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*DCY* OPERATOR'S MANUAL Z200 Series EZtrak™ OMM172177 ISSUE J4 (ENGLISH) 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. If this product contains a gasoline engine: WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
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Introduction Thank You for Purchasing a John Deere Product We appreciate having you as a customer and wish you many years of safe and satisfied use of your machine. Using Your Operator’s Manual This manual is an important part of your machine and should remain with the machine when you sell it. Reading your operator’s manual will help you and others avoid personal injury or damage to the machine.
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Contents Product Identification Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Record Identification Numbers Product Identification . . . . . . . . . . . . . . . . . . . . . . . . 3 Zero Turn Mowers Safety Labels—Text . . . . . . . . . . . . . . . . . . . . . . . . . 4 PIN (170001-) Safety Labels—No Text . . . . . . . . . . . . . . . . . . . . . .
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Safety Labels—Text Safety Labels—Text Safety Label Location MXT010723—UN—16APR14 Z235 model shown.
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Safety Labels—Text Understanding The Machine Safety Labels DANGER/WARNING/CAUTION MXAL42363—UN—22MAY13 The machine safety labels shown in this section are placed in important areas on your machine to draw attention to potential safety hazards. On your machine safety labels, the words DANGER, WARNING, and CAUTION are used with this safety-alert symbol. DANGER identifies the most serious hazards.
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Safety Labels—Text Accumulation of grass, leaves and other debris on or near hot or moving parts can cause a fire. Inspect machine before, during and after use. Shut off engine and allow machine to cool before cleaning. For clean-out locations refer to service label. DANGER MXAL42770—UN—09APR13 ROTATING BLADE • Do not put hands or feet under or into mower when engine is running. THROWN OBJECTS • Before mowing, clear area of objects that may be thrown by blade.
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Safety Labels—No Text Safety Labels—No Text Safety Label Location MXT010725—UN—22APR14 A — Avoid Injury From Rotating Blades M118041 B — Avoid Injury From Getting Caught in Belts M136436 C — Read Operator’s Manual, Keep Children Away From Mower, Avoid Injury From Thrown Objects, Avoid Injury From Tipping M168199 D — Avoid Injury From Getting Caught in Belts M160860 E — Avoid Injury From Rotating Blades, Avoid Injury From Thrown Objects M138631 F — Avoid Injury From Rotating Blades, Avoid Injury From Throw
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Safety Labels—No Text Avoid Injury From Rotating Blades MXAL42784—UN—09APR13 • Do not put hands or feet under or into mower when engine is running. • Do not operate mower without discharge chute or entire grass catcher in place. Avoid Injury From Getting Caught in Belts Read Operator’s Manual and Avoid Injury M136436—UN—24MAY13 • Stay clear of moving belts. • Do not operate machine without shields in place.
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Safety • Make sure that children stay clear of mower at all times when the engine is running. This cutting machine is capable of amputating hands and feet and throwing objects. Failure to observe the following safety instructions could result in serious injury or death. Avoid Injury From Thrown Objects • Read, understand and follow all instructions on the machine and in manuals provided, and view safety video, before starting.
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Safety • Do not change the engine governor settings or overspeed the engine. Operating the engine at excessive speed can increase the hazard of personal injury. • If you hit an object or if abnormal vibration occurs, stop the machine and inspect it. Make repairs before you operate. • Use only accessories and attachments approved by the manufacturer of the machine. Keep safety labels visible when installing accessories and attachments. • Do not wear radio or music headphones.
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Safety • Never allow children or an untrained person operate the machine. Instruct all operators not to give children a ride on the machine or in an attachment. • Keep children indoors, out of the mowing area, and in the watchful eye of a responsible adult, other than the operator, when a mower is being operated. • Stay alert to the presence of children. Never assume that children will remain where you last saw them. Turn the machine off if a child enters the work area.
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Safety Operating Near Hazards • Total towed weight must not exceed combined weight of pulling machine, ballast and operator. Use counterweights or wheel weights as described in the attachment or pulling machine operator’s manual. • Excessive towed load can cause loss of traction and loss of control on slopes. Reduce towed weight when operating on slopes. • Never allow children or others in or on towed equipment. • Use only approved hitches. Tow only with a machine that has a hitch designed for towing.
