12 112111 03 13 2120685 14 64262 012 15 4163028 16 64018 18 17 2302125 7 18 48393 19 38297 20 4115864 7 21 64209 03 22 64164 12 23 128169 24 4115849 25 412907
27. KWASHER 7 16 LOCKNUT 7 16 WASHER 3 8 LOCKWASHER 3 8 BOLT 3 8 16 X 1 1 4 NUT 3 8 16 HEX PIN COTTER BUMPER RUBBER PLUG WASHER FORMED WASHER RUBBER QTY ITEM PART NO FIGURE 12 DESCRIPTION QTY 49 STEERING DECK LIFT ZT 200 Series FIGURE 13 N 50 ZT 200 STEERING DECK LIFT Series 4 FIGURE 13 DESCRIPTION QTY ITEM PARTNO DESCRIPTION QTY 1 4136780 S ENGINE DECK W LABS 1 2 4136792 METER HOUR 1 3 2188161 VALVE TANK SELECTOR 1 4 1104057 BOLT M10 1 50X25 3 5 41221727 LEVER TRACTION CNTRL 2 6 4122173 BRKT TRACTION LEVER 2 7 2183074 BRKT HANDLE 2 8 4144705 GRIP HANDLE 2 9 2188145 BEARING 75ID SELF ALIGN 4 10 64123 15 BOLT 3 8 16X3 4 HEX 8 11 64141 4 NUT WLF 3 8 16 8 12 4112105 7 WLDMT MTN CONTRL RH 1 4112104 7 WLDMT MTN CONTRL LH 1 13 64205 011 BLI MET 10 1 50 40 2 14 110406 SCREW M10X1 5X30 HH 12 15 64237 03 LOCKNUT NYLON M10 1 5 20 16 64263 013 BLT FLG HD M10 1 5 X 30 8 17 64205 008 BLI MET M10 1 50X55 1 18 64163 43 VVSHR 4431 454 X1X11GA 1 19 2183073 SPACER 2 20 4159920 7 WLDMT CRADLE 1 21 64168 2 COTTER HAIRPIN 08X1 19 4 22 27205517 WLDMT DECK LIFT LEVER 1 23 41629047 WLDMT LVR STOP LATCH 1 24 2720517 7 BRKT INNER DECK LIFT 1 25 2720516 BRKT OUTER DECK LIFT 1 26 4116590 7 BRACKET LIFT LINK 2 27 2120501 7 HANDLE LIFT ARM 1 28 4159060 ASSY PIN amp LANYARD 1 29 64188 53 PIN CLEVIS 1 2X1 0 1
28. LACK STRIPE m 1 PURPLE W ORANGE STRIPE L 2 7 ORANGE WI PURPI STRIPF 5 3 RED DARK BLUE BLACK BLACK Y RFD Y YELLOW EBLOCK SOLENOID YELLOW WI BLACK STRIPE GROU ND 1 2 8 RED WI WHITE STRIPE GY GREEN W YELLOW STRIPE 0 BROWN 0 10 BROWN WI YELLOW STRIPE VEJ VE DELAY MODULE C BLADES amp TRACTION RELAY Co DELAY RELAY 9 STARTER RELAY 87 NC 30 87 NO 85 86 RELAY SCHEMATIG 15 28 pe dy z 13 a Ue a lt 14 l TRACTION 9 5 E CONTROL 0 4 a SEAT SWITCH 2 Od jam 7 HOUR METER 6 CONTROL a 14 Di 2 79 14 GA 12V 18 14 ADAPTER D DELAY MODULE OPERATION SCHEMATIC AUXILLARY 1 1 ERECTO sero NNECTION CLUTCH MAGNE OPTIONAL IGNITION TYPICAL RELAY SWITCH 10 20 RELAY 15 LNLRGIZLD ENGINE OPLRAILS WHEN 15 CLOSED BLADE DISENGAGEDJ DR WHEN 81 CLOSED DPERATOR IN POSITION FOR APPROX 1 2 SECOND AFTER 51 IS OPENED 42 Series FIGURE 9 ITEM PART NO DESCRIPTION QTY ITEM PART DESCRIPTION QTY 9 1 4158085 HARNESS VVIRING MAIN 1 9 2 148082 20 FUSE 20 AMP 2 9 3 108061 13 CABLE BATTERY 36 BLACK 1 9 4 4124009 SWITCH SEAT NO 1 9 5 4143068 JUMPER SEAT SWITCH 1 9 6 4136792 METER HOUR 1 9 7 2122221 02CABLE BATT W CONDUIT 1 INCLUDES ITEMS 16
29. LAMP 1 31 64246 03 NUT WHIZ 10 1 50 4 32 108009 05 CONTROL CHOKE 55 1 33 64025 04 NUT 3 8 24 HEX 1 34 64263 002 BLT FLG HD M6 1 0 X 16 2 33 BRAKES REAR WHEEL ZT 200 Series FIGURE 5 TORQUE TO 225 FT LBS 34 AAA Series FIGURE 5 ITEM PART NO DESCRIPTION QTY ITEM PART DESCRIPTION QTY 4136780 S ENGINE DECK W LABS 4158803 7 WLDMT BRAKE ARM LH 4158801 7 WLDMT BRAKE ARM RH 128102 SPRING EXTENSION 4159241 7 WLDMT BRAKE LEVER 4159701 ROD BRAKE CONTROL 2182387 7 GUIDE SPRING 38020N CLEVIS YOKE 5 16 PLATE 4159281 BRAKE PARKER 9A 4159281 001 Brake Back Plate w Pads 9B 4159281 002 Brake Drum 9C 4159281 003 Brake Screw 9D 4159281 004 Brake Hub 10 64163 06 WSHR 768 756X1 25X14 11 4159000 BAR PARKING BRAKE 1 12 4159280 MOTOR PARKER 2 INCLUDES ITEMS 32 amp 33 gt gt Xx B N a Nanana 13 4158422 ASSY WHEEL24X12 12 2 1985085 02 TIRE 24X12 00 12NHS 4PLY2 ITEM 34 USED ON 942233E 942237E amp 942249E 14 4158460 ASSY WHEEL 23 X 8 5 12 2 ITEM 14 USED ON 942220E 15 64187 03 WHEEL NUT 1 2 20 16 64188 02 PIN CLEVIS 5 16 1 17 64061 25 ROLL PIN 1 4X1 1 4 18 2188155 GRIP 1 4 1 4 1 2 19 2183063 01SPACER 32MM LONG 20 4158421 ASSY WHEEL 23 X 10 5 12 2 ITEM 34 USED ON 942221E 44E amp 48E CO 21 85010N ZERK 1 4 28 STR SLFTHRD 1 22 64144 34 SNAP RING 50 1 23 2188145 BEARING 751D SELF ALIGN 2 24 64123 15 BOLT 3 8
