TECHNICAL REFERENCE MANUAL

ZERO - TURN RIDERS
SSZ STT

SERVICING SCAG PRODUCTS FROM A TO Z SERVICING SCAG PRODUCTS FROM A TO Z

STT & SSZ TECHNICAL REFERENCE MANUAL

SSZ - TABLE OF CONTENTS
SUBJECT Section 1 - Machine Setup and Activation 1.1 Introduction & Directional Reference 1.2 Removing the Crating 1.3 Battery Preparation 1.4 Install Drive Wheels 1.5 Install Seat Assembly 1.6 Install Steering Control Levers 1.7 Remove Machine from Shipping Pallett 1.8 Installing the Cutter Deck 1.9 Check Tire Pressure 1.10 SSZ-48 Cutter Deck Mounting/Leveling 1.11 SSZ-52 & SSZ-61 Cutter Deck Mounting/Leveling 1.12 Cutter Deck Pitch 1.13 Install Cutter Deck Drive Belt 1.14 Install Discharge Chute 1.15 Install Battery 1.16 Verify Fluid Levels Section 2 - Adjustments 2.1 Neutral Adjustment 2.2 Brake Adjustment 2.3 Tracking Adjustment 2.4 Replace Hydraulic Pump Belt Section 3 - Electrical System 3.1 Electrical Testing 3.2 Engine Cranking Circuit 3.3 PTO Circuit 3.4 Operator Presence Circuit 3.5 Wiring Diagram - Kohler Engine 3.6 Troubleshooting - Engine Cranking Circuit 3.7 Troubleshooting - PTO Circuit 3.8 Troubleshooting - Operator Presence Circuit Section 4 - Lubrication & Maintenance 4.1 Grease Fitting Lubrication Chart Index 4.2 Lubrication Chart TIME (00:01) (00:46) (01:16) (01:49) (02:35) (02:59) (03:12) (03:27) (04:22) (04:39) (05:31) (06:59) (07:43) (08:25) (09:00) (09:41) PAGE 1 1 1 2 2 2 2 3 3 3-4 4-5 5 5 6 6 6-7

(10:26) (12:22) (13:08) (14:04)

7 8 8 9

(15:16) (15:16) (18:06)

10 10 10-11 11 12 13 14 15

16 17

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STT & SSZ TECHNICAL REFERENCE MANUAL

STT - TABLE OF CONTENTS
SUBJECT Section 1 - Machine Setup and Activation 1.1 Introduction & Directional Reference 1.2 Removing the Crating 1.3 Battery Preparation 1.4 Install Drive Wheels 1.5 Install Steering Control Levers 1.6 Install Seat Assembly 1.7 Check Tire Pressure 1.8 Install Battery 1.9 Verify Proper Fluid Levels 1.10 Dump Valve Location Section 2 - Adjustments 2.1 Neutral Adjustment 2.2 Tracking Adjustment 2.3 Parking Brake Adjustment 2.4 Cutter Deck Adjustment 2.5 Cutter Deck Pitch Adjustment 2.6 Cutter Deck Height Adjustment 2.7 Drive Belts Section 3 - Electrical System 3.1 Electrical Testing 3.2 Interlock Module - Kohler Engine 3.3 Interlock Module - Kawasaki Engine 3.4 Engine Cranking Circuit 3.5 PTO Circuit 3.6 Operator Presence Circuit 3.7 Wiring Diagram - Kohler Engine 3.8 Wiring Diagram - Kawasaki Engine 3.9 Troubleshooting - Engine Cranking Circuit-no crank 3.10 Troubleshooting - Engine Cranking Circuit-KH crank 3.11 Troubleshooting - Engine Cranking Circuit-KA crank 3.12 Troubleshooting - Operator Presence Circuit 3.13 Troubleshooting - PTO Circuit Section 4 - Lubrication & Maintenance 4.1 Grease Fitting Lubrication Chart Index 4.2 Cutter Deck Drive Gearbox 4.3 Lubrication Chart Appendix 5.1 General Torque Specification Chart II TIME (21:42) (22:16) (22:52) (23:24) (24:11) (24:46) (25:12) (25:26) (26:01) (27:54) (28:41) (30:08) (31:07) (32:21) (33:10) (34:18) (34:43) (39:33) (38:27) (42:45) PAGE 18 18 18 19 19 19 20 20 20-21 21 22 23 24 25 26 26-27 27 28 29-30 30-31 31 32 32 33 34 35 36 37 38 39

40 40 41

42

STT & SSZ TECHNICAL REFERENCE MANUAL

SECTION 1 - SSZ MACHINE SETUP AND ACTIVATION
1.1 INTRODUCTION (00:01)

The following instructions are provided to aid you in assembling the Scag Super Zero-Turn, SSZ mower. Carefully follow each procedure for maximum assembly efficiency. -NOTEFollow all shop safety procedures while assembling the mower. -NOTEThe "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)

Begin setup by removing the crating and packing materials from around the tractor. Remove any nails or staples from the pallet that could cause injury during assembly procedures, or damage a tire when removing the machine from the pallet. Lay out and identify the loose hardware referring to page 5 of the SSZ Assembly Instructions Manual.

WARNING:
Severe chemical burns can result from improper handling of battery electrolyte. When handling batteries, wear protective clothing and safety glasses. Always have a fresh source of water available at all times. IN CASE OF EXTERNAL CONTACT AND/OR EYE CONTACT: Flush with water for at least 15 minutes and get immediate medical attention. IN CASE OF INTERNAL CONTACT: Drink large quantities of water, followed by Milk of Magnesia, beaten egg, or vegetable oil. CALL A PHYSICIAN IMMEDIATELY! DO NOT give fluids that induce vomiting.

1.3

BATTERY PREPARATION (01:16)

Loosen the two plastic wing nuts, and remove the battery cover. See Figure 1-1. Disconnect the black negative cable, then the red positive cable. Disconnect the battery breather tube, and lift the battery from the battery box. Place the battery on a clean flat surface, and fill the battery cells to the proper level with electrolyte solution. Charge the battery at 3 to 5 amps for about two hours. Follow the instructions included with the battery charger. For more information on battery charging and maintenance, reference the Assembly Instructions Manual or Scag Fundamentals, Battery Section .