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Safety • Never operate machine in a closed area where dangerous carbon monoxide fumes can collect. • Keep all nuts and bolts tight, especially blade attachment bolts, to be sure the equipment is in safe working condition. • Never tamper with safety devices. Check their proper operation regularly. • Keep machine free of grass, leaves or other debris build-up. Clean up oil or fuel spillage and remove any fuel-soaked debris. Allow the machine to cool before storing.
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Machine Cleanout Handling Fuel Safely • Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion. Welding can structurally weaken or deform the wheel. • When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly.
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Machine Cleanout • Excess lubrication or fuel/oil leaks or spills on the machine can also serve as collection sites for debris. Prompt machine repair and oil/fuel cleanup will minimize the potential for debris collection and reduced cooling throughout machine life. • Bearing failures or overheating can result in a fire. To reduce this risk, always follow the instructions in the machine operator’s manual regarding lubrication intervals and locations.
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Assembly Check Machine Safety System Perform safety system check to make sure the electronic safety interlock circuit is functioning properly. Perform all tests. (See Testing Safety System in the OPERATING section.) Operating Controls MXAL42791—UN—09APR13 6. Under the seat (H), including the battery (I) and wiring harness. Assembly Charge and Connect Battery CAUTION: The battery produces a flammable and explosive gas.
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Operating Operator Station Controls MXT010729—UN—17APR14 A — Left Motion Control Lever B — Headlight (If equipped) C — Park Brake Lever D — Deck Height Pin E — Mower Deck Lift Lever F — Mower Deck Lift Pedal (If Equipped) G — Right Motion Control Lever H — Fuel Tank Cap I — Ignition Key Switch J — Hourmeter K — Mower Engagement Switch L — Throttle/Choke Control Lever M — Optional Kits Switch N — Low Fuel Indicator Light • Insect repellent spray may damage plastic and painted surfaces.
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Operating Mounting and Dismounting Machine MXAL42795—UN—09APR13 2. To adjust motion control lever height, remove two bolts and nuts and raise or lower each control lever to your comfort level. • For highest lever position, use holes (A). • For lowest lever position, use holes (B). 3. You can also adjust motion control levers slightly forward or rearward (C) within slotted holes. MXAL42793—UN—09APR13 • Do not step on the mower deck when mounting and dismounting the machine.
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Operating 2. Inflate tires to the correct pressure. 3. Position caster wheels to the forward driving position. 4. Set mower to preferred cutting height, and lower deck into the mowing position. 5. Measure mower level (side-to-side). MXT005331—UN—22MAY13 MXAL42797—UN—09APR13 A convenient leveling gauge (A) (AM130907) is available from your dealer. c. Adjust mower level, if necessary, by turning rear nuts (E) clockwise to raise the side of the mower deck, or counterclockwise to lower the mower deck. a.
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Operating 42 and 48 Inch Mower MXAL42801—UN—09APR13 MXAL42803—UN—09APR13 42 Inch Mower shown. c. Remove access panel and adjust mower level, if necessary, by loosening front nut (F) on front lift rod. Turn rear nut (G) clockwise to raise front of mower or counterclockwise to lower it. Tighten front nut after adjustment is complete. NOTE: Verify that deck will latch in transport position.
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Operating Testing Park Brake Switch 2. Sit on seat. 1. Park machine safely. (See Parking Safely in the SAFETY section.) 3. First test: a. With the park brake locked, start engine. 2. Sit on seat. b. Move right motion control lever inward. 3. Unlock the park brake. Result: Engine should stop. If engine does not stop, there is a problem with your safety interlock circuit. 4. Try to start engine. Result: Engine must not crank. If engine cranks, there is a problem with your safety interlock circuit. 4.
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Operating Using the Hourmeter Neutral Position • The hour meter shows the number of hours the engine has run. The hour meter does not accumulate hours with the engine off when the key is in the run position. Use the hour meter to determine when your machine has reached the recommended service intervals. • Turn the key to STOP position when not using the machine. • Hour meter cannot be reset.
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Operating Reverse Travel MXAL42811—UN—09APR13 2. To turn sharply to the left, push right control lever (C) forward and pull left control lever (D) rearward at the same time. MXAL42809—UN—09APR13 1. Look down and behind, then gradually move both motion control levers evenly rearward (B) from neutral. To speed up, move the levers farther rearward. To slow down smoothly, slowly move the levers toward neutral. Right Turn Left Turn MXAL42812—UN—09APR13 1.