30. LOCK SYSTEM Start The PTO blades must be off traction levers in neutral lock and parking brake on for engine to crank Run Operator must be in seat to take parking brake off to move traction levers out of the neutral lock position or to turn the PTO blades on or the engine will kill The parking brake must be off for the traction levers to move out of the neutral 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 eliminates annoying engine cutout from operation over rough terrain WEIGHT 1025 Ibs 465 kg CONTROLS Throttle choke power takeoff PTO clutch switch traction levers parking brake lever lift lever FUEL SYSTEM One tank on each side of operator each with a shut off 1 4 turn Total capacity 9 1 2 gallons 40 liters Fuel selector shutoff switch on front panel 1 4 turn Replaceable fuel filter MAXIMUM GROUND SPEEDS Forward 8 5 mph 13 7 km h Reverse 4 mph 6 4 km h WHEELS amp TIRES Drive wheels 942220E 23 X 8 50 12 4 Ply Turf Tread Tires 942244 942221E 942248E 23 X 10 5 12 4 Ply Turf Tread Tires 942233E 942237E 24 12 00 12 4 Ply Turf 942249E Tread Tires Casters 13 X 5 00 6 4 Ply Smooth Tread Tires USED ON 52 DECKS 13 X 6 5 6 4 Ply Smooth Tread Tires USED ON 61 DECKS Pressure 14 p s i 1 kg cm
31. MT LOCK PUSHBAR 2 33 85010N ZERK 1 4 28 STR 5 34 64123 152 BLT HEX 5 8 11X5 2 35 64123 50 BOLT HEX 3 8 16X1 1 2 3 2 3 3 3 1 1 36 64229 02 LOCKNUT NYLON 5 16 18 37 4118314 SPACER BLADE 16MM 38 64229 06 LOCKNUT NYLON 5 8 11 39 64123 187 BLT HEX 5 8 18X3 75 40 64123 208 5 8 18X1 5 41 4128004 BEARING 42 4134342 7 BAFFLE RIGHT FRONT 48 43 4128002 END CAP 57 92 SIDE DISCHARGE ZT 200 Series FIGURE 17 12 39 TORQUE TO 70 FT LBS 49 56 58 ZT 200 92 SIDE DISCHARGE FIGURE 17 ITEM PARTNO DESCRIPTION QTY ITEM PARTNO DESCRIPTION QTY 4154185 S 52INCH DECK W LABELS 1 44 2188131 SPRING EXTENSION 2 2722574 2 COVER BELT RH 2122515 2 COVER BELT LH 38524 KNOB 4 PRONG 3 8 16 4147115 ASSY 4149017 7 HINGE CHUTE RUBBER 64229 03 LOCKNUT NYLON 3 8 16 64123 173 3 8 16 4 1 2 2721512 ROLLER 1 45 64163 73 WSHR 625IDX1 120DX 06A R 1 46 64018 2 BLT CRG 1 4 20X3 4 2 47 64163 64 WSHR 1 015 1 500 14 1 48 64229 01 LOCKNUT 1 4 20 NYLON 1 49 4134338 7 BAFFLE FRT CTR 52 54 35 50 4118427 7 BAFFLE FRONT LH 2 51 4127999 SEAL 6 52 4163155 INNER RING 10 64123 68 BOLT HEX 5 17 18X1 2 53 4163041 SPACER 11 2308140 PULLEY ENGINE 3 54 64144 40 SNAP RING 12 112111 02 BLADE 18 00 OFFSTHLFT 3 55 64018 3 BOLT 3 8 16X1 CARRIAGE 6 1 1 1 1 1 1 1 6 4 1 1 N O gt 13 2120685 SPACER ROLLER 56 64268 03 NUT FL NYLN LOCK 3 8 16