WARNING:
Lead-acid batteries produce flammable and explosive gases. To avoid personal injury when checking, testing, or charging batteries, DO NOT use smoking materials near batteries, keep arcs and flames away from batteries, provide proper ventilation and wear safety glasses.

1

STT & SSZ TECHNICAL REFERENCE MANUAL

1.4

INSTALL DRIVE WHEELS (01:49)

To install the rear drive wheels, begin by applying the parking brake. Remove the lug nuts from the axle hub studs. Carefully raise the rear of the machine high enough to allow the wheels to be placed on the axle hub. Remove the lug nuts from the axle studs. Turn the wheel so the valve stem is facing outward, and slide the wheel onto the studs. 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. Using the torque sequence shown in Figure 1-2, torque the lug nuts to 65 foot pounds. Carefully lower the machine back onto the shipping pallet.
FREE WHEEL POSITION

1

3

4

2
Torque Sequence

Figure 1-2

Torque Sequence

RUN POSITION

DUMP VALVE LEVER

1.5

INSTALL SEAT ASSEMBLY (02:35)

To mount the seat on an SSZ 48, attach the seat to the base using four 5/16-18 X 3/4" serrated flange capscrews. 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

1.6

INSTALL STEERING CONTROL LEVERS (02:59)

Figure 1-3

Dump Valve Lever

Mount the right and left speed control levers to the outside of the control lever bars. Secure the handles using four 3/8 -16 x 1" serrated flange capscrews.

1.7

REMOVE MACHINE FROM SHIPPING PALLET (03:12)

Open the hydraulic dump valves, allowing the machine to roll freely. See Figure 1-3. Disengage the parking brake. Carefully roll the unit forward off of the crate.

2

STT & SSZ TECHNICAL REFERENCE MANUAL

1.8

INSTALLING THE CUTTER DECK (03:27)

Remove the crate and packaging from the cutter deck. With assistance, slide the cutter deck off the crate bottom. The length of both push arms should be approximately 15-1/8" from the center of the bushing to the center of the ball joint. See Figure 1-4. Position the cutter deck underneath the mower deck mounting frame. Remove both rear anti-scalp rollers to allow the push arm shafts to slide from their cutter deck mounting brackets. Position the cutter deck to align the holes in the deck mounting bracket with the holes in the push arms. Attach the cutter deck to the push arms by sliding the shaft through the holes in the deck mounting brackets and the push arms. See Figure 1-5.

15-1/8"

0708962

Figure 1-4

Push Arm Length

1.9

CHECK TIRE PRESSURE (04:22)

Check the tires for proper air pressure. Front caster wheel - 25 PSI Rear drive wheel - 15 PSI Adjust if necessary.

0708963

Figure 1-5

Install Push Arm Shafts

1.10 SSZ-48 CUTTER DECK MOUNTING / LEVELING

(04:39)

The SSZ-48 uses metal support links to mount the deck to the frame. Be sure that the elongated holes in the links face upward when installed. See Figure 1-6. Insert one 3/8-16 X 1-1/2" hex head bolt through the bottom hole of each of the four deck support links. Thread a 3/8-16 serrated flange nut backward onto each of the bolts until it bottoms out. See Figure 1-6. Insert the bolts through the mounting holes on the cutter deck and secure using 3/8-16 serrated flange nuts. At this time, leave the nut on the left rear corner of the cutter deck.

48" DECK
0708964

Figure 1-6 3

Cutter Deck Support Links

STT & SSZ TECHNICAL REFERENCE MANUAL

Tighten the spring compression nut on the cutter deck adjustment rods until they bottom out on the threads. See Figure 1-7.
Spring Compression Nut Jam Nut

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. At the discharge side of the cutter deck, measure the distance from the rear bottom edge of the cutter deck to the ground. On the opposite side of the cutter deck, measure the distance from the rear bottom edge of the cutter deck to the ground. If required, move this side of the deck to match the measurement at the opposite side of the deck. Secure in place by tightening the left rear deck supporting chain mounting bolt. Check both sides again to be sure that they are equal.

0709963

Figure 1-7

Deck Adjustment Rod

1.11 SSZ-52 & SSZ-61 CUTTER DECK MOUNTING / LEVELING (05:31)
The SSZ-52 and 61 use chains to mount the deck to the frame. See Figure 1-8. Insert one 3/8-16 X 1-1/2" hex head bolt through the bottom link of each of the four deck support chains. Thread a 3/8-16 serrated flange nut backward onto each of the bolts until it bottoms out. Insert the bolts through the mounting holes on the cutter deck and secure using 3/8-16 serrated flange nuts. At this time, leave the nut on the left rear corner loose for leveling adjustment. Tighten the spring compression nut on the cutter deck adjustment rods until they bottom out on the threads. See Figure 1-7. 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. At the discharge side of the cutter deck, measure the distance from the rear bottom edge of the cutter deck to the ground.

SSZ-48
Figure 1-8

SSZ-52 And SSZ-61
Cutter Deck Mounting

4

STT & SSZ TECHNICAL REFERENCE MANUAL

On the opposite side of the cutter deck, measure the distance from the rear bottom edge of the cutter deck to the ground. If required, move this side of the deck to match the measurement at the opposite side of the deck. Secure in place by tightening the left rear deck supporting chain mounting bolt. Check both sides again to be sure that they are equal.

BELT NUT "J" BOLT

1.12

CUTTER DECK PITCH (06:59)
WASHER END OF L- SHAPED BRACKET
SC204G

Measure the distance from the center rear bottom edge of the cutter deck to the ground. Measure the distance from the center front bottom edge of the cutter deck to the ground. The front edge of the cutter deck should be 1/4" lower than the rear. This is called the “pitch” of the cutter deck. To adjust the pitch of the deck, loosen the jam nuts on the deck adjustment rods. See Figure 1-7, page 4. Turn the spring compression nut until the proper pitch is obtained. Repeat this procedure on the other side of the deck. Retighten the jam nuts when the adjustment is correct. Recheck the distance from the front of the deck to the ground to confirm proper adjustment.

