Simplicity ZT4000 Bedienungsanleitung

5101610

Rev C

Dealer Setup

& Adjustment Instructions

Simplicity ZT4000 Series Zero-Turn Riding Mower

TABLE OF CONTENTS:

SETUP PROCEDURES

Quick Setup List..................................................2

Uncrating..........................................................3

Connect the Battery..............................................3

Tractor Assembly ................................................4

Ground Speed Control Lever Assembly ...........................4

Seat Assembly..................................................................5

Roll Bar Assembly...............................................6

Check Fluid levels ...............................................7

Check Engine Oil Level.....................................................7

Check Hydraulic Oil Level.................................................7

Check Tire Pressure.............................................7

Mower Assembly.................................................8

Check Torque - Mower Blades .........................................8

Deck Lift Rod Timing & Leveling Adjustment...............8

Check Deck Drive Belt ........................................ 10

Lubrication...................................................... 12

Adding Fuel..................................................... 13

Starting The Engine ........................................... 13

Perform Safety Checks........................................ 13

Functional Tests .............................................................13

Safety Interlock System .................................................14

ADJUSTMENT PROCEDURES

Neutral Adjustment............................................ 14

Return-To-Neutral Adjustment............................... 15

Parking Brake Adjustment.................................... 15

Suspension Adjustment....................................... 16

This Dealer Setup Instruction covers the following products:

ZT4000 Series Zero-Turn Riding Mower

Model No.: Description:

5900707 ZT4000B2444 44” Mower Deck

5900765 ZT4000B2648 48” Mower Deck

5900960 ZT4000B2748 48” Mower Deck

Attention Setup Personnel:

The safety warnings provided in this

guide and in the operator’s manual

included with the unit contain important

information that must be obeyed when

assembling, setting-up, operating, servicing,

transporting, or storing the unit.

These warnings are highlighted by the safety alert

triangle symbol shown above, which signifies that

an important safety message is being provided.

You must read, understand, and follow these

warnings and instructions, and use safe shop

and work practices at all times while working on

or around this unit and all other outdoor power

equipment.

Sections and items denoted by the Setup

symbol provide the information necessary to fully

assemble, test, and prepare the units described

above for delivery to your customers.

A Quick Setup List is provided on page 2 of this booklet

to help you identify and check that the items have been

performed.

Additional information concerning functional

tests, general adjustment procedures, and the

location of normal lubrication points are included

in these instructions.

Although all required lubrication and normal adjustments on

factory-assembled components are done at the factory, this

additional information is provided to assist you in ensuring

that each unit is delivered to the customer in proper working

order.

Not for

Reproduction

ZT4000 - 44” & 48” Mower Deck

www.simplicitymfg.com2

Quick Setup List

Page Setup Procedure Steps to Perform

3 Uncrating ❏Remove Crate & Banding.

❏Loosen Hydraulic Release Valves.

❏Release Parking Brake and Roll Tractor forward off skid.

❏Tighten Hydraulic Release Valves.

3 Connect Battery Cables ❏Connect Battery Cables.

4 Tractor Assembly ❏Assemble the Ground Speed Control Levers.

❏Assemble the Seat.

❏Connect the Seat Switch Harness.

6 Roll Bar Assembly ❏Assemble the Retainer Pins.

❏Assemble the Top Loop.

❏Install the Roll Bar.

8 Check Fluid Levels ❏Check Engine Oil Level.

❏Check Hydraulic Oil Level.

❏Check Tire Pressure

9 Check Mower Assembly ❏Check Blade Bolt Torque

❏Check and Level Mower Deck

❏Check Deck Drive Belt

12 Lubrication & Fuel Preparation ❏Lubricate all grease and oil points.

❏Add fuel.

❏Start the Engine.

13 SAFETY CHECK ❏Check for LOOSE HARDWARE.

❏Check all OPERATOR CONTROLS.

❏Perform SAFETY INTERLOCK SYSTEM CHECK.

com, select the appropriate brand, click “My Resources,”

select the “Product Registration and Rebate” icon and

then the “New Product Registration / Rebate” tab. Fill out

and submit the online product registration form.

Setup Procedures

Not for

Reproduction

ZT4000 - 44” & 48” Mower Deck

Uncrating

1. Using a reciprocating utility saw or equivalent, cut the

crate away from the bottom skid. Remove the crate.

Remove the shrink-wrap plastic.

2. Cut the nylon banding from the front of the frame and

the rear bumper.

3. Open the hydraulic release valves (A, Figure 1). To

open the release valves, turn the release valve, which is

located on front of the pump, COUNTER-CLOCKWISE

two (2) full turns MAXIMUM.