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Operating Engaging Mower CAUTION: Clear mowing area of all bystanders when operating this machine. Thrown objects could cause serious injury or death. Keep hands and feet away from blades and discharge opening. Do not mow in reverse unless absolutely necessary. 1. Adjust mower to desired cutting height. 2. Start engine. 3. Release park brake. 4. Move both motion control levers to the neutral position. 5. Set throttle lever to the RUN position.
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Operating Unplugging Mower, Bagger, or Material Collection System the bypass valves: CAUTION: Do not attempt to unplug attachment with machine running. • R o ta tin g bl ad e s ar e d an ge ro u s . S h u t o ff the en gi n e a nd r e m o v e t h e k e y b e f o r e g e t t i n g o ff t h e s e a t t o i n s p e c t t h e machine and attachment. • T h ro w n o b j e c t s c a n c a u s e s e ri o u s i n j u ry.
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Operating 8. Flush water under deck for approximately one minute. 9. Disengage mower blades. 10. Stop engine. 11. Turn off water and remove garden hose and quick-coupler from wash port. 12. Remove quick-coupler from garden hose and store for future use. Transporting Machine on Trailer NOTE: Trailer capacity must exceed combined machine weight and attachment weight. (See Specifications section in operator’s manual). Be sure trailer has all the necessary lights and signs required by law.
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Service Intervals Mowing Tips • • • • • • • Service Intervals Mow grass with throttle lever in the full fast / mow position. Mow grass when it is dry. Keep mower deck and discharge chute clean. Mow with sharp blades. Properly level mower deck for a smooth cut. Mow grass frequently. Use a travel speed that fits the conditions: - Mow tall or wet grass twice. Cut grass at half desired height – then cut at desired height. - Travel slow when mowing tall or thick grass.
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Service Lubrication Every 200 Hours 48TD Mower Decks • Check / adjust engine valve clearance. See your John Deere dealer for this service. Service Lubrication Grease IMPORTANT: Avoid Damage! Use recommended John Deere greases to avoid component failure and premature wear.
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Service Engine Lubricating Front Caster Spindles Emission Control System Certification Label NOTE: Tampering with emission controls and components by unauthorized personnel may result in severe fines or penalties. Emission controls and components can only be adjusted by EPA and/or CARB authorized service centers. Contact your John Deere Retailer concerning emission controls and component questions. CAUTION: To avoid injury, Do not lubricate machine while the engine is running.
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Service Engine Checking Engine Oil Level IMPORTANT: Dirt and contamination can enter engine when checking oil level. Clean area around dipstick before loosening or removing. IMPORTANT: Failure to check the oil level regularly could lead to serious engine problems if oil level is out of the operating range: • • • • C h ec k oi l le v e l be fore o pe ra ti ng . C h ec k o i l l e v e l w he n the e ng in e i s c o l d a n d n ot ru nn i ng . K e ep oi l l e v e l b etw e e n th e d ip s ti c k ma rk s .
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Service Engine Cleaning Air Intake Screen and Engine Fins 5. Clean guard and flywheel cover of debris. IMPORTANT: Be careful to maintain position of fuel pump assembly (D), clips (E) for fuel line, and any other attached components when removing parts from side of engine. CAUTION: Compressed air can cause debris to fly a long distance. • C le a r w ork area of b y s ta n de rs . • We a r e y e p r o t e c t i o n w h e n u s i n g c o m p r e s s e d a i r f o r cleaning purposes.
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Service Engine Checking Spark Plug 2. Let engine cool. IMPORTANT: To prevent engine damage, do not allow any foreign objects to fall into the carburetor air intake. CAUTION: Touching hot surfaces can burn skin. The engine, components, and fluids will be hot if the engine has been running. Allow the engine to cool before servicing or working near the engine and components. 1. Park machine safely (See Parking Safely in the SAFETY section). MXAL42833—UN—09APR13 3.
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Service Transmission Adjusting Carburetor 8. Install clamps and check for leaks. NOTE: Carburetor is calibrated by the engine manufacturer and is not adjustable. Cleaning Engine Screen Guard The twin cylinder engine incorporates a removable guard over the rotating flywheel cover at the top of the engine. The guard should be removed to check for and remove any debris daily in conjunction with checking engine oil level.