Figure 1-9 Belt Adjustment

NUT "J" BOLT

WASHER BELT

1.13

INSTALL CUTTER DECK DRIVE BELT (07:43)

SC205G

Route the blade drive belt around the electric clutch pulley. Make sure the belt is properly seated in all of the cutter deck pulleys. Check the deck drive belt tension. The spring flat washer should be flush with the end of the L-shaped bracket. Adjust tension by turning the lock nut if required. See Figure 1-9. Check the tension of the right hand blade drive belt using a belt tension gauge. Adjust the belt so that it deflects 1/2" with 10 pounds of pressure. The tension on the right hand cutter deck belt can be adjusted by tightening or loosening the locknut on the J-bolt. See Figure 1-10 or Figure 1-11. Reference Scag Fundamentals Belt Section for details on troubleshooting belts. 5

Figure 1-10 52" Cutter Deck RH Belt Adjustment

BELT WASHER NUT "J" BOLT
SC206G

Figure 1-11 48" & 61" Cutter Deck RH Belt Adjustment

STT & SSZ TECHNICAL REFERENCE MANUAL

1.14

INSTALL DISCHARGE CHUTE (08:25)

To mount the discharge chute, use two 5/16 -18 X 1" bolts and elastic stop nuts. Install the rearward bolt, then lift the lower spring leg with a box wrench. Lower the spring over the chute support bracket, and release the spring. Install the front bolt and nut. See Figure 1-12. Tighten the bolts only enough to remove excessive endplay in the chute. When properly installed, the spring should cause the discharge chute to drop down to the operating position.

Figure 1-12 Install Discharge Chute

1.15

INSTALL BATTERY (09:00)

Connect the battery breather tube to the receptacle on the battery cap and place the charged battery in the battery box. Connect the red positive cable to the positive terminal on the battery, tighten the bolt and slide the boot over the terminal. Connect the black negative cable to the negative terminal and tighten the bolt. Coat each terminal with a nonconductive grease, such as NAPA # 765-1302 or # 765-1303, to prevent corrosion. Install the battery cover and tighten the two wing nuts. See Figure 1-13.

1.16

VERIFY FLUID LEVELS (09:41)
Figure 1-13 Battery Installation

New machines are shipped without engine oil. Check the oil level and fill to the proper level as outlined in the engine manual furnished with each machine. Do not overfill the engine with oil. Engine damage could result. Fill the hydraulic tank with SAE 20W50 motor oil to about 2 inches below the bottom of the filler neck. Approximately four quarts will be needed. Do not overfill the hydraulic tank. Add fuel to the fuel tank. Always use a good quality fuel

WARNING:
Do not overfill the engine with oil. Severe engine damage could result.

WARNING:
Do not overfill the hydraulic tank. Fill to approximately 2 inches below the top of the filler neck.

6

STT & SSZ TECHNICAL REFERENCE MANUAL

with a minimum octane rating of 87. Observe all safety rules for fuel handling. Clean up any spills, and properly dispose of fuel soaked rags. Do not overfill the tank. Leave at least one inch of space to allow room for fuel expansion. Check all hardware and hydraulic fittings for the proper tightness. Refer to the Torque Specification Chart on page 42 when specific torques are not given. Apply lubricant to all grease fittings. Reference pages 16 and 17 for the SSZ Lubrication Chart.

WARNING:
Never smoke while handling fuel, do not handle fuel near sparks or open flames, and never refuel a hot engine. Do not overfill the tank.
DUMP VALVE LEVER

FREE WHEEL POSITION

RUN POSITION

SECTION 2 - ADJUSTMENTS (10:26)
2.1 NEUTRAL ADJUSTMENT (10:26)

Block the front tires to prevent the machine from moving. Safely raise the rear of the machine and place jack stands under the machine. Remove the rear drive wheels. Move the dump valve lever to the run position. See Figure 2-1. 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. The drive wheels are adjusted separately using the turnbuckles located under the seat. Loosen the jam nut on the turnbuckle. See Figure 2-2.
JAM NUT
SC200G

Figure 2-1 Dump Valve Lever

If a drive wheel is rotating forward, rotate the turnbuckle clockwise. If a drive wheel is rotating rearward, adjust the turnbuckle counterclockwise. Adjust the turnbuckle until the drive wheel stops turning. See Figure 2-2. Tighten the jam nut to secure the neutral position. Adjust the other drive wheel if necessary. Actuate the speed control levers forward and reverse. Allow the levers to self-center and check that the drive wheels remain in neutral. The neutral return mechanisms on the fenders are adjusted at the factory. Readjustment should not be necessary. Figure 2-2

Adjust TURNBUCKLE clockwise or counterclockwise until drive wheels stop rotating
SC201G

Neutral Adjustment

CAUTION:
Stop engine and remove key from the ignition before making any adjustments. Wait for all moving parts to come to a complete stop before beginning work.
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STT & SSZ TECHNICAL REFERENCE MANUAL

2.2

BRAKE ADJUSTMENT (12:22)

SWIVEL LESS TENSION

If a brake adjustment becomes necessary, carefully raise the rear of the machine and place on jack stands. Block the front tires to prevent the machine from moving. Remove the rear drive tires.
BRAKE ROD

Place the brake lever in the disengaged position. 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. Carefully remove the machine from the jack stands.

MORE TENSION

Figure 2-3 Brake Rod Adjustment

2.3

TRACKING ADJUSTMENT (13:08)

Locate the turnbuckle for the left-hand pump under the operator seat in front of the hydraulic tank. Loosen the nut securing the turnbuckle to the bellcrank. Adjust the position of the turnbuckle by moving it in the mounting slot. Move it forward to slow the left wheel or move it backward to speed up the left wheel. See Figure 2-4.
FASTER

If difficulty is experienced when making hydrostatic drive adjustments, or if hydrostatic operation is erratic, review the Hydraulic Section of Scag Fundamentals.

NUT SLOWER

CAUTION:
Stop engine and remove key from the ignition before making any adjustments. Wait for all moving parts to come to a complete stop before beginning work. Components can get hot during operation. Allow all components to cool before making any adjustments.

BELLCRANK TURNBUCKLE
SC203G

Figure 2-4

Tracking Adjustment

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STT & SSZ TECHNICAL REFERENCE MANUAL

2.4

REPLACE HYDRAULIC PUMP BELT (14:04)

BELT COVER

To replace the hydro pump drive belt, first remove the two 1/4" nuts from the belt guard and remove the belt guard. See Figure 2-5. 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. Remove the belt from around the hydraulic pump pulleys and from the engine drive pulley. Mount the new belt around the engine pulley and the two 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 pulley. Slowly move the idler arm up until the belt is fully engaged in the idler pulley. Remove the breaker bar and check to be sure that the belt is routed and seated properly in all of the pulleys. Reinstall the belt guard. See Figure 2-5.

