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SERVICING SCAG
SCAG PRODUCTS
PRODUCTS FROM
FROM A
A TO
TO Z
Z
TECHNICAL REFERENCE MANUAL
STT
ZERO - TURN RIDERS
SSZ
STT & SSZ TECHNICAL REFERENCE MANUAL
Section 2 - Adjustments
2.1 Neutral Adjustment (10:26) 7
2.2 Brake Adjustment (12:22) 8
2.3 Tracking Adjustment (13:08) 8
2.4 Replace Hydraulic Pump Belt (14:04) 9
I
STT & SSZ TECHNICAL REFERENCE MANUAL
Appendix
5.1 General Torque Specification Chart 42
II
STT & SSZ TECHNICAL REFERENCE MANUAL
-NOTE-
Follow all shop safety procedures while assembling
the mower.
-NOTE-
The "Right" and "Left", "Front" and "Rear" of the
machine are referenced from the operator's
perspective when seated in the normal operating
position and facing forward.
Figure 1-1 Battery Removal
1.2 REMOVING THE CRATING (00:46)
1
STT & SSZ TECHNICAL REFERENCE MANUAL
With the tapered side of the nut toward the wheel, thread
all the lug nuts onto the studs until they are snug against
the rim.
DUMP VALVE
RUN
Using the torque sequence shown in Figure 1-2, torque FREE LEVER
POSITION
the lug nuts to 65 foot pounds. WHEEL
POSITION
Carefully lower the machine back onto the shipping pallet.
Use four 5/16 -18 serrated flange nuts to attach the seat
adjustment rails when mounting the seat to an SSZ 52 or
SSZ 61. SC200G
2
STT & SSZ TECHNICAL REFERENCE MANUAL
With assistance, slide the cutter deck off the crate 15-1/8"
bottom.
Place the cutter deck height control lever into one of the
middle holes on the height control bracket.
- IMPORTANT -
Make sure the machine is on a flat level surface.
0709963
- IMPORTANT -
Make sure the machine is on a flat level surface.
4
STT & SSZ TECHNICAL REFERENCE MANUAL
Recheck the distance from the front of the deck to the BELT
ground to confirm proper adjustment.
Check the tension of the right hand blade drive belt using BELT
a belt tension gauge. Adjust the belt so that it deflects WASHER
1/2" with 10 pounds of pressure.
The tension on the right hand cutter deck belt can be NUT
adjusted by tightening or loosening the locknut on the
"J" BOLT
J-bolt. See Figure 1-10 or Figure 1-11. SC206G
Reference Scag Fundamentals Belt Section for details on Figure 1-11 48" & 61" Cutter Deck
troubleshooting belts. RH Belt Adjustment
5
STT & SSZ TECHNICAL REFERENCE MANUAL
New machines are shipped without engine oil. Check the Figure 1-13 Battery Installation
oil level and fill to the proper level as outlined in the
engine manual furnished with each machine.
6
STT & SSZ TECHNICAL REFERENCE MANUAL
Move the dump valve lever to the run position. See SC200G
Figure 2-1.
Figure 2-1 Dump Valve Lever
Start the engine, release the parking brake and verify the
speed control levers are in neutral. Check if one or both
of the wheels are turning. If the wheels are turning in
either direction, neutral adjustment is required.
7
STT & SSZ TECHNICAL REFERENCE MANUAL
Remove the hairpin from brake rod swivel joint. Turn the
swivel joint clockwise to increase brake force. Repeat
the procedure on the other side, and engage and
disengage the parking brake several times to assure
secure brake application without dragging. See Figure
2-3.
CAUTION: BELLCRANK
Stop engine and remove key from the
ignition before making any adjustments. TURNBUCKLE
Wait for all moving parts to come to a com- SC203G
8
STT & SSZ TECHNICAL REFERENCE MANUAL
Insert a 1/2" breaker bar into the square hole on the idler
arm assembly. Apply pressure to the breaker bar, moving
the idler arm assembly until the belt becomes slack and
can be easily removed from the idler pulley. Remove the
belt from the idler pulley. Slowly and carefully move the
idler arm up until it rests against the hydraulic tank
support. Figure 2-5 Hydraulic Belt Cover
Mount the new belt around the engine pulley and the two IDLER PULLEY
pump pulleys. See Figure 2-6.
Feed the belt up towards the idler pulley. The belt must
twist between the pump pulleys and the idler pulleys as
shown in Figure 2-6.
Using the breaker bar, carefully push the idler arm down
so that the new belt can be easily mounted on the idler ENGINE PULLEY
pulley.
9
STT & SSZ TECHNICAL REFERENCE MANUAL
SECTION 3 - ELECTRICAL SYSTEM For the starter to crank on the SSZ, the following
parameters must be met:
(15:16)
1.) Speed control handles must in the outward,
3.1 ELECTRICAL TESTING neutral lock position.
The electrical system on the SSZ incorporates an engine 2.) PTO switch must be in the "off" position.
cranking circuit, operator presence interlock circuit, and a
PTO circuit. Follow the wiring diagram completely 3.) Ignition switch in the start position.
through all affected circuits during electrical testing.