32. NLRIAZLD ENGINE OPERA IL SI WHEN 52 15 CLOSED BLADE DISENGAGED OR WHEN 31 IS CLOSED OPERATOR IN POSITIICN J UR FOR APPROX 1 2 SECOND AFI LR 51 IS OPLNLD 44 t u PA PAE AA Series FIGURE 10 ITEM PART NO DESCRIPTION QTY ITEM PART DESCRIPTION QTY 4158085 HARNESS WIRING MAIN 1 148082 20 FUSE 20 AMP 2 108061 13 36 BLACK 1 4124009 SWITCH SEAT NO 1 4143068 JUMPER SEAT SWITCH 1 4136792 METER HOUR 1 2122221 01CABLE BATT W CONDUIT 1 INCLUDES ITEMS 20 4 21 NOOR WD 2122221 02CABLE BATT W CONDUIT 1 USED ON 942249E ONLY INCLUDES ITEMS 20 amp 21 8 128010 KEY SWITCH 1 9 2722325 RELAY 40AMP SEALED 3 10 2188154 MODULE DELAY 1 11 2121505 SWITCH PTO 1 12 2721337 CLUTCH ELECTRIC 1 USED ON 25HP amp 27HP ONLY INCLUDES 2720949 WIRE ASSY 2122016 CLUTCH ELECTRIC 19HP 1 USE ON 19HP MODELS ONLY INCLUDES 2720949 VVIRE ASSY 13 2120949 ASSY CLUTCH WIRE 1 14 108208 SWITCH DBL POLE 2 15 2188156 SWITCH NONO DBL POLE 1 16 38665 SOLENOID 1 17 2188224 HARNESS JUMPER 1 NOT USED ON 942249E MODEL 18 108061 04 CABLE BATTERY 20 RED 1 19 2188225 WIRE GROUND 1 20 112386 BOOT BAT TERM POS 1 21 2308095 COVER TERMINAL 3 22 4142266 CONNECTOR 12V 1 45 SEAT ASSEMBLY amp ROPS ZT 200 Series FIGURE 11 17 23 22 BRACKET ON ENGINE DECK WELDMENT 46 ZT 200 SEAT ASSEMBLY amp ROPS Series FIGURE 11 ITEM PART NO DESCRIPTION QTY ITEM PART DESCRIPTION QTY 1 41224
33. PEED 22 ZT 200 SPECIFICATIONS Series Check Tire Pressures Lubricate All Points Check Nuts 8 Bolts ENGINE Check Engine Coolant Level Where Applicable Check Oil Level Clean Air Cleaner Element Clean Cooling Fins Replace Air Cleaner Element Clean amp Gap Spark Plugs NOTE After first 5 hours of operation replace engine oil hydraulic oil and both filters 23 SPECIFICATIONS ZT 200 Series CUTTERDECKS MODEL NUMBER TYPE Side Discharge CUTTING WIDTH WIDTH WIDTH CHUTE UP WIDTH CHUTE DOWN high lift BLADE low lift optional NUMBER OF BLADES BLADE LENGTH 16 25 41 cm BLADE THICKNESS 205 5 2 mm 16778 ft min 5114 m min 3600 Engine RPM TIP SPEED DAILY PRODUCTION 8 hr 6 mph Up to 22 9 acres 9 3 ha CONSTRUCTION Fabricated and welded 10 gauge double layer steel top with 7 gauge side skirts Full floating design CUTTERDECK DRIVE SYSTEM Electric clutch brake drives belt directly from engine to center spindle of cutterdeck No twists in drive belt SPINDLES Top mounted and maintenance free with 1 shaft in precision machined aluminum housing SPECIFIC TORQUES BLADE BOLT TORQUE 70 FT LBS 95 Nm WHEEL HUB NUTS 225 FT LBS 237 Nm ENGINE CRANKSHAFT BOLT 50 FT LBS 68 Nm 24 942221E 942244E 942233E 942237E 942248E 942249E Side Discharge Side Discharge high lift low lift optional high lift l
34. RUBBER 66 4163030 7 WLDMT IDLER PIN gt a N OT 61 BELTS CUTTERDECK ZT 200 Series FIGURE 19 5022 ROTI SIT ISD CO 62 ZT 200 BELTS CUTTERDECK Series FIGURE 19 ITEM PARTNO DESCRIPTION QTY ITEM PARTNO DESCRIPTION QTY 1 2188176 BELT CUTTERDECK 54 1 2720815 54 1 USED ON 52 SD DECK 3 128003 BELT CUTTERDECK 61 1 4 2188134 61 1 USED ON 61 SD DECk 5 128110 BELT CUTTERDECK 48 1 6 2720815 48 1 USED ON 48 DECK 63 ZT 200 Series DECALS POWER UNIT FIGURE 20 N Ta lt K De Y g 2 Y yi ar HYDRAULIC RESERVOIR 20 3 DOCUMENT TUBE 17 A SA 7 in OS KK Ih AO y wr 4 gt EA 2 cc KRI 64 ZT 200 Series ITEM 20 1 20 2 20 3 20 4 20 5 20 6 20 7 20 8 20 9 20 10 20 11 20 12 20 13 20 14 20 15 20 16 20 17 20 18 20 19 20 20 PART NO 4157861 4158401 2000735 2000590 2000691 4156160 2000693 2000698 4114158 2000700 2000701 2720742 2720743 4118843 2000706 4116761 340830 4163037 4162919 4162920 4162921 4162923 4162915 4162916 4162914 DECALS POWER UNIT DESCRIPTION QTY LABEL PROCAT LABEL BOB CAT 10 5 LABEL OPER MAN LABEL WARN BATTERY LABEL HYDR OIL FILL LABEL CONTROL PANEL LABEL PARK BRAKE LABEL DBL FUEL LEAKS LABEL TIRES LABEL RH TRACTION LA