4. Push down on the parking brake lever (A, Figure 2) to

release the parking brake.

5. Be sure there are no nails or sharp objects on the bottom

skid to puncture the machine’s tires. Roll the machine

forward off the bottom skid.

6. After moving the tractor, re-engage the pumps (drive

position) by turning the release valves CLOCKWISE and

tighten to 80-120 in/lbs (9-13.5 Nm).

Figure 2. Disengaging the Parking Brake

(lever shown in disengaged position)

A. Parking Brake Lever

Figure 1. Hydraulic System By-Pass

A. Hydraulic Release Valve

(left-hand pump shown)

Figure 3. Connect Battery

A. Positive (+) Cable & Terminal

B. Negative (-) Cable & Terminal

Connect Battery Cables

1. Connect the red positive battery cable (B, Figure 3) to

the positive battery post.

2. Connect the black negative battery cable (A) to the

negative battery post.

WARNING

Battery acid can cause severe burns. Wear

protective gear when handling the battery.

Open flames and sparks can cause the

battery to explode.

BATTERY SAFETY RULES:

• Battery acid causes severe burns. Avoid contact with

skin.

• Wear eye protection when handling the battery.

• To avoid an explosion, keep flames and sparks away

from battery, especially while charging.

• When installing the battery cables, CONNECT THE

POSITIVE (+) CABLE FIRST and negative (-) cable last.

If not done in this order, the positive terminal can be

shorted to the frame by a tool.

NOTICE

When cutting the crate from the bottom skid, use caution

around the tires and the mower rollers.

Not for

Reproduction

ZT4000 - 44” & 48” Mower Deck

www.simplicitymfg.com4

Tractor Assembly

Ground Speed Control Lever Assembly

There is a LEFT-HAND and a RIGHT-HAND ground speed

control lever. When assembled to the control lever mount,

the control lever base should be pointing towards the rear of

the machine as shown in Figure 4.

1. Remove the ground speed control lever and the

mounting hardware from the handle bar box.

2. Install the ground speed control levers (A, Figure 4) on

the control lever mount using the 5/16-18 x 3/4” bolts

(B), 5/16” lock washers (C) and 5/16” flat washers (D).

Prior to tightening the bolts align the levers with each

other.

Ground Speed Control Lever Adjustment

The ground speed control levers can be adjusted in three

ways. The height of the levers, the alignment of the control

levers, and the placement of the control levers (how close

the ends are to one another) can be adjusted.

Height Adjustment

1. Remove the mounting hardware (B, C & D, Figure 4).

2. Position the ground speed control lever (A) either up

or down from its original position and reinstall the

mounting hardware.

3. Perform the Alignment Adjustment.

Alignment Adjustment

1. Loosen the mounting hardware (B, C & D, Figure 4).

2. Pivot the ground speed control levers (A) forward or

backwards to align with each other.

3. Once alignment is achieved, retighten the hardware.

Placement Adjustment

1. Loosen the placement bolt jam nut (E, Figure 4).

2. Turn the placement bolt (F) in or out to adjust the

amount of distance between the ends of the ground

speed control levers.

Figure 4. Ground Speed Control Lever Installation

A. Ground Speed Control Lever

B. 5/16-18 x 3/4” Bolt(s)

C. 5/16” Lock Washer(s)

D. 5/16” Flat Washer(s)

E. Placement Bolt Jam Nut

F. Placement Bolt

Not for

Reproduction

ZT4000 - 44” & 48” Mower Deck

Figure 5. Install the Seat & Connect the Harness

A. 5/16-18” Nylock Flange Nuts

B. Seat Switch Harness Plug

C. Seat Switch

Figure 6. Seat Adjustment

A. Seat Adjustment Lever

Assemble the Seat

1. Unpack the seat.

2. Install the seat onto the seat mount plate and secure with

the 5/16-18 nylock flange nuts (A, Figure 5)

3. Connect the seat swtich wire harness (B) to the seat

switch.

Seat Position Adjustment

The seat can be adjusted forwards or backwards.

1. Move the seat adjustment lever (A, Figure 6) to the left,

position the seat as desired, and release the lever to lock

the seat into position.