Perform basic tests of the engine cranking circuit by
3.2 ENGINE CRANKING CIRCUIT (15:16) connecting the test light between the battery negative
terminal and the green wire in the harness end of the
The engine cranking circuit is a switched 12-volt supply engine connector. Turn the ignition key to the start
circuit that supplies power from the battery to energize position. The test light should illuminate when the speed
the starter solenoid, and crank the engine. The circuit control levers are out, and the PTO is off.
starts with voltage supplied to the ignition switch. In the
‘on’ position, 12 volts is available at the accessory The test light will go out when either speed control lever
terminal on the ignition switch. From the ignition switch, is moved out of the neutral lock position, or the PTO is
12-volt power is supplied to the PTO switch. With the turned on while holding the key to the start, engine crank,
PTO off, the circuit connects through the PTO switch to position.
the PTO start interlock relay. The windings of the relay
are grounded at all times, so the relay closes when the If the test light does not come on, individually test the
PTO is in the ‘off’ position. neutral lock switches and the PTO switch.
When turning the ignition switch to the start position, 12 Reference the Engine Cranking Circuit Flowchart on
volts is sent to the starter relay. The circuit passes page 13 for additional testing.
through the relay contact points to the right neutral lock
switch. 3.3 PTO CIRCUIT
With the right speed control handle in the outward, neutral
The PTO circuit on the SSZ machine requires that the
lock position, the switch is closed, and the circuit
following parameters are met in order for the PTO clutch
continues through the left neutral start switch.
to engage:
With the left speed control handle in neutral lock, 12 volts
1.) Ignition switch is in the "on" position.
is transfered to the start relay. The windings of the start
relay are grounded at all times. The relay contacts close,
2.) Seat switch is depressed.
and 12 volts is supplied to the starter solenoid to engage
the starter and crank the engine.
3.) PTO switch in the "on" position.
If the PTO is engaged, the PTO start solenoid opens, and
The operator presence system must be working properly
interrupts the crank circuit, preventing the engine from
in order for the PTO clutch to engage. When both
cranking.
systems are working properly, the engine will stop
anytime the operator leaves the seat with the PTO
When a speed control lever is moved out of the neutral
engaged.
lock position, the circuit opens, and does not allow the
engine to crank. The circuit is wired this way to ensure
Perform the basic tests of the PTO circuit by using a test
safe starting conditions. Make sure the controls are
light. Place the test light clip on a ground and check the
properly positioned and all switches are properly adjusted
test light connection by placing the probe onto the positive
to fully activate the switch before performing in-depth
terminal of the battery.
electrical testing.
With the previously listed parameters met, begin by
10
STT & SSZ TECHNICAL REFERENCE MANUAL
testing for power and ground at the clutch. Next, move The second terminal of the seat switch is grounded at all
to the PTO clutch connector and test for voltage and times. If the operator is in the seat, the seat switch is
ground. open, and the circuit is broken. In this condition, any
positioning of the speed control handles or PTO will not
Next, test the PTO switch for proper operation. Finally, affect engine operation.
test the ignition switch to identify any possibly faults.
If the operator moves out of the seat, the seat switch
Replace any switch found to be faulty. If power or closes, and the entire ignition ground circuit is closed,
ground is lost between two points, test for continuity in stopping the engine. Any movement of controls out of
the wiring harness to locate the broken connection or neutral, or engaging the PTO switch, will close the
wire. ignition ground circuit and kill the engine when the
operator is out of the seat.
Reference the PTO Circuit Flowchart on page 14 for
additional testing. For a basic ground circuit check of the operator presence
system, begin by turning the ignition key to the 'off'
3.4 OPERATOR PRESENCE CIRCUIT position. Connect the test light between the battery
(18:06) positive terminal and the black wire at the engine
connector. If the light illuminates, a ground exists which
The operator presence interlock system is designed to will prevent the engine from operating. With the key in
stop the engine if the operator leaves the seat at any time the 'off' position, a ground should be present at this point.
while the machine is moving or the PTO switch is on.
Turn the ignition key to the 'on' position. The test light
The following parameters must be met to test the should be off. Raise the seat to simulate an operator not
operator presence system: being in the seat. Check the system by moving the speed
control handles individually from the neutral lock position.
1.) Ignition switch is in the "on" position. The test light should illuminate when either lever is moved
inward.
2.) Seat switch is depressed.
Move the speed control handles back to the neutral lock
3.) Steering control levers are in the outward position. Turn the PTO switch on, and the circuit will
locked position. ground the ignition, causing the test light to illuminate.
4.) PTO switch is in the disengaged position. With the seat switch depressed, the test light should not
illuminate when the levers are moved in or the PTO is on.
Once the engine has been started, for the it to continue
running, the operator must be seated whenever the speed Reference the Operator Presence Circuit Flowchart on
control handles are moved inward from the neutral lock page 15 for step by step testing procedures.
position or the PTO is moved to the ‘on’ position.
These steps will help to isolate a particular component
When the operator presence system is activated, the such as a switch, wiring harness, or connectors that may
circuit grounds the ignition to kill the engine. The ground have a fault, which is causing an operating problem.
wire from the ignition is connected to one terminal on
each neutral lock switch, and to the PTO switch. The If additional tests are required to determine the exact
opposite terminal of the switch on each speed control cause of a problem, use the test techniques demonstrated
handle, and the PTO switch, is connected in series with in Scag Fundamentals Electrical Section to test each
one terminal of the seat switch. component individually.