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Service Transmission Adjusting Neutral Creep 1. Park machine safely. (See Parking Safely in the SAFETY section.) 2. Remove style panel for better access to adjustment components (if desired): MXAL42841—UN—09APR13 2. Adjust tracking with the 13 mm socket on the free end of the deck height adjustment lock pin (A) as follows: MXT010730—UN—17APR14 NOTE: Tracking bolts limit top forward speed.
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Service Mower Checking and Replacing Transaxle/Transmission Drive Belt CAUTION: Components are installed under spring tension. Wear eye protection and use proper tools when installing and removing components with spring tension. CAUTION: Entanglement in a belt or sheave can cause serious injury. Stop engine and wait for all moving parts to stop. 4. Insert a 3/8 in.
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Service Mower 3. Rotate foot plate up using finger pull (B). 6. Disconnect mower drive belt: 4. Remove foot plate. Installing Foot Plate 1. Place tabs (C) of foot plate into slots in frame. 2. Lower foot plate. 3. Install bolt (A). Removing Mower Deck (42C) 1. Park machine safely. (See Parking Safely in the SAFETY section.) 2. Allow engine and muffler to cool completely. CAUTION: Rotating blades are dangerous.
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Service Mower 8. Remove spring clip (K) and pin from each side of rear mower bracket. 6. Disconnect mower drive belt: 9. Raise lift linkage to transport lock position: a. Pull pin and raise mower lift lever fully upward. b. Install pin just below lift lever to lock into raised position. 10. Rotate front caster wheels to maximize clearance. 11. Slide mower out from under the machine. • Do not operate the machine without the mower deck: Machine may become unstable without the mower deck attached.
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Service Mower 11. Slide mower out from under the machine. • Do not operate the machine without the mower deck: Machine may become unstable without the mower deck attached. Move machine only by hand. (See Moving Machine by Hand in OPERATING section.) Installing Mower Deck (42C) 1. Park machine safely. (See Parking Safely in the SAFETY section.) 2. Allow engine and muffler to cool completely CAUTION: Rotating blades are dangerous.
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Service Mower • Install 3/8-inch ratchet onto square hole (G) in tension arm and rotate clockwise to release tension on belt, while installing mower belt onto center spindle sheave (H). Make sure belt is properly seated on all sheaves. 8. Install foot plate. Replacing Mower Drive Belt (42 Inch Mower) 1. Park machine safely. (See Parking Safely in SAFETY section.) 2. Allow engine and muffler to cool completely. 3. Remove mower deck. 4.
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Service Mower MXAL42863—UN—09APR13 Shown without sheave for clarity only. 9. Make sure belt guide (E) is indexed properly into hole (F) on tension arm (G). MXT010733—UN—17APR14 10. Tighten sheave hardware to specification. • Loosen nut (C) and bolt (D) on sheaves, and remove belt from all sheaves. Specification Sheave — Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 N·m (35 lb-ft) 5. Inspect belt for wear or damage; replace as necessary. 11.
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Service Electrical 2. Raise mower deck to highest position to access blades. Installing Mower Blades 1. Align the splined center hole in the blade with the splined spindle shaft (K) and put the blade onto the mower spindle shaft with cutting edge toward ground. 2. Install washer (B), with cupped side towards blade, and install nut (A) to secure blade onto splined spindle shaft. 3. Block mower blade with a piece of wood to prevent spinning and tighten nut to specification. Specification Nut — Torque . . . .
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Service Electrical 7. Attach cables to battery terminals, beginning with the positive cable, using washers and nuts. 8. Apply spray lubricant to terminal to prevent corrosion. Using Booster Battery CAUTION: The battery produces a flammable and explosive gas. The battery may explode: • D o n o t s mo k e o r h a v e o p e n flfla am e n e a r b a t t e r y. • We a r e y e p r o t e c t i o n a n d g l o v e s . • D o n o t j u mp s t a rt o r c h a r g e a f ro z e n b a t t e r y.
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Service Miscellaneous Filling Fuel Tank 5. Remove the fuse and check metal strip in fuse window. Discard fuse(s) if strip is broken. 6. Push new, correct amp, fuse into correct socket. CAUTION: Fuel vapors are explosive and flammable: 7. Lower operator’s seat. • • • • • • • Service Miscellaneous Using Proper Fuel and Stabilizer IMPORTANT: Using stale, contaminated or improper fuel can result in engine and fuel system damage.