HYDRAULIC SUPPORT

Figure 2-5

Hydraulic Belt Cover

IDLER PULLEY

ENGINE PULLEY

PUMP PULLEYS

Figure 2-6 Hydraulic Drive Belt Configuration

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STT & SSZ TECHNICAL REFERENCE MANUAL

SECTION 3 - ELECTRICAL SYSTEM (15:16)
3.1 ELECTRICAL TESTING

For the starter to crank on the SSZ, the following parameters must be met: 1.) Speed control handles must in the outward, neutral lock position. 2.) PTO switch must be in the "off" position. 3.) Ignition switch in the start position. Perform basic tests of the engine cranking circuit by connecting the test light between the battery negative terminal and the green wire in the harness end of the engine connector. Turn the ignition key to the start position. The test light should illuminate when the speed control levers are out, and the PTO is off. The test light will go out when either speed control lever is moved out of the neutral lock position, or the PTO is turned on while holding the key to the start, engine crank, position. If the test light does not come on, individually test the neutral lock switches and the PTO switch. Reference the Engine Cranking Circuit Flowchart on page 13 for additional testing.

The electrical system on the SSZ incorporates an engine cranking circuit, operator presence interlock circuit, and a PTO circuit. Follow the wiring diagram completely through all affected circuits during electrical testing.

3.2

ENGINE CRANKING CIRCUIT (15:16)

The engine cranking circuit is a switched 12-volt supply circuit that supplies power from the battery to energize the starter solenoid, and crank the engine. The circuit starts with voltage supplied to the ignition switch. In the ‘on’ position, 12 volts is available at the accessory terminal on the ignition switch. From the ignition switch, 12-volt power is supplied to the PTO switch. With the PTO off, the circuit connects through the PTO switch to the PTO start interlock relay. The windings of the relay are grounded at all times, so the relay closes when the PTO is in the ‘off’ position. When turning the ignition switch to the start position, 12 volts is sent to the starter relay. The circuit passes through the relay contact points to the right neutral lock switch. With the right speed control handle in the outward, neutral lock position, the switch is closed, and the circuit continues through the left neutral start switch. With the left speed control handle in neutral lock, 12 volts is transfered to the start relay. The windings of the start relay are grounded at all times. The relay contacts close, and 12 volts is supplied to the starter solenoid to engage the starter and crank the engine. If the PTO is engaged, the PTO start solenoid opens, and interrupts the crank circuit, preventing the engine from cranking. When a speed control lever is moved out of the neutral lock position, the circuit opens, and does not allow the engine to crank. The circuit is wired this way to ensure safe starting conditions. Make sure the controls are properly positioned and all switches are properly adjusted to fully activate the switch before performing in-depth electrical testing.

3.3

PTO CIRCUIT

The PTO circuit on the SSZ machine requires that the following parameters are met in order for the PTO clutch to engage: 1.) Ignition switch is in the "on" position. 2.) Seat switch is depressed. 3.) PTO switch in the "on" position. The operator presence system must be working properly in order for the PTO clutch to engage. When both systems are working properly, the engine will stop anytime the operator leaves the seat with the PTO engaged. Perform the basic tests of the PTO circuit by using a test light. Place the test light clip on a ground and check the test light connection by placing the probe onto the positive terminal of the battery. With the previously listed parameters met, begin by 10

STT & SSZ TECHNICAL REFERENCE MANUAL

testing for power and ground at the clutch. Next, move to the PTO clutch connector and test for voltage and ground. Next, test the PTO switch for proper operation. Finally, test the ignition switch to identify any possibly faults. Replace any switch found to be faulty. If power or ground is lost between two points, test for continuity in the wiring harness to locate the broken connection or wire. Reference the PTO Circuit Flowchart on page 14 for additional testing.

The second terminal of the seat switch is grounded at all times. If the operator is in the seat, the seat switch is open, and the circuit is broken. In this condition, any positioning of the speed control handles or PTO will not affect engine operation. If the operator moves out of the seat, the seat switch closes, and the entire ignition ground circuit is closed, stopping the engine. Any movement of controls out of neutral, or engaging the PTO switch, will close the ignition ground circuit and kill the engine when the operator is out of the seat. For a basic ground circuit check of the operator presence system, begin by turning the ignition key to the 'off' position. Connect the test light between the battery positive terminal and the black wire at the engine connector. If the light illuminates, a ground exists which will prevent the engine from operating. With the key in the 'off' position, a ground should be present at this point. Turn the ignition key to the 'on' position. The test light should be off. Raise the seat to simulate an operator not being in the seat. Check the system by moving the speed control handles individually from the neutral lock position. The test light should illuminate when either lever is moved inward. Move the speed control handles back to the neutral lock position. Turn the PTO switch on, and the circuit will ground the ignition, causing the test light to illuminate. With the seat switch depressed, the test light should not illuminate when the levers are moved in or the PTO is on. Reference the Operator Presence Circuit Flowchart on page 15 for step by step testing procedures. These steps will help to isolate a particular component such as a switch, wiring harness, or connectors that may have a fault, which is causing an operating problem. If additional tests are required to determine the exact cause of a problem, use the test techniques demonstrated in Scag Fundamentals Electrical Section to test each component individually.