11
BLACK
BLACK RED
YELLOW YELLOW
RED RED
BLACK BLACK
RED
BATTERY BLACK
BLACK
3.5
HOURMETER
BLACK AMMETER
BLUE
PTO
RED
RED
RE
D IGNITION
BLACK SWITCH
RED
WHITE
SWITCH
GREEN
YELLOW
YELLOW RED
ENGINE FUSES
HARNESS RED RED
RED
ADAPTER RED
PLUG GREEN
BLACK GREEN
12
GREEN
BLUE
RED BLACK
ENGINE BLACK
RELAY
CONNECTOR BLUE
/RED
RED
BLACK
ALTERNATOR
GREEN GREEN
BLACK
IGNITION
(WHITE) BLACK
SEAT
BLACK SWITCH GREEN
GREEN
BLACK
LEFT NEUTRAL
RED
BLACK GREEN RED
INTERLOCK RIGHT NEUTRAL
WIRING DIAGRAM - KOHLER ENGINE
RED INTERLOCK
BLACK
BLUE
RED RED
BLUE
STT & SSZ TECHNICAL REFERENCE MANUAL
Parameters = Perform Basic Electrical Checklist
PTO switch off
Ignition switch in start position
Does the battery Seat switch depressed
Parking brake engaged
have at least NO Steering control levers in neutral YES Replace
12.0 volts? lock position Is there a ground
Ignition
at the Black
YES Is there voltage switch.
YES wire at the Turn the
at the Blue-Red
starter relay? Ignition
wire at the
Charge or switch to the
NO starter relay?
replace the start position
battery. YES
YES NO
Is there voltage
Is there voltage Is there voltage at the Red
Does the at the Red at the Green NO
NO wire at the
battery have at least wire at the starter NO wire at the engine Ignition switch?
9 volts with the NO relay? connector
key in the start plug?
position? YES Is there voltage
at the Green
YES Repair or replace Repair or replace NO
3.6
wire at the
faulty wire or faulty wire or
Ignition switch?
Replace the connection. YES connection.
faulty fuse. Is there voltage YES
Is there voltage
at the GreeN wire
present at the Green
NO at the engine NO
wire at the starter
harness adaptor
Test the fuses relay?
plug?
STT & SSZ TECHNICAL REFERENCE MANUAL
13
wire at the at the Black
NO
PTO relay? (D) wire at the
Replace the
Repair or replace PTO relay?
Consult the Engine Neutral YES
switch. NO faulty wire or
Manufacturers Manual connection in the
for further testing. Does green wire between
NO the right neutral the Ignition switch
YES interlock switch
Does and the PTO relay.
the left neutral test properly? Turn the Ignition
YES Is there voltage
interlock switch at the Green switch to the off
test properly? YES NO position.
(B) wire at the
PTO relay? Replace
PTO relay.
ENGINE CRANKING CIRCUIT
Is there voltage
at the Yellow wire YES
YES Is there voltage
at the ignition
Is there voltage Is there voltage
switch ? at the Red wire Is there voltage
YES at the single Red at the white
at the ignition YES at the White wire
NO wire at the YES (C) wire at the
switch ? at the
PTO switch? PTO relay?
NO NO PTO switch?
white
NO NO
NO (C)
Repair or replace
faulty wire or green green
Repair or replace (A) (B)
connection Process Repair or replace
faulty wire or
be tw e en f use Replace faulty wire or
connection between Replace
block and ignition Ignition connection between
ignition switch and PTO switch.
switch. switch. PTO switch and
PTO switch. Starter black (D) PTO relay.
Relay
STT & SSZ TECHNICAL REFERENCE MANUAL
START
Perform the following Parameters = All basic electrical checks performed
(ie battery voltage, fuses, etc.)
procedures Operator presence system tests properly
using a test light. PTO switch on
Ignition switch on
Airgap properly adjusted on clutch (0.015)
YES
Is there a
Is there voltage
ground
at the Blue Replace the
YES at the Black YES
wire at the PTO PTO Clutch
wire at the PTO
clutch?
clutch?
NO NO
Repair or replace
the faulty wire or
connection in the
harness.
Is there a poor
connection at either
YES
side of the Repair or replace
PTO connector? Repair faulty
connection or the faulty wire or
wiring at PTO connection in the
NO
connector. Red wire in the
harness.
NO
Is there
Is there voltage at Is there voltage at
voltage at the
the Blue wire at the NO NO the Red wire at the
single Red wire at
PTO switch? Ignition switch?
the PTO switch?
YES YES YES
Repair or replace
Test the wiring the faulty wire or
Replace the
harness for continuity. connection
PTO switch.
Repair or replace between the PTO
the harness. switch and the
Ignition switch.