35. ck 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 Contact your authorized CGC Inc dealer Hardware Tighten any nuts and bolts found loose Replace any broken or missing cotter pins Repair any other problems before operating Tire pressure Tires should be kept inflated at 14 Ibs in 1 0 kg cm Improper tire inflation can cause rapid tire wear and poor traction Uneven inflation can cause uneven cutting BATTERY A WARNING Battery acid is caustic and fumes Check the electrolyte level every 100 hours of are explosive and can cause serious injury or death operation 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 Use insulated tools wear protective glasses or goggles and protective clothing when working with batteries Read and obey the battery manufacturer s instructions Tighten cables securely to battery terminals and apply a light coat of silicone dielectric grease to terminals and cable ends to prevent corrosion Keep terminal covers in place Be certain the ignition switch is OFF and the key has been remove
36. connected and PTO disengaged AFTER FIRST FIVE 5 HOURS While the engine is warm 1 Remove drain cap D and drain the crankcase Dispose of used oil in accordance with local requirements Clean and replace the cap Change oil filter Fill the crankcase with fresh oil to the full mark Do not overfill See engine manual for oil specifications DAILY Check oil level with the dipstick If oil is needed add fresh oil of proper viscosity and grade See engine manual for oil specifications Do not overfill Replace dipstick before starting engine PERIODIC OIL CHANGES 1 See engine manual for oil and filter change inter vals after the break in period 2 Follow instructions for first oil change above SPARK PLUGS Remove each plug and check condition Good operating conditions are indicated if the plug has a light coating of grey or tan deposit A white blistered coating indicates overheating A black coating indicates an over rich fuel mixture Both may be caused by a clogged air cleaner or improper carburetor adjustment Do not sandblast wire brush or otherwise attempt to repair a plug in poor condition Best results are obtained with a new plug Set plug gap as specified in engine manual FUEL FILTER CARBURETED MODELS An inline fuel filter is located in the fuel supply line Inspect at every oil change to make sure it is clean and unobstructed Replace if dirty 11 MAINTENANCE ZT 200 Series
37. d before servicing the battery 1 Verify battery polarity before connecting or dis connecting the battery cables When installing the battery always assemble the RED positive battery cable first and the ground BLACK negative cable last When removing the battery always remove the ground negative cable first and the red posi tive cable last ZT 200 MAINTENANCE Series LUBRICATION Every 50 hours of operation lubricate the following points 1 4 with grease Deck lift rockshaft 1 point Deck lift pivots 6 points Brake lever pivot 1 point Push arms 2 points located at rear of cutterdeck under each fuel tank Caster wheel pivots 2 points Lubricate every 500 hours or once a year HRS NOTE ON BLADE SPINDLES The blade spindles on these machines use a superior sealed bearing that does not require relubrication MAINTENANCE ZT 200 Series HYDRAULIC SYSTEM Fluid level in the hydraulic system should be checked after the first 5 hours of operation and every 100 hours thereafter or when a leak has occurred If the fluid is low check all components for leaks To check remove reservoir cap M The fluid level should be at the bottom of the filler tube If low top up do not overfill Use one of the oils listed below SAE 15W40 motor oil SAE 20W50 motor oil 15WS50 synthetic motor AFTER FIRST FIVE 5 HOURS 1 Remove plug N to drain hydraulic reservoi