3.4

OPERATOR PRESENCE CIRCUIT (18:06)

The operator presence interlock system is designed to stop the engine if the operator leaves the seat at any time while the machine is moving or the PTO switch is on. The following parameters must be met to test the operator presence system: 1.) Ignition switch is in the "on" position. 2.) Seat switch is depressed. 3.) Steering control levers are in the outward locked position. 4.) PTO switch is in the disengaged position. Once the engine has been started, for the it to continue running, the operator must be seated whenever the speed control handles are moved inward from the neutral lock position or the PTO is moved to the ‘on’ position. When the operator presence system is activated, the circuit grounds the ignition to kill the engine. The ground wire from the ignition is connected to one terminal on each neutral lock switch, and to the PTO switch. The opposite terminal of the switch on each speed control handle, and the PTO switch, is connected in series with one terminal of the seat switch. Activating either neutral lock switch by moving the speed control handle out of neutral, or the PTO switch by engaging the mower blades extends the ignition ground circuit to the seat switch. 11

BLACK RED YELLOW

BLACK

RED RED RED BLACK BLACK BLACK HOURMETER RED RED BLUE BLACK
RE

YELLOW

BLACK

3.5

BATTERY

AMMETER

YELLOW

GREEN

IGNITION SWITCH RED RED RED

YELLOW FUSES

WHITE

RED

BLACK

D

PTO SWITCH

RED

RED

ENGINE HARNESS ADAPTER PLUG GREEN GREEN BLACK RED BLACK BLUE /RED RED GREEN BLACK BLACK GREEN

BLUE

ALTERNATOR

BLACK

WIRING DIAGRAM - KOHLER ENGINE

BLACK RED

GREEN

RED

BLACK LEFT NEUTRAL INTERLOCK

GREEN

BLUE

12
BLACK BLACK BLUE

BLACK RELAY

ENGINE CONNECTOR

IGNITION (WHITE)

GREEN

SEAT SWITCH

GREEN

RED

RIGHT NEUTRAL INTERLOCK

STT & SSZ TECHNICAL REFERENCE MANUAL

RED

RED

Parameters =

Does the battery have at least NO 12.0 volts? YES Is there voltage at the Blue-Red wire at the starter relay? YES NO NO YES YES Is there a ground at the Black wire at the starter relay? NO Turn the Ignition switch to the start position Replace Ignition switch.

Perform Basic Electrical Checklist PTO switch off Ignition switch in start position Seat switch depressed Parking brake engaged Steering control levers in neutral lock position

YES

Charge or replace the battery.

Is there voltage at the Red wire at the starter relay? NO NO YES Repair or replace faulty wire or connection. NO YES Repair or replace faulty wire or connection.

Does the battery have at least 9 volts with the NO key in the start position? Is there voltage at the Green wire at the Ignition switch? YES NO

Is there voltage at the Green wire at the engine connector plug?

Is there voltage at the Red wire at the Ignition switch?

3.6

YES

Replace the faulty fuse. Is there voltage present at the Green NO wire at the starter relay? YES Replace the starter relay. NO Is there voltage at the GreeN wire at the engine harness adaptor plug?

STT & SSZ TECHNICAL REFERENCE MANUAL

Test the fuses with a test light. Are any of the fuses Y E S blown?

NO

Repair or replace faulty wire or connection in the ground circuit. NO

YES Is there a ground at the Black (D) wire at the PTO relay?

ENGINE CRANKING CIRCUIT

13
Replace the Neutral switch. NO YES NO YES YES Does the right neutral interlock switch test properly? YES Does the left neutral interlock switch test properly? Is there voltage at the Green (B) wire at the PTO relay? NO Is there voltage at the single Red YES wire at the PTO switch? NO NO NO NO Replace Ignition switch. Repair or replace faulty wire or connection between ignition switch and PTO switch. Replace PTO switch.

Is there voltage at the Green (A) wire at the PTO relay?

Consult the Engine Manufacturers Manual for further testing.

Repair or replace faulty wire or connection in the green wire between the Ignition switch and the PTO relay.

Turn the Ignition switch to the off position. Replace PTO relay. YES

Is there voltage at the Yellow wire YES at the ignition switch ?

NO

Is there voltage at the Red wire YES at the ignition switch ?

Is there voltage at the White wire YES at the PTO switch?

Is there voltage at the white (C) wire at the PTO relay? white (C) green (A) green (B) NO

Repair or replace faulty wire or connection be tw e en f use block and ignition switch.

Process
Starter Relay

black (D)

Repair or replace faulty wire or connection between PTO switch and PTO relay.

STT & SSZ TECHNICAL REFERENCE MANUAL

3.7
START
Perform the following procedures using a test light.
Parameters =

PTO CIRCUIT

All basic electrical checks performed (ie battery voltage, fuses, etc.) Operator presence system tests properly PTO switch on Ignition switch on Airgap properly adjusted on clutch (0.015)

Do the fuses test correctly?
YES

NO

Replace the faulty fuse.

Is there voltage at the Blue wire at the PTO clutch?
NO

YES

Is there a ground at the Black wire at the PTO clutch?
NO

YES

Replace the PTO Clutch

Repair or replace the faulty wire or connection in the harness. Is there a poor connection at either YES side of the PTO connector?
NO

Repair faulty connection or wiring at PTO connector.

Repair or replace the faulty wire or connection in the Red wire in the harness.

NO

Is there voltage at the Blue wire at the NO PTO switch?
YES

Is there voltage at the NO single Red wire at the PTO switch?
YES

Is there voltage at the Red wire at the Ignition switch?
YES

Test the wiring harness for continuity. Repair or replace the harness.

Replace the PTO switch.

Repair or replace the faulty wire or connection between the PTO switch and the Ignition switch.

14

STT & SSZ TECHNICAL REFERENCE MANUAL

3.8
START
Perform the following procedures using a test light.

OPERATOR PRESENCE CIRCUIT

Parameters =

Perform the Basic Electrical Checklist. PTO switch off Ignition switch on Steering levers in neutral lock position Seat switch depressed

Place the test light clip on the positive battery terminal.

Place the test light probe at the black wire at the engine connector to check for ground.

Test wiring harness for continuity. Repair or replace harness.

YES

Move the PTO switch to the engaged position. YES Does the test light illuminate?
NO

Move the seat switch to the disengaged position. Does the test light illuminate?
NO

YES

Move the left steering control lever to the inward YES position. Does the test light illuminate?
NO

Move the right steering control lever to the inward position. Does the test light illuminate?
NO

Replace the PTO switch.

Replace the seat switch.