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Service Miscellaneous MXAL42875—UN—09APR13 MXAL42874—UN—09APR13 3. Remove the wheel nuts (A). 3. Safely lift front of machine at machine frame point (C). Place jack stands or other stable supports onto machine frame locations (D). 4. Remove the wheel assembly. CAUTION: Explosive separation of tire and rim parts is possible when they are serviced incorrectly: 4. If only lifting front of machine, block rear wheels remaining on ground to avoid movement of machine.
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Troubleshooting MXAL42878—UN—09APR13 9. Inspect bushing wear areas (H), and bolt holes (I) for wear or damage. Replace if necessary. Assembly • Apply grease to caster shaft and bolt. • Assemble in the reverse order of disassembly. • Tighten caster locknut and bolt to specification. MXAL42876—UN—09APR13 3. Support caster assembly and remove flange bolt (A) and cap (B). Specification Caster Locknut — Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 N•m (35 lb-ft) 4.
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Troubleshooting Engine IF CHECK Poor Engine Performance Dirt in fuel system or fuel is old. Replace fuel with fresh stabilized fuel. Obtain fuel from another supplier before suspecting machine problems. Suppliers blend fuels differently and changing suppliers will generally solve any performance problems Fuel blended with alcohol or ether may CHECK Engine Loses Power Engine overheating. Too much oil in engine. Dirty air cleaner. Faulty spark plug. Travel speed is too fast for conditions.
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Storage IF CHECK Too Much Vibration Debris on mower deck or in sheaves. Damaged drive belt. Damaged sheaves or sheaves out of alignment. 8. Lubricate grease points and check tire pressure. Preparing Fuel and Engine For Storage Fuel: Blades out of balance. Front Tires Vibrate If you have been using “Stabilized Fuel,” add stabilized fuel to tank until the tank is full. Set front tire pressure to 10 psi.
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Specifications 3. Check battery electrolyte level, if your battery is not maintenance free. Charge battery if necessary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ethanol Blended Fuel (Up to 10%) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MTBE Reformulated Fuel (Up to 15%) 4. Install battery. Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replaceable - paper element 5.
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Warranty Recommended Lubricants has failed due to abuse, neglect, or improper maintenance or unapproved modifications. • You are responsible for presenting your spark ignited off-road engine equipment to a John Deere Turf and Utility distribution center or service center as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.
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Warranty Evaporative System: • • • • • • • The purchaser must request warranty service from a John Deere dealer authorized to sell John Deere batteries, and present the battery to the dealer with the top cover plate codes intact.
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Getting Quality Service Warranty Code Free Replacement Period John Deere Quality Continues with Quality Service Pro Rata Warranty Period F 90 Days 60 Months G 12 Months 60 Months H 12 Months 60 Months 6 6 Months 0 Months 12 12 Months 0 Months 18 18 Months 0 Months John Deere provides a process to handle your questions or problems, should they arise, to ensure that product quality continues with your John Deere dealer’s parts and service support.
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Service Record Service Record Record Service Dates Oil Change Oil Filter Change (If Equipped) Lubricate Machine 52 Air Cleaner Element Check/Clean Fuel Filter Change
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Slope Gauge Slope Gauge 53
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Slope Gauge 54
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Slope Gauge Slope Gauge Template NOTE: Cut along left boundary line of graphic as a guide to remove template. MXT007077—UN—11JUN13 Use this slope gauge to determine if a slope is too steep for safe operation. Do not operate your machine on a slope greater than what is recommended in your Operator’s Manual. See Operating on Slopes in the Safety Section. • Fold along the appropriate line (A) to match the recommended slope. • Align this edge (B) with a vertical surface, a tree, building, fence pole, etc.
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Slope Gauge 56
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Index A Mower, Removing Deck ( 42C) . Mower, Removing Deck (48). . . Mower Troubleshooting . . . . . . Mowing Tips . . . . . . . . . . . . . . Air Cleaner Elements ( Twin Cylinder), Checking and Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 B Battery and Terminals, Cleaning . . . . . . . . . Battery, Charge and Connect at Assembly . Battery, Removing and Installing. . . . . . . . . Battery, Service Safely . . . . . . . . . . . . . . . .
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Notes
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Notes
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Notes