38. ed by CGC Inc will result in the CGC Inc Warranty being voided Any and all liability for personal injury and or property damage caused by any unauthorized modifications add on accessories or products not approved by CGC Inc will be considered the responsibility of the individual s or company designing and or making such changes CGC Inc will vigorously pursue full indemnification and costs from any party responsible for such unauthorized post manufacture modifications and or accessories should personal injury and or property damage result This Operator s Manual should be regarded as part of the machine Suppliers of both new and second hand machines must make sure that this manual is provided with the machine ILEA EL INSTRUCTIVO Si no lee Ingles pida ayuda a alguien que si lo lea para que le traduzca las medidas de seguridad COMMERCIAL GROUNDS CARE INC e MODEL SERIAL NUMBER EEE JOHNSON CREEK IN U S A ZT 200 Series This symbol means ATTENTION BECOME ALERT Your safety and the safety of others is involved Signal word definitions The signal words below are used to identify levels of hazard seriousness These words appear in this manual and on the safety labels attached to CGC Inc machines For your safety and the safety of others read and follow the information given with these signal words and or the symbol shown above DANGER indicates an imminently hazardous situa
39. il Level Change Oil And Filter MACHINE X Operation X Pressures Check Top Off X Battery See engine manufacturer s manual ZT 200 MAINTENANCE RECORD Series oO aaa NOTES DATE GENERAL Check Tire Pressures Lubricate All Points Check Nuts amp Bolts ENGINE Check Engine Coolant Level Where Applicable s w p Air Cleaner Element E u Replace Air Cleaner Element Clean amp Gap Spark Plugs NOTE After first 5 hours of operation replace engine oil hydraulic oil and both filters MAINTENANCE ZT 200 Series 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 blades on and either traction lever out of neutral lock Also make sure engine coolant temperature gauge light flashes upon turning key to the ON position Operator Presence Interlock System Run Operation The operator 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 by one move the parking brake to the OFF position traction levers out of the neutral lo
40. ition Remove the engine cutterdeck belt from the deck idlers and pulley see engine cutterdeck belt replacement Push it aside but don t remove it from the machine Run the cutterdeck belt off the idler as shown Remove it from the deck Install the new belt by performing these steps in reverse order Take care to get the new belt on the correct side of the belt guides Re install engine cutterdeck belt see engine cutterdeck belt replacement PUMP DRIVE BELT Remove engine cutterdeck belt see engine cutterdeck belt replacement Attach an extension to a 3 8 drive ratchet Insert the ratchet extension in the square hole of the pump drive idler arm Use the ratchet handle to rotate it enough to remove the pump drive belt Install a new pump drive belt in the same manner as it was removed Re install engine cutterdeck