14
STT & SSZ TECHNICAL REFERENCE MANUAL
START
YES
NO NO NO NO
15
STT & SSZ TECHNICAL REFERENCE MANUAL
LUBRICATION NO. OF
LOCATION INTERVAL LUBRICANT PLACES
1 Caster Wheel Pivot 100 Hours/Bi-Weekly Chassis Grease 2
2 Caster Wheel Bearings 100 Hours/Bi-Weekly Chassis Grease 2
3 Idler Arm Pivot 200 Hours/Monthly Chassis Grease 1
4 Cutter Deck Spindles 40 Hours/Weekly US Lithium MP White Grease 2125 3
5 Idler Arm Pivot 100 Hours/Bi-Weekly Chassis Grease 1
6 Push Arm 100 Hours/Bi-Weekly Chassis Grease 2
7 Height Adjustment 100 Hours/Bi-Weekly Chassis Grease 3
8 Bell Crank 100 Hours/ Bi-Weekly Chassis Grease 4
9 Idler Arm Pivot 100 Hours/Bi-Weekly Chassis Grease 1
10 Control Levers 100 Hours/Bi-Weekly Chassis Grease 2
16
STT & SSZ TECHNICAL REFERENCE MANUAL
CHASSIS GREASE
( 100 HOURS / BI-MONTHLY )
10 CHASSIS GREASE
( 200 HOURS / MONTHLY )
6 8
10
3 4
2 8 6
390S0180
17
STT & SSZ TECHNICAL REFERENCE MANUAL
-NOTE-
The "Right" and "Left", "Front" and "Rear" of the Figure 1-1 Battery Removal
machine are referenced from the operators
perspective when seated in the normal operating
position and facing forward.
18
STT & SSZ TECHNICAL REFERENCE MANUAL
Remove the lug nuts from the axle hub studs. Turn the
wheel so the valve stem is facing outward, and slide the 2
wheel onto the studs. With the tapered side of the nut Torque Sequence
toward the wheel, thread the lug nuts onto the studs until
they are snug against the rim.
Figure 1-2 Torque Sequence
Using the torque sequence shown in Figure 1-2, torque
the lug nuts to 65 foot pounds.
- NOTE -
Some machines may be shipped with both steering
levers bolted to the right control lever bar. In this
case remove the upper steering lever and mount it to
the left side. When correctly mounted, the steering Figure 1-3 Install Control Levers
levers should be pointing towards each other and
adjusted for operator comfort.
Remove the two 5/16-18 X 4" bolts from the seat hinge.
See Figure 1-4.
Place the seat onto the seat hinge. Align the holes of the
seat hinge, and re-install the two 5/16-18 X4" bolts. SEAT
Seat Cable StopCABLE
19
STT & SSZ TECHNICAL REFERENCE MANUAL
WARNING: 030467-13
Severe chemical burns can result from battery Figure 1-5 Radiator Fill Level
electrolyte. Always wear protective eyewear,
clothing, and gloves when handling batteries.
Always keep a source of fresh water available
to flush skin should contact occur.
New machines are shipped without engine oil. Check the Figure 1-6 Coolant Bottle Fill Level
engine oil level and fill to the proper level as outlined in
the engine manual furnished with the machine.
- IMPORTANT -
Do not overfill with oil. WARNING:
Engine damage could result. Use EXTREME caution when removing the
radiator cap. NEVER remove cap when hot.
On Kawasaki liquid cooled engines, the coolant level in
the recovery tank should be in the range between the “H”
Coolant may be under pressure and
and “L” lines. See Figure 1-6. extremely hot.
Fill the hydraulic tank with SAE 20W50 motor oil. See HYDRAULIC OIL
Figure 1-7. Approximately six quarts will be needed. RESERVOIR
Fill to about three inches below the top of the neck. Do
not overfill the hydraulic tank. Re-install and tighten
the tank cap.
Add fuel to the fuel tank. See Figure 1-8. Always use a
good quality fuel with a minimum octane rating of 87. FUEL CAP
on the upper left side of both pumps. The valve on the Figure 1-8 Fuel Tank Location
right pump may be slightly hidden under the engine. See
Figure 1-9.
-IMPORTANT-
Refer to the Basic Operation section of Scag
Fundamentals before operating this machine. Make
DUMP VALVE
sure all operators are properly trained and CONTROL LEVER
thoroughly familiar with all of the controls before
operating the mower.
CAUTION:
The drive unit can get hot during operation 390S0141
and could cause burn injuries. Allow engine
and drive components to cool completely Figure 1-9 Dump Valve Location
before making any adjustments.
21
STT & SSZ TECHNICAL REFERENCE MANUAL
SECTION 2 - ADJUSTMENTS (28:41) Turn the rod one direction and observe the reaction of the
drive wheel. If the wheel creeps faster, begin turning the
rod slowly in the opposite direction. If the wheel slows,
2.1 NEUTRAL ADJUSTMENT (28:41)
continue turning until the wheel begins to creep in the
opposite direction. Move the rod back to a position
Neutral or tracking adjustments will need to be made if:
midway between the two points.
A. The steering control levers are in the neutral
position and the machine creeps forward or Tighten the jam nuts to secure the neutral position and
backward. (Neutral Adjustment). repeat the procedure for the other drive wheel if
necessary. Actuate the steering control levers forward
and reverse several times and return them to the neutral
B. The steering control levers are in the full forward
position. Verify that the drive wheels are still in neutral
position and the mower pulls to one side or the
and readjust if necessary.
other when traveling in a forward direction.
- NOTE -
(Tracking Adjustment, Section 2.2, page 23).