Not for

Reproduction

ZT4000 - 44” & 48” Mower Deck

www.simplicitymfg.com6

Roll Bar Assembly

Install the Roll Bar

1. See Figure 6. Remove and save the (2) bottom 1/2-13

X 3-1/4” bolt (A, Figure 7), 1/2” SAE washer, and 1/2-

13 hex nylock flange nut (A, Figure 7) that secures the

bumper to the frame of the machine. Discard the 1/2-13

hex jam nuts that are tightened on the threads of the 1/2-

13 X 3-1/4” bolts.

2. Lay a piece of cardboard on the ground behind the

machine, and then lay the roll bar on the cardboard with

the roll bar decals facing upward. The cardboard will

prevent damage to the paint on the roll bar.

3. From the outside loosely install the 1/2-13 X 3-1/4” bolt

(A, Figure 8) and 1/2 SAE washer (B) through the rollbar

(C), then through the bumper, and the frame of the

machine, and then loosely install the 1/2-13 hex nylock

flange nut (D).

4. Remove and save the (4) upper 1/2-13 X 3-1/4” bolts (A,

Figure 9), 1/2 SAE washers (B) and 1/2-13 hex nylock

flange nuts (D) that secure the bumper to the frame of

the machine. Discard the 1/2-13 hex jam nuts that are

tightened on the threads of the 1/2-13 X 3-1/4”bolts.

5. Position the roll bar (C, Figure 9) into the upright

position and from the outside loosely install 1/2-13 X

3-1/4” bolts, 1/2 SAE washers through the roll bar, then

through the bumper, and the frame of the machine, and

then loosely install the 1/2-13 hex nylock flange nuts.

NOTE: With the roll bar in the upright position the safety

decals should be facing towards the front of the

machine.

6. Tighten the (6) 1/2-13 X 3-1/4” bolts (A) that secure the

roll bar to the machine to 75 ft lbs (102 Nm).

Figure 7. Remove the Bottom Bolts

A. Lower Roll Bar Mounting Hardware (RH side shown.)

Figure 8. Installing the Roll Bar in the Bottom Hole (RH side

shown)

A. 1/2-13 X 3-1/4” Bolt

B. 1/2 SAE Washer

C. Roll Bar

D. 1/2-13 Hex Nylock Flange Nut

Figure 9. Installing the Roll Bar in the Upright Position (RH

side shown)

A. 1/2-13 X 3-1/4” Bolt

B. 1/2 SAE Washer

C. Roll Bar

D. 1/2-13 Hex Nylock Flange Nut

Not for

Reproduction

ZT4000 - 44” & 48” Mower Deck

Check

Fluid Levels

Check Engine Oil Level

1. Use the dipstick (A, Figure 10) to check the engine

oil level. If necessary add engine oil. Check engine

manufacturer’s owner’s manual for oil recommendations.

Check Hydraulic Oil Level

NOTE: Do not open the hydraulic reservoir unless oil is being

added.

1. Before removing the reservoir cap, make sure the area

around the reservoir cap and fill neck of the reservoir is

free of dust, dirt, or other debris.

2. Unscrew the reservoir cap (B, Figure 11).

3. Look down the filler neck of the hydraulic oil reservoir

(A, Figure 11) and observe the oil level. When cold, the

oil level should be approximately 4” (10 cm) below top

of the filler neck.

4. If necessary, add SAE 20W-50 motor oil. DO NOT use

synthetic oils.

5. Reinstall the reservoir cap.

Figure 12. Checking Tire Pressure

Check Tire Pressures

Tire pressure should be checked periodically, and

maintained at the levels shown in the chart. Note that these

pressures may differ slightly from the “Max Inflation”

stamped on the side-wall of the tires. The pressures shown

provide proper traction, improve cut quality, and extend tire

life.

Figure 11. Checking Hydraulic Oil Level

A. Hydraulic Oil Reservoir

B. Reservoir Cap

Figure 10. Pre-start Checks

A. Crankcase Oil Fill

Tire Serial Number Pressure

psi bar

Front 2013129510 & Below 40 2,76

Front 2013129511 & Above 25 1,72

Rear All 15 1,03

Not for

Reproduction

ZT4000 - 44” & 48” Mower Deck

www.simplicitymfg.com8

Check Mower

Assembly

Check Torque - Mower Blades

1. Park machine on a flat, level surface and engage the

parking brake.

2. Lock the deck lift pedal in the 5” (12,7 cm) position.

3. Check that blades are installed with the tabs pointing up

towards the deck as shown in Figure 13. Torque bolts

to 70 ft.lbs. (94 Nm).

Figure 13. Check Blade Torque

A. Blade Bolt

B. Flat Washer

WARNING

Avoid injury! Mower blades are sharp.

• Mower blades are sharp. For your personnal safety, do

NOT handle mower blades with bare hands.

• Careless or improper handling of blades may result in

serious injury.