belt see engine cutterdeck belt replacement 20 ZT 200 Series SPECIFICATIONS POWER UNITS ENGINES Construction Aluminum block with cast in cast iron sleeves Aluminum head Configuration 4 stroke vertical shaft V twin cylin der overhead valve air cooled or liquid cooled DRIVE SYSTEM Full hydrostatic pump and wheel motor combination for independently controlled drive wheels Pump Parker 12cc variable displacement piston pump Motors Parker displacement MB series Direct drive 1 1 4 31 8mm diameter output shaft Turn Radius True Zero OPERATOR PRESENCE INTER
41. jam nuts E against the clips F and at the adjusting screws G Retighten nuts I at this time ZT 200 ASSEMBLY AND SETUP Series 6 COUNTERBALANCE SPRINGS a Raise the cutterdeck all the way b Adjust the spring A with nut B 52 cutterdecks to a length of 9 1 8 232 mm 61 cutterdecks to a length of 9 9 16 242 mm The springs may be tightened or loosened from this point according to personal preference NOTE The 48 cutterdecks do not have counterbalance springs 7 FINAL PREPARATIONS Check the engine and hydraulic oil levels Top up with the correct oil if necessary Use 10W30 motor oil for the engine Use fresh clean 15W40 or 20W50 motor oil 15W50 synthetic motor oil for the hydraulic system Remove the battery from the machine Fill the battery to the bottom of the vent wells with acid and trickle charge for several hours AA WARNING Battery acid is caustic and fumes are explosive and can cause Serious injury or death Use insulated tools wear protective glasses or goggles and protective clothing when working with batteries Read and obey the battery manufacturer s instructions Be certain the ignition switch is OFF and the key has been removed before servicing the battery a Verify battery polarity before connecting or disconnecting the battery cables b When installing the battery always assemble the RED positive battery cable first and the ground BLACK negative cable last C
42. lts are tensioned by spring loaded idlers No adjustment is required 16 ZT 200 ADJUSTMENTS Series CONTROL LEVERS There are two mounting positions for the control levers upper and lower The lower position works well for most people Taller operators may need the upper position To adjust the height of the control levers Remove bolts A and nuts B Align holes in control lever D with appropriate holes in traction lever bracket C Install bolts A and nuts The upper mounting hole for the control levers is slotted to allow fore aft adjustment and to allow alignment of the levers To adjust or align the control levers Loosen nuts B Adjust control lever position Tighten nuts B PARKING BRAKE Park machine on a smooth level surface Support the machine with the rear wheels off the ground using jack stands or equivalent DO NOT rely on mechanical or hydraulic jacks Remove rear wheels Measure spring length O with parking brake N in the OFF position Move parking brake N to the ON position and measure length of spring O again When spring deflects 3 8 it is properly adjusted If adjustment is required return parking brake N to the OFF position Disconnect one end of rod M at the brake and loosen jam nut Adjust rod M in or out as required until 3 8 de flection in brake spring O is achieved with park ing brake N in the ON position Reconnect rod M and retighten jam nut