Replace the left steering control lever switch

Replace the right steering control lever switch

15

STT & SSZ TECHNICAL REFERENCE MANUAL

4.1

GREASE FITTING LUBRICATION CHART INDEX (Reference Figure 4-2, page 17)
LUBRICATION LOCATION INTERVAL 100 Hours/Bi-Weekly 100 Hours/Bi-Weekly 200 Hours/Monthly 40 Hours/Weekly 100 Hours/Bi-Weekly 100 Hours/Bi-Weekly 100 Hours/Bi-Weekly 100 Hours/ Bi-Weekly 100 Hours/Bi-Weekly 100 Hours/Bi-Weekly LUBRICANT Chassis Grease Chassis Grease Chassis Grease US Lithium MP White Grease 2125 Chassis Grease Chassis Grease Chassis Grease Chassis Grease Chassis Grease Chassis Grease NO. OF PLACES 2 2 1 3 1 2 3 4 1 2

1 2 3 4 5 6 7 8 9 10

Caster Wheel Pivot Caster Wheel Bearings Idler Arm Pivot Cutter Deck Spindles Idler Arm Pivot Push Arm Height Adjustment Bell Crank Idler Arm Pivot Control Levers

+

Compatible Greases:

Mobilix #2 found at Mobil Service Stations Ronex MP found at Exxon Service Stations Super Lube MEP #2 & Super Stay-M #2 found at Conoco Stations Shell Alvania #2 found at Shell Service Stations Lidok EP #2 found at industrial shops

16

STT & SSZ TECHNICAL REFERENCE MANUAL

4-2

SSZ LUBRICATION CHART

GREASE FITTING LUBRICATION
LUBRICANT / INTERVAL LITHIUM MP WHITE GREASE 2125 ( 40 HOURS / WEEKLY ) CHASSIS GREASE ( 100 HOURS / BI-MONTHLY )

10

CHASSIS GREASE ( 200 HOURS / MONTHLY )

7 4 5

1

2

6

8

10

9

3

4

1

2

8

6
390S0180

17

STT & SSZ TECHNICAL REFERENCE MANUAL

SECTION 1 - STT MACHINE SETUP AND ACTIVATION
1.1 INTRODUCTION (21:42)

The following instructions are provided to aid you in assembling the STT, Turf Tiger, mower. Note that all hardware needed to assemble the machine is in place. Carefully follow each procedure for maximum assembly efficiency. -NOTEFollow all shop safety procedures while assembling the mower. -NOTEThe "Right" and "Left", "Front" and "Rear" of the machine are referenced from the operators perspective when seated in the normal operating position and facing forward. Figure 1-1 Battery Removal

1.2

REMOVING THE CRATING (22:16)

WARNING:
Severe chemical burns can result from improper handling of battery electrolyte. When handling batteries, wear protective clothing and safety glasses. Always have a fresh source of water available at all times. IN CASE OF EXTERNAL CONTACT AND/OR EYE CONTACT: Flush with water for at least 15 minutes and get immediate medical attention. IN CASE OF INTERNAL CONTACT: Drink large quantities of water, followed by Milk of Magnesia, beaten egg, or vegetable oil. CALL A PHYSICIAN IMMEDIATELY! DO NOT give fluids that induce vomiting.

Begin the setup by cutting the ties holding the seat to the top of the crate. Continue by removing the crating and packing materials from around the tractor. Remove any nails or staples from the pallet, that could cause injury during assembly procedures, or damage a tire when removing the machine from the pallet. Set the tires and seat aside. Remove the fuel tank cap from the seat support and install it in the fuel tank. Place the operator’s manual aside where it will not be misplaced.

1.3

BATTERY PREPARATION (22:52)

Loosen the two plastic wing nuts, and remove the battery cover. See Figure 1-1. Disconnect the black negative cable, then the red positive cable. Disconnect the battery breather tube, and lift the battery from the battery box. Place the battery on a clean flat surface and fill the battery cells to the proper level with electrolyte solution. Charge the battery at 3 to 5 amps for about two hours. Follow the instructions included with the battery charger. For more information on battery charging and maintenance, reference Scag Fundamentals Battery Section.

WARNING:
Lead-acid batteries produce flammable and explosive gases. To avoid personal injury when checking, testing, or charging batteries, DO NOT use smoking materials near batteries, keep arcs and flames away from batteries, provide proper ventilation, and wear gloves and safety glasses at all times.

18

STT & SSZ TECHNICAL REFERENCE MANUAL

1.4

INSTALL DRIVE WHEELS (23:24)
1

To install the drive wheels, start by applying the parking brake. Block the front tires to prevent the machine from rolling. Carefully raise the rear of the machine high enough to allow the wheels to be placed onto the axle hub. Remove the lug nuts from the axle hub studs. Turn the wheel so the valve stem is facing outward, and slide the wheel onto the studs. With the tapered side of the nut toward the wheel, thread the lug nuts onto the studs until they are snug against the rim.

3

4

2
Torque Sequence

Figure 1-2 Using the torque sequence shown in Figure 1-2, torque the lug nuts to 65 foot pounds. Carefully lower the machine back onto the shipping pallet.

Torque Sequence

STEERING LEVER

1.5

INSTALL STEERING CONTROL LEVERS (24:11)

Remove the top serrated flange bolt from each control lever bar. Lift the speed control lever up from the shipping position until the top holes in the speed control lever and control lever bar align. Reinstall and tighten the bolts. See Figure 1-3. - 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 levers should be pointing towards each other and adjusted for operator comfort.

CONTROL BAR

Figure 1-3

Install Control Levers

1.6

INSTALL SEAT ASSEMBLY (24:46)

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. Install and securely tighten the two elastic stop nuts. Do not over tighten the bolts. Be sure that the seat moves up and down without binding. Connect the seat cable to the base of the seat. Be sure that the seat cable bolt does not contact the seat hinge. 19

SEAT Seat Cable StopCABLE

Seat Hinge SEAT HINGE

Figure 1-4

Install Seat Assembly

STT & SSZ TECHNICAL REFERENCE MANUAL

1.7

CHECK TIRE PRESSURE (25:12)
FILL TO BOTTOM OF NECK

Check the tires for proper air pressure. Front caster wheel - 25 PSI Rear drive wheel - 15 PSI Adjust as necessary.

1.8

INSTALL BATTERY (25:26)

Place the charged battery in the battery box, and connect the battery breather tube to the nipple on the battery cap.