The right hand control rod will be changed in 1999 to
With an operator in the seat and the machine in neutral, a straight rod similar to the current style of left hand
start the engine and disengage the parking brake. Check control rod. At that time, the right hand control rod
if one or both of the wheels are turning. If a wheel is will be adjusted the same as the left control rod.
rotating slightly, or creeping, the speed control rod for that
drive pump must be adjusted. Loosen the two jam nuts If you experience difficulty in achieving a sound neutral
on the speed control rod. See Figure 2-1 for right side position, refer to the Hydraulics information in Scag
adjustments and Figure 2-2 for left side adjustments. Fundamentals.
CONTROL
ROD
LOOSEN
HERE
LOOSEN
HERE
390S0149 390S0147
LOOSEN
HERE
TURN
HERE
2.2 TRACKING ADJUSTMENT (30:08) If at full speed the mower pulls right, it is an indication
that the left wheel is turning faster than the right wheel.
Stop the engine and remove the key from the ignition To adjust this condition, proceed as follows:
before making any adjustments. Wait for all moving parts
to come to a complete stop before beginning work.
1. Stop the machine and place the steering control
levers in the neutral position. Loosen the lock
WARNING: nuts securing the ball joints at each end of the LH
The engine and drive components can get hot steering control rod. Rotate the control rod to
lengthen the rod. This will cause the control rod to
during operation. Allow engine and drive
stroke the LH pump less, slowing down the LH
componentsto cool before making any wheel. Tighten the lock nuts. See Figure 2-2.
adjustments to avoid burns.
CONTROL
ROD
LOOSEN
HERE
LOOSEN
HERE
390S0149 390S0147
LOOSEN
HERE
TURN
HERE
At the left brake, measure the distance between the JAM NUT
lower nut on the brake actuating rod and the brake LOOSEN
HERE
actuating lever. There should be 1/8- inch clearance
between the lower nut and the actuator arm. See Figure
2-4.
24
STT & SSZ TECHNICAL REFERENCE MANUAL
JAM NUT
ADJUST HERE
CUTTER DECK
ADJUSTING BOLT
390S0174
25
STT & SSZ TECHNICAL REFERENCE MANUAL
43
15
48
1
the measurement at the front of the deck is not 1/4"
5
1.
2
5
2.
3
5
3.
CONTROL ROD
4
5
lower, the cutter deck pitch must be adjusted as follows:
4.
5
5
5.
IN T
6
G
TT H
C EIG
H
U
Loosen the jam nuts on both of the adjusting rods. See
Figure 2-8. Using a wrench on the spring compression
nut, turn the adjusting rods until the 1/4" forward pitch is
obtained on both the RH and the LH side of the cutter
deck. Tighten both jam nuts. LOOSEN
HERE
- NOTE -
HEIGHT ADJUSTMENT PEDAL 390S014A
To prevent the cutter deck from teetering, all four
cutter deck hanging chains must have tension on Figure 2-9 Cutter Deck
them. If all four chains do not have tension on them Height Adjustment
and the deck teeters, you must readjust the cutter
deck as outlined in the Section 2-4 and Section 2-5.
390S0175
Turn the control rod until there is a 1/4" space between
the rear deck stop and the top of the cutter deck, see Figure 2-10 Cutter Deck Stop
Figure 2-10. Tighten the jam nuts on the control rod. Measurement
26
STT & SSZ TECHNICAL REFERENCE MANUAL
43
15
48
Release the deck from the transport positon and allow the
1
5
1.
2
5
2.
3
5
3.
CONTROL ROD
deck to move to the 3" cutting height position.
4
5
4.
5
5
5.
IN T
6
G
TT H
C EIG
H
U
Check the measurement from the floor to the cutter blade
tip. If the measurement is not at 3", an adjustment can be
made using the deck height control rod. See Figure 2-11.
-NOTE- LOOSEN
HERE
If an adjustment was made, be sure that the cutter
deck can easily be locked into the transport position.
HEIGHT ADJUSTMENT PEDAL 390S014A
27
STT & SSZ TECHNICAL REFERENCE MANUAL
3.1 ELECTRICAL TESTING (34:43) The key switch must remain on for all other switch tests.
Tests can be performed in any order after the first test.
The electrical system on the STT incorporates a solid
state module, which controls the function of the engine The orange wire is connected to the speed control lever
crank and operator presence interlock circuits. The basic switches. The test light should illuminate when both the
function of these circuits is the same as with other levers are out in the neutral lock position, and should go
products. However the use of the module simplifies the out when either or both of the levers are moved inward.
wiring system because all basic switch and circuit tests Be sure to test both steering levers.
can be performed at the interlock module connector.
The seat switch is tested at the brown wire. The test
Two different interlock modules are used on the STT, light should illuminate when pressing down on the seat
determined by the engine option. The Kohler engine uses switch, and go out when releasing the switch.
a magneto type ignition system, which requires an
external grounding of the magneto kill wire to stop the The pink wire is connected to the brake switch. The
engine. This ground is provided through the interlock light will be on when the brake is on. Release the brake,
module at the white wire. and the test light should go out.
The Kawasaki engine uses a battery type ignition, which The light blue wire is connected to the PTO switch.
is supplied battery voltage to operate. The voltage supply When the switch is moved to the off position, the test light
for this ignition is provided through the interlock module will be on, and will go out when the PTO switch is pulled
from the white wire. to the on position.