43. n and towards the front of the tractor 12 ZT 200 MAINTENANCE Series ENGINE COOLING Continued operation with a clogged cooling system will cause severe overheating and can result in en gine damage Daily Clean air intake screen 9 Every 100 hours Clean cooling fins beneath blower housing H with reference to information in the engine manufacturer s manual 13 MAINTENANCE 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 A as shown with grain perpendicular 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 Blades may be sharpened by filing or grinding Inspect blades before sharpening Replace bent or cracked blades Replace blades when the lift portion has worn thin Maintain cut angle at 30 Do not overheat blades when sharpening Always use CGC Inc blades Use of another manufacturer s blades may be dangerous 14 ZT 200 Series 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
44. ow lift optional 0 25 6 35 mm 3 18 46 cm 205 5 2 mm 18850 ft min 5745 m min 3500 Engine RPM 18585 ft min 5665 m min 3600 Engine RPM Up to 29 5 acres 11 9 ha Up to 25 5 acres 10 3 ha ANTI SCALP ROLLERS 48 Cutterdecks 3 Rollers 52 Cutterdecks 6 Rollers 61 Cutterdecks 7 Rollers CUTTING HEIGHT amp PRODUCTION Height Spring assisted lift lever allows easy setting of cut heights from 1 1 2 to 4 1 2 in 1 4 increments Set and forget feature allows height of cut to be set and returned to without searching from operator position NOTE 48 cutterdecks do not use spring assisted lift levers eries UPPER ENGINE DECK ASSY FIGURE 1 59 26 66 TO STARTER CONNECTION ZT 200 Series ZT 200 UPPER ENGINE DECK ASSY Series 2 1 DESCRIPTION QTY ITEM PARTNO DESCRIPTION QTY 1 4118340 ENG KAW 25 HDAC 1 43 64163 55 WASHER 328X 75X14 GA 4 4114746 S AIR FILTER PRIMARY 1 44 2188146 STRIP WEAR 2 4114747 S AIR FILTER SAFETY 1 45 64123 15 BOLT 3 8 16X3 4 HEX 8 2122214 FILTER OIL 1 46 64152 23 1 4 20X3 8 LG SP SCREW 4 38666 FILTER FUEL 1 47 38304 02 FLGD PLASTIC 2 2 4137278 PUMP HYDROSTATIC 12CC 2 48 810149 BUMPER RUBBER 8 SEE FIGURE 8 FOR BREAKDOWN 49 69216 7 CAP RESERVOIR 1 3 4136780 5 DECK VVILABS 1 50 64018 23 BLT CRG 3 8 16X3 4 4 4 1 51 4159840
45. r Dis pose of used oil in accordance with local require ments Clean and replace the plug Change hydraulic oil filter G Fill the reservoir with fresh oil to the bottom of the reservoir filler tube using an oil from the list above Do not overfill pue I PERIODIC OIL CHANGES Change the hydraulic fluid and hydraulic filter sie after each 500 hours of operation using the same procedure given above View from below machine NOTES Before servicing the hydraulic system stop the engine disconnect spark plug wires and disengage the PTO After any hydraulic line is opened plug or cap it promptly to reduce the risk of contamination Do use sealant 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 suf ficient 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 10 ZT 200 MAINTENANCE Series ENGINE OIL Do not perform engine maintenance without the engine off spark plug wires dis