WARNING:
Severe chemical burns can result from battery 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.
Connect the red positive cable to the positive terminal on the battery and tighten the bolt. Connect the black negative cable to the negative battery terminal and tighten the bolt. Coat each terminal with a non-conductive grease, such as NAPA # 765-1302 or # 765-1303, to prevent corrosion. Slide the protective boot over the positive terminal. Install the battery cover and tighten the two wing nuts. Figure 1-5

030467-13

Radiator Fill Level

1.9

VERIFY FLUID LEVELS (26:01)
Figure 1-6 Coolant Bottle Fill Level

New machines are shipped without engine oil. Check the 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. Engine damage could result. On Kawasaki liquid cooled engines, the coolant level in the recovery tank should be in the range between the “H” and “L” lines. See Figure 1-6. Carefully remove the radiator cap. Make sure the radiator is full to the bottom of the neck. See Figure 1-5. Use a good coolant hydrometer to check the coolant freeze protection strength. Engine coolant must be of sufficient strength to protect the engine from freezing at the lowest temperature at which the machine is operated or stored. Refill with a 50-50% mixture of distilled water and anti-freeze. 20

WARNING:
Use EXTREME caution when removing the radiator cap. NEVER remove cap when hot. Coolant may be under pressure and extremely hot.

STT & SSZ TECHNICAL REFERENCE MANUAL

Fill the hydraulic tank with SAE 20W50 motor oil. See Figure 1-7. Approximately six quarts will be needed. Fill to about three inches below the top of the neck. Do not overfill the hydraulic tank. Re-install and tighten the tank cap. Check all hardware for the proper tightness. Refer to the Torque Specification Chart on page 42 when specific torques are not given. Apply lubricant to all grease fittings. Reference pages 40 and 41 for the Lubrication Chart.

HYDRAULIC OIL RESERVOIR

390S0154

WARNING:
Never smoke while handling fuel. Do not handle fuel near sparks or open flames, and never refuel a hot engine.
Add fuel to the fuel tank. See Figure 1-8. Always use a good quality fuel with a minimum octane rating of 87. Observe all safety rules for fuel handling. Clean up any spills, and properly dispose of fuel soaked rags. Do not overfill the fuel tank. Leave at least one inch of space in the fuel tank to allow room for fuel expansion.

Figure 1-7 Hydraulic Tank

FUEL CAP

1.10

DUMP VALVE LOCATION (27:54)

Be sure the hydrostatic drive dump valves are closed for proper operation of the machine. The valves are located on the upper left side of both pumps. The valve on the right pump may be slightly hidden under the engine. See Figure 1-9. -IMPORTANTRefer to the Basic Operation section of Scag Fundamentals before operating this machine. Make sure all operators are properly trained and thoroughly familiar with all of the controls before operating the mower. Carefully and slowly drive the machine off the crate. Remove all remaining packing materials and crating from the work area.

416981

Figure 1-8 Fuel Tank Location

DUMP VALVE CONTROL LEVER

CAUTION:
The drive unit can get hot during operation and could cause burn injuries. Allow engine and drive components to cool completely before making any adjustments.
21
390S0141

Figure 1-9

Dump Valve Location

STT & SSZ TECHNICAL REFERENCE MANUAL

SECTION 2 - ADJUSTMENTS (28:41)
2.1 NEUTRAL ADJUSTMENT (28:41)

Neutral or tracking adjustments will need to be made if: A. The steering control levers are in the neutral position and the machine creeps forward or backward. (Neutral Adjustment). B. The steering control levers are in the full forward position and the mower pulls to one side or the other when traveling in a forward direction. (Tracking Adjustment, Section 2.2, page 23). With an operator in the seat and the machine in neutral, start the engine and disengage the parking brake. Check if one or both of the wheels are turning. If a wheel is rotating slightly, or creeping, the speed control rod for that drive pump must be adjusted. Loosen the two jam nuts on the speed control rod. See Figure 2-1 for right side adjustments and Figure 2-2 for left side adjustments.
CONTROL ROD LOOSEN HERE

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, continue turning until the wheel begins to creep in the opposite direction. Move the rod back to a position midway between the two points. Tighten the jam nuts to secure the neutral position and 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 position. Verify that the drive wheels are still in neutral and readjust if necessary. - NOTE The right hand control rod will be changed in 1999 to a straight rod similar to the current style of left hand control rod. At that time, the right hand control rod will be adjusted the same as the left control rod. If you experience difficulty in achieving a sound neutral position, refer to the Hydraulics information in Scag Fundamentals.

LOOSEN HERE

390S0149

390S0147

CONTROL ROD LOOSEN HERE TURN HERE

ASSIST SPRING ADJUSTMENT

LOOSEN HERE

390S0148

SERVICE BULLETIN 406--INCORRECT BELT ADJUST HERE 390S0146 OPERATING ANGLE

Figure 2-1 RH Speed Control Rod 22

Figure 2-2 LH Speed Control Rod

STT & SSZ TECHNICAL REFERENCE MANUAL

2.2

TRACKING ADJUSTMENT (30:08)

Stop the engine and remove the key from the ignition before making any adjustments. Wait for all moving parts to come to a complete stop before beginning work.

If at full speed the mower pulls right, it is an indication that the left wheel is turning faster than the right wheel. To adjust this condition, proceed as follows: 1. Stop the machine and place the steering control levers in the neutral position. Loosen the lock nuts securing the ball joints at each end of the LH steering control rod. Rotate the control rod to lengthen the rod. This will cause the control rod to stroke the LH pump less, slowing down the LH wheel. Tighten the lock nuts. See Figure 2-2. 2. If at full speed the mower pulls left, it is an indication that the right wheel is turning faster than the left wheel. To adjust this condition, use the same procedure as outlined in step 1 on the RH steering control rod. See Figure 2-1. -NOTEAfter making the adjustment as outlined in step 1 and 2, the machine should drive straight and not creep forward or backward when in the neutral postion.

WARNING:
The engine and drive components can get hot during operation. Allow engine and drive componentsto cool before making any adjustments to avoid burns.
-NOTEBefore proceeding with this adjustment, be sure that the caster wheels turn freely and that the tire pressure in the drive wheels is correct. If the tire pressure is not correct, the machine will pull to the side with the lower pressure. Also, verify that both steering levers are adjusted so they are even with each other.