These different modules each require a different method The green wire supplies a ground to the starter relay to
of testing the output from the white wire. assist in completing the starting circuit. Reference the
Engine Cranking Circuit for testing procedures.
The following series of tests are all that is required to test
the entire electrical system. If all tests are up to
specifications and a system fault exists, the module is
defective.
28
STT & SSZ TECHNICAL REFERENCE MANUAL
1.) Ignition switch is in the "on" position. The second is a drive system protection check to
determine if the engine will be stopped if the speed
2.) Seat switch is depressed. control levers are moved to the drive position while the
brake is applied.
3.) Steering control levers are in the outward,
neutral lock position. For the first check, place the test light clip to the positive
battery terminal. Test the light at the negative battery
4.) PTO switch is in the off position. terminal to verify proper connection. Place the test light
probe at the white wire in the interlock module
5.) Brake in the engaged position. connector. The ignition switch must be in the on
position, the brake must be in the engaged position, the
When the controls are moved from any of these positions, speed control levers in the neutral lock position, and the
the ground through the module will be a closed circuit, and PTO switch off.
the test light will be on.
INTERLOCK MODULE
LH CTRL ARM RH CTRL ARM
RED ORG
+12V ARMS-OUT
SEAT
GRN BRN
STARTER SEAT -ON
BRAKE
WHT PINK
MAGNETO KILL BRAKE-ON
PTO
BLK LT BLUE
GROUND PTO-OFF
RUN
CRANK
KEYSWITCH
SWITCH POSITIONS
+ BATTERY
LH CTRL ARM
RH CTRL ARM
CLOSED WHEN ARMS ARE OUT
The light in the engine ignition wire will be off with the 2.) Seat switch is either engaged or disengaged.
seat switch up or down. Allow the seat switch to remain
in the up position. Moving any one of the controls to its 3.) Steering control levers are in the outward
opposite position while the seat switch is up will cause the neutral lock position.
light at the white ignition wire to go on.
4.) PTO switch is in the disengaged position.
For the second test, press the seat switch down with the
brake on, and the speed control levers in the neutral lock 5.) Brake in the engaged position.
position. The test light should be off. Move either speed
control lever out of neutral lock. The light should go on. When the controls are moved from any of these positions,
Leave the speed control lever moved inward, and move the 12 volt supply will be interrupted, causing the engine
the brake to the off position. The light will turn off. to die. Proper operation of a Kawasaki powered STT
machine provides that the engine will stop anytime the
Moving any one switch to its opposite position will cause operator leaves the seat without stopping the PTO,
the light to go out. Be sure to test each switch for a engaging the parking brake, and placing the steering
complete test of the interlock circuit. control levers in the neutral lock position.
3.3 KAWASAKI INTERLOCK MODULE Two basic ignition interlock tests are performed while the
(38:27) test light is connected to the white wire at the interlock
module connector.
When testing the interlock module on a Kawasaki
powered unit, begin by checking for 12 volts through the The first is a safety check to determine if the engine
white wire in the module. Attach the test light clip to a ignition will be stopped when the operator leaves the seat
good ground. Place the test light probe on the white wire anytime the parking brake is disengaged, the PTO is on or
at the module connection. The test light will light, the speed control levers are moved from the neutral lock
indicating 12 volts through the module, only when all of position.
the following parameters are met:
The second is a drive system protection check to
1.) Ignition switch is in the "on" position. determine if the engine will be stopped if the speed
INTERLOCK MODULE
LH CTRL ARM RH CTRL ARM
RED ORG
+12V ARMS-OUT
SEAT
GRN BRN
STARTER SEAT -ON
BRAKE
WHT PINK
IGNITION KILL BRAKE-ON
PTO
BLK LT BLUE
GROUND PTO-OFF
RUN
CRANK
KEYSWITCH
SWITCH POSITIONS
+ BATTERY
LH CTRL ARM
RH CTRL ARM
CLOSED WHEN ARMS ARE OUT
control levers are moved to the drive position while the green wire to test the engine cranking circuit. The test
brake is applied. light should illuminate, indicating a ground is present.
Next, with the ignition key in the start position, place the
For the first check, the ignition key must be in the on test light probe at the green wire on the back of the
position, the brake must be in the engaged position, the ignition switch. The test light should illuminate.
speed control levers in the neutral lock position, and the
PTO switch off. Follow the green wire from ignition switch to the starter
relay. Place the test light probe at the green wire (A)
The test light in the white, ignition wire will illuminate with going into the starter relay. See diagram below. The
the seat switch up or down. test light should illuminate with the ignition key in the start
position. Test the green wire (B) on the opposite side of
Allow the seat switch to remain in the up position. the relay with the test light to confirm that the circuit is
Moving any of the controls to its opposite position while completed through the relay. The test light may illuminate
the seat switch is up will cause the test light to turn off. dimly on the green-white wire leaving the relay. This is
normal. It is being caused by resistance in the coil inside
Note: The Kawasaki engine allows for a slight delay of the relay.
before cutting off ignition to prevent backfiring if the
operator bounces in the seat on rough terrain. The starter relay has a constant twelve volt supply of
electricity from the battery and is dependant upon the
For the second test, press the seat switch down with the relay to complete the engine cranking circuit. If all the
brake on, and the speed control levers in the neutral lock circuits test correctly, move the test light clip to a ground
position. The light should illuminate. Move either speed to begin checking for voltage in the circuit. Using the test
control lever out of neutral lock. The light should go out. light probe, test both of the fuses. Test for twelve volts at
Leave the speed control lever inward, and move the the red-yellow wire (C) going into the starter relay.
brake to the off position. The test light should illuminate. Twelve volts should pass through the relay from the red-
yellow wire into the green-white wire (D) energizing the
Moving any one switch to its opposite position will cause starter solenoid if the conditions listed at the begining of
the light to go out. Be sure to test each switch for a Section 3.4 are met.
complete test of the interlock circuit.