46. t of the chains H at all four corners Tighten the jam nuts E against the clips F and at the adjusting screws G Retighten nuts I at this time COUNTERBALANCE SPRINGS a Raise the cutterdeck all the way b Adjust the spring A with nut B 52 cutterdecks to a length of 9 1 8 232 mm 61 cutterdecks to a length of 9 9 16 242 mm The springs may be tightened or loosened from this point according to personal preference NOTE The 48 cutterdecks do not have counterbalance springs ADJUSTMENTS 15 ADJUSTMENTS ZT 200 Series 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 N to 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 pres sure For best results adjust the rear deck rollers for the height of cut to be used see below REAR DECK ROLLERS The rear outside deck rollers are adjustable up and down to provide improved deck flotation and scalp 1 1 2 2 1 2 ing protection at various heights of cut They are not 2 1 2 3 1 2 intended to ride continuously on the ground Adjust no closer than 3 8 10mm to the ground 3 1 2 8 Higher Height of cut ranges for roller adjustment BELTS All be
47. tion which if not avoided WILL result in death or serious injury WARNING indicates a potentially hazardous situation which if not avoided COULD result in death or serious injury CAUTION indicates a potentially hazardous situation which if notavoided MAY resultin minor or moderate injury It may also be used to alert against unsafe practices or property damage CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided MAY result in property damage MODEL NUMBER This number appears on sales literature technical manuals and price lists SERIAL NUMBER This number appears only on your mower It contains the model number followed consecutively by the serial number Use this number when ordering parts or seeking warranty information ZT 200 ASSEMBLY AND SETUP Series TOOLS REQUIRED FOR ASSEMBLY Wrecking bar Claw hammer Ratchets 3 8 Sockets 3 8 1 2 17 mm Wrenches 13 mm 15 17 mm 18 mm 1 1 16 1 1 8 Straight edge Tire pressure gauge Blocks for deck leveling NOTE All references below to the right or left are with respect to an operator at the controls UNCRATE UNIT Discard packing materials Remove and discard shipping brackets Tighten caster wheel axle bolts against caster axle spanner bushings INSTALL SEAT a Install bushings J in seat plate Z Install seat assembly onto the unit using 2 pins X and 2
48. tions and warnings completely Do not remove or defeat any safety features Make sure those who operate this machine are as well informed and careful in its use as you are See a CGC Inc dealer for any service or parts needed CGC Inc service ensures that you continue to receive the best results possible from CGC Inc products You can trust CGC Inc replacement parts because they are manufactured with the same high precision and quality as the original parts CGC Inc designs and builds its equipment to serve many years in a safe and productive manner For longest life use this machine only as directed in the manuals keep it in good repair and follow safety warnings and instructions You ll always be glad you did Commercial Grounds Care Inc One Bob Cat Lane Johnson Creek WI 53038 0469 TABLE OF CONTENTS FIGURES 01 2008 SAFETY NOTICE Unauthorized modifications may present extreme safety hazards to operators and bystanders and could also result in product damage Commercial Grounds Care Inc strongly warns against rejects and disclaims any modifications add on accessories or product alterations that are not designed developed tested and approved by CGC Inc Engineering Department Any CGC Inc product that is altered modified or changed in any manner not specifically authorized after original manufacture including the addition of after market accessories or component parts not specifically approv
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