• Blade mounting bolts must each be installed with a flat

washer then securely tightened. Torque blade mounting

bolts to 70 ft.lbs (94 Nm).

Figure 14. Check Lift Rod Timing

Deck Lift Rod Timing

And Leveling Adjustment

1. Park machine on a flat, level surface. Disengage the

PTO, stop the engine and engage the parking brake.

Rear tires must be inflated to 15 psi (1,03 bar); front

tires to 40 psi (2,76 bar).

2. To check the lift rod timing, measure and record the

distance between the lift pivots and the rod pivots.

Repeat for other side of unit. See Figure 14.

3. If the measurements are equal, skip to Step 5. If the

measurements are NOT equal (greater than 1/8” (3,17

mm) difference), adjustment is required, continue with

Step 4.

4. Refer to Figure 15. To adjust the lift rod timing, adjust

the 5/8” hex nuts on either side of the front lift pivot

until the measurements are equal. Repeat for other

side.

5. Place the deck height adjustment pin in the 4” (10,2 cm)

position.

Figure 15. Adjust Lift Rod Timing

Not for

Reproduction

ZT4000 - 44” & 48” Mower Deck

Figure 17. Hanger Chain Adjustment

Figure 16. 2 x 4 Locations

A. 1/4” Spacers

44” Models (S/N: All): 48” Models (S/N: 2014720668 &

Below):

6. Refer to Figure 16. Place 2 x 4 blocks under each corner

of the mower deck with the 3-1/2” sides being vertical.

Place a 1/4” (0,64 cm) thick spacer on top of the rear 2 x

4 blocks.

7. Adjust the front eyebolts until the chains are tight and

the deck is still resting on the 2 x 4’s. Tighten jam nuts.

See Figure 17.

8. Loosen the nuts and allow the rear of the deck to rest

on the 2 x 4’s and 1/4” spacers. Slide the chains in the

slots until the chains are tight and tighten the nuts. See

Figure 17.

9. Remove all 2 x 4 blocks and spacers from under the

mower deck.

10. For your safety, DO NOT handle mower blades with bare

hands. Position the outside mower blades so that they

face front-to-back (Figure 18).

11. Measure from the front tip of the blade from the cutting

edge to the ground. Measure from the rear tip of the

blade from the cutting edge to the ground. Repeat

this process for the other side of the machine. The

front measurements should be 4” (10,2 cm), the back

measurements should be 4-1/4” (10,8 cm).

48” Models (S/N: 2014720669 & Above)

6. Refer to Figure 16. Place 2 x 4 blocks under each corner

of the mower deck with the 3-1/2” sides being vertical.

7. Adjust the front eyebolts until the chains are tight and

the deck is still resting on the 2 x 4’s. Tighten jam nuts.

See Figure 17.

8. Loosen the nuts and allow the rear of the deck to rest on

the 2 x 4’s. Slide the chains in the slots until the chains

are tight and tighten the nuts. See Figure 17.

9. Remove all 2 x 4 blocks from under the mower deck.

10. For your safety, DO NOT handle mower blades with bare

hands. Position the outside mower blades so that they

face front-to-back (Figure 18).

11. Measure from the front tip of the blade from the cutting

edge to the ground. Measure from the rear tip of the

blade from the cutting edge to the ground. Repeat

this process for the other side of the machine. The

measurements should be 4” (10,2 cm).

Figure 18. Checking the Blade Height Measurement

Not for

Reproduction

ZT4000 - 44” & 48” Mower Deck

www.simplicitymfg.com10

Check Deck Drive Belt

1. Make sure the V-side of the belt runs in the pulley

grooves (Figure 19).

2. If belt is not properly seated, use a 1/2” breaker bar, and

place the square end in the square hole located in the

end of the idler arm (A, Figures 20). Carefully rotate the

breaker bar COUNTER-CLOCKWISE, which will relieve

the tension on the belt exerted from the idler arm and

spring.

3. Re-seat belt and carefully release the tension on the

breaker bar.

WARNING

Spring loaded components can kick back

causing injuries.

Use extreme caution when rotating the idler arm with the

breaker bar, due to the increased tension in the spring

as the idler arm is being rotated. Injury may result if the

breaker bar is prematurely released while the spring is

under tension.

NOTICE

To avoid damaging belts, do NOT pry belts over pulleys.

Figure 20. Mower PTO Belt

A. Idler Arm

B. Stationary Idler Pulley

Figure 19. Mower PTO Belt Routing

A. Spindle Pulley

B. PTO Drive Belt

C. Spring-loaded Idler Pulley

D. Stationary Idler Pulley

Not for

Reproduction

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