Moving any of the switches to their opposite position will
3.4 ENGINE CRANKING CIRCUIT (42:45) cause the light to go out. Be sure to test each switch for
a complete test of the cranking circuit.
In order for the engine to crank and to test the engine
cranking circuit, all of the following parameters must be Reference the flowcharts on pages 35, 36 and 37 for
met: assistance in troubleshooting the engine cranking system.
Place the test light clip on a ground. Place the test light
probe on the light blue wire at the interlock module
connector. The test light should illuminate with the switch
in the off position. Reference the flowchart on page 39
to assist you in troubleshooting the PTO circuit.
Once the engine has been started, the engine will stay
running when the operator leaves the seat only if the
PTO is disengaged, the parking brake is engaged, and the
speed control levers are in the outward, neutral lock
position.
32
WHITE
GREEN GREEN
RED
YELLOW FUSE
YELLOW
BLACK
HOURMETER
RED
BATTERY
WHITE
BLUE
WHITE
LIGHT BLUE
GREEN
YELLOW
RED-YELLOW
RED
STT & SSZ TECHNICAL REFERENCE MANUAL
BLACK
BLACK
RED
RED
PINK PINK
BLACK
BLACK
33
PINK
INTERLOCK MODULE
ORANGE
RED-YELLOW
ALTERNATOR
BROWN
IGNITION BRAKE
GREEN/WHITE
(WHITE) SWITCH
RED
RED
BLACK
RED
BLACK
SEAT SWITCH
3.7 STT WIRING DIAGRAM - KOHLER ENGINE
BLUE
BLUE BLUE
WHITE
GREEN GREEN
RED
AMMETER
FUSE RED/YELLOW PTO
RED
GREEN
SWITCH
RED
FUSE
RED
YELLOW
RED
RED
BLACK
WHITE
BLACK
RED
BATTERY
WATER WHITE
TEMP
HOURMETER RED
LIGHT BLUE
YELLOW
BLACK
RED
B/W
PINK PINK
RED / YELLOW
RED
BLUE
RED
GREEN
PINK
34
GREEN
ENGINE
CONNECTOR RELAY
RED / YELLOW
BLACK WHITE
WHITE
BROWN
ORANGE
BLACK
SWITCH
SWITCH
RED RED RED
GREEN / WHITE
RED
RED
RED
RED
BLACK
SEAT SWITCH
3.8 STT WIRING DIAGRAM - KAWASAKI ENGINE
RED
BLACK LEFT NEUTRAL LOCK RIGHT NEUTRAL LOCK
SWITCH SWITCH
BLACK FUEL PUMP
BLUE
BLUE
STT & SSZ TECHNICAL REFERENCE MANUAL
STT & SSZ TECHNICAL REFERENCE MANUAL
Replace the
green/white
ignition Starter (D)
switch. Relay
Does the battery
have at least 9.0 volts
NO
with the ignition key in
the start position?
Repair or replace
YES connection or
YES wiring.
Replace
faulty Is there voltage
fuse.
at the Red wires on NO
the Ignition switch?
Perform the following
Test all fuses with the procedures
test light. Are any YES using a test light.
of the fuses blown? Consult the Operator Place the test light
Presence Circuit clip to ground to
Flowchart test for 12 volts.
NO
YES
Replace or repair
Is there voltage Unplug the Green (B) Replace
wiring harness.
present at the Green- wire from the relay. relay.
NO
White (D) wire at the
starter relay?
YES
Is there a ground
present at the Green Is there voltage
NO
(A) wire at the present at the Green
starter relay? YES
wire at the interlock
module?
YES Replace Is there voltage
relay. present at the Green-
NO NO
White wire at the
starter solenoid?
YES
Repair Green-White
Consult the Engine wire between the
Is there voltage Replace the
Manufacturers relay and the starter
present at theGreen interlock module.
NO manual. solenoid.
(B) wire at the
starter relay?
YES
35
STT & SSZ TECHNICAL REFERENCE MANUAL
Does
the battery have at
least 9 volts with the NO
ignition key in the
start position? Perform the following procedures
YES using a test light as noted.
YES
YES
Replace or repair
wiring harness.
Kohler
Engine
Consult the Engine
Manufacturer's Manual
for further testing.
36
STT & SSZ TECHNICAL REFERENCE MANUAL
NO
NO
Replace or repair
wiring harness.
Kawasaki
Engine
Consult the Engine
Manufacturer's Manual
for further testing.
37
STT & SSZ TECHNICAL REFERENCE MANUAL
START
Test Black
Perform the following procedure wire between
using a test light at the Interlock Does the test light Does the test light
Module and
illuminate at the Black illuminate at the
Module connector. Place the test light NO YES Switch for
wire in the Interlock Black wire at the
clip to the positive battery terminal to continuity.
Module connector? Ignition switch?
test for ground. Repair or
YES NO replace.
YES
YES
Does the test light
illuminate at the Pink Test wiring harness for
NO
wire in the Interlock continuity. Repair or Replace the
Module connector. replace harness. Seat
Switch.
YES YES
38
START
Perform the following procedures
using a test light. Place the Ignition Parameters = All basic electrical checks performed
switch in the on position. Is there power PTO switch on
at the LIGHT BLUE Replace the Ignition switch on
NO Airgap adjusted on PTO clutch to .015".
wire at the PTO PTO switch.
switch?
YES
Test the
Replace the Repair or replace the Light Blue wire
fuses. Is there a YES
faulty fuse(s). between the Interlock module and
blown fuse?
the PTO switch as needed.
NO
Is there power
at the Light
Blue wire at the YES NO
interlock module
connector?
3.13
39
Is there power
at
at the BLUE wire YES NO
the PTO switch?
YES
Is there power Is there power YES
at the double RED wire at at the RED wire going
YES YES
the rear of the into the rear of the Is there a ground
Ignition switch? PTO switch? and voltage at the PTO
clutch?
STT - PTO CIRCUIT
NO NO
NO
Is there power
at both sides of the Is there a good ground
Blue wire at YES at the Black wire on YES
Replace the the PTO clutch both sides of the PTO
Ignition switch. connector? clutch connector?
NO NO
LUBRICATION NO. OF
LOCATION INTERVAL LUBRICANT PLACES
1 Caster Wheel Pivot 500 Hours/Yearly Chassis Grease 2
2 Caster Wheel Bearings 100 Hours/Bi-Weekly Chassis Grease 2
3 Brake Actuator 200 Hours/Monthly Chassis Grease 2
4 Cutter Deck Bellcranks 100 Hours/Bi-Weekly Chassis Grease 4
5 Cutter Deck Pusharms 100 Hours/Bi-Weekly Chassis Grease 2
6 PTO Spindle 40 Hours/Weekly +Lithium MP White Grease 2125 1
7 Cutter Deck Spindle 40 Hours/Weekly +Lithium MP White Grease 2125 3
8 Brake Handle 200 Hours/Monthly Chassis Grease 1
9 Cutter Deck Drive Shaft 100 Hours/Bi-Weekly Chassis Grease 3
CHASSIS GREASE
( 100 HOURS / BI-MONTHLY )
CHASSIS GREASE
( 200 HOURS / MONTHLY )
CHASSIS GREASE
( 500 HOURS / YEARLY )
4
6 3 5 7 2
2 4 5 9 3 9
390S0145
41
STT & SSZ TECHNICAL REFERENCE MANUAL
APPENDIX
5.1 GENERAL TORQUE SPECIFICATION CHART
Grade Number 5 8
Standard
COARSE THREAD Number
Threads / TORQUE TORQUE
Bolt Size Inch Foot Pounds Newton-Meters Foot Pounds Newton-Meters
Inches Average Average Average Average
1/4 20 10 13.5 14 18.3
5/16 18 19 25.5 27 35.9
3/8 16 39 52.3 50 67.1
7/16 14 59 80.0 77 104.4
1/2 13 88 119.4 121 164.1
9/16 12 121 164.1 176 238.7
5/8 11 165 223.8 242 328.2
3/4 10 297 402.7 418 566.8
Grade Number 5 8
Standard
FINE THREAD Number
Threads / TORQUE TORQUE
Bolt Size Inch Foot Pounds Newton-Meters Foot Pounds Newton-Meters
Inches Average Average Average Average
1/4 28 11 14.7 15 20.5
5/16 24 21 27.8 29 39.1
3/8 24 43 57.0 55 73.1
7/16 20 54 87.2 84 113.8
1/2 20 96 130.1 132 178.9
9/16 18 132 178.9 192 260.2
5/8 18 180 243.9 264 357.7
3/4 16 324 438.9 456 617.8
Metric # 8-32
Thread TORQUE TORQUE TORQUE 42 - Inch Lbs.
Bolt Size Pitch Mm Ft. Lb. Nm Ft. Lb. Nm Ft. Lb. Nm 4.7 - Nm
Mm Average Average Average SAE GRADE 8
M6 1.0 7 10 10 14 13 17 CAPSCREW
M8 1.25 18 25 26 35 30 41
M10 1.25 36 49 51 69 61 83 # 10-32
M10 1.50 40 54 55 85 86 115 60 - Inch Lbs.
M12 1.75 63 86 88 120 107 145 6.8 - Nm
NOTE: Scag Power Equipment uses grade 5 bolts unless otherwise specified.
These values apply to fasteners when installed dry.
They do not apply if oil, special graphite, moly-disulphide greases, or other extreme pressure lubricants are used.
Bolt head identification marks as per grade. Actual manufacturing marks may vary.
Service Information Sheet # 44 General Torque Specification Chart 42
MEMBER
c
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Training Council CERTIFICATION
The contents of this video-based training program are the property of Scag Power Equipment and may not
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© 1998
Scag Power Equipment
Division of Metalcraft of Mayville, Inc. Part No. 02001-07