CONTROL ROD LOOSEN HERE

LOOSEN HERE

390S0149

390S0147

CONTROL ROD LOOSEN HERE TURN HERE

ASSIST SPRING ADJUSTMENT

LOOSEN HERE

390S0148

SERVICE BULLETIN 406--INCORRECT BELT ADJUST HERE 390S0146 OPERATING ANGLE

Figure 2-1 RH Speed Control Rod 23

Figure 2-2 LH Speed Control Rod

STT & SSZ TECHNICAL REFERENCE MANUAL

2.3

BRAKE ADJUSTMENT (31:07)

LOOSEN HERE

Move the brake lever to the disengaged position. The distance between the top of the frame and the bottom of the handle should be two and one quarter inches. See Figure 2-3. If adjustment is needed, loosen the jam nuts at the ends of the brake control rod , and turn the rod until the two and one quarter inch dimension is achieved. See Figure 2-3. Tighten the jam nuts. To adjust the lower brake linkage, engage the brake handle. Block the front tires to prevent the machine from moving and raise the rear of the machine. Remove the rear wheels. At the left brake, measure the distance between the lower nut on the brake actuating rod and the brake actuating lever. There should be 1/8- inch clearance between the lower nut and the actuator arm. See Figure 2-4. If an adjustment is required, loosen the jam nut below the clevis at the top of the rod and turn the bolt head at the bottom of the rod until the 1/8-inch dimension is achieved. Tighten the jam nut. See Figure 2-4. Repeat the adjustments on the right side of the machine, replace the drive wheels and test the brake.
1/8 INCH BOLT HEAD ADJUST HERE

LOOSEN HERE

2 1/4 INCHES
390S0152

Figure 2-3

Brake Lever Adjustment

JAM NUT LOOSEN HERE

390S0153

Figure 2-4

Brake Rod Adjustment

24

STT & SSZ TECHNICAL REFERENCE MANUAL

2.4

CUTTER DECK ADJUSTMENT (32:21)

The cutter deck must be properly adjusted for optimum cutting performance. Many factors can negatively influence the cutter deck performance, such as having improper pitch of the deck or the deck not being level. Begin leveling the cutter deck by placing the cutter deck height control into one of the middle holes on the height control bracket. - NOTE Make sure the machine is on a flat level surface. At the discharge side of the cutter deck, measure the distance from the front bottom edge of the cutter deck to the ground. See Figure 2-5. On the opposite side of the cutter deck, measure the distance from the front bottom edge of the cutter deck to the ground. See Figure 2-6. The two measurements should be equal. If adjustment is required, loosen the cutter deck adjusting bolt and move the left side of the deck to match the measurement at the right side of the deck. Remove the slack from the deck supporting chain, and tighten the cutter deck adjusting bolt. See Figure 2-7.

416982

Figure 2-5 Measure Distance at Front Right Side of Cutter Deck

416983

CAUTION:
Stop engine and remove key from ignition before making any adjustments. Wait for all moving parts to come to a complete stop before beginning work.

Figure 2-6 Measure Distance at Front Left Side of Cutter Deck

JAM NUT

ADJUST HERE

CUTTER DECK ADJUSTING BOLT
390S0174

Figure 2-7 Cutter Deck Adjusting Bolt

25

STT & SSZ TECHNICAL REFERENCE MANUAL

2.5

CUTTER DECK PITCH ADJUSTMENT (33:10)

The front of the cutter deck should be 1/4" lower than the rear of the cutter deck for best cutting performance. This is called the pitch of the cutter deck. To check for proper deck pitch, be sure that the mower is on a flat, level surface and the tires are properly inflated. Check the distance from the bottom of the cutter deck to the floor at the rear RH side of the cutter deck directly behind the cutter deck hanging chains. Next check the distance from the bottom of the cutter deck to the floor at the front RH side of the cutter deck directly in front of the cutter deck hanging chains. The measurement at the front of the cutter deck should be 1/4" lower than the measurement at the rear of the deck. Make these measurements at the LH side of the cutter deck also. If the measurement at the front of the deck is not 1/4" lower, the cutter deck pitch must be adjusted as follows: 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. - NOTE To prevent the cutter deck from teetering, all four cutter deck hanging chains must have tension on them. If all four chains do not have tension on them and the deck teeters, you must readjust the cutter deck as outlined in the Section 2-4 and Section 2-5.

JAM NUT

ADJUST HERE

CUTTER DECK ADJUSTING BOLT

390S0174

Figure 2-8

Cutter Deck Pitch Adjustment

CONTROL ROD
G IN T TT H U C EIG H

LOOSEN HERE

HEIGHT ADJUSTMENT PEDAL

6

5.

5

5

4.

5

4

3.

5

3

2.

5

2

1.

5

1

Figure 2-9 Cutter Deck Height Adjustment

2.6

CUTTER DECK HEIGHT ADJUSTMENT

The cutter deck height adjustment is made to ensure that the cutter deck is cutting at the height indicated on the cutting height index gauge. To check for proper deck height, be sure that the mower is on a flat, level surface and the tires are properly inflated.
1/4"

Place the cutter deck in the transport position, foot pedal fully depresssed and locked. Loosen the jam nuts on both ends of the deck height control rod. See Figure 2-9. 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. Tighten the jam nuts on the control rod. 26

DECK STOP
390S0175

Figure 2-10 Cutter Deck Stop Measurement

43 15 48

LANYARD PIN

390S014A

STT & SSZ TECHNICAL REFERENCE MANUAL

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. -NOTEIf an adjustment was made, be sure that the cutter deck can easily be locked into the transport position.
LOOSEN HERE

HEIGHT ADJUSTMENT PEDAL

G IN T TT H U C EIG H

6

Check the cutter deck cutting height by placing the lanyard pin in the 3" position on the cutting height index. Release the deck from the transport positon and allow the deck to move to the 3" cutting height position.

CONTROL ROD
5 5.

5

5 4.

4

5 3.

3

5 2.

2

5 1.

1

390S014A

CAUTION:
Stop engine and remove key from ignition before making any adjustments. Wait for all moving parts to come to a complete stop before beginning work. 2.7 DRIVE BELTS (34:18)

Figure 2-11 Cutter Deck Height Adjustment

Each drive belt on the Turf Tiger is equipped with a spring loaded idler tensioning system for optimum belt life and ease of maintenance. The belts should be checked for proper alignment and wear after the first 2, 4, 8, and 10 hours of operation. Thereafter, the belts should be checked every 40 hours of operation or weekly, whichever comes first. To verify proper operation of the spring-loaded idler system, make sure that all idler arms move freely and are applying tension to the belts. Verify that the pulleys are in alignment with each other and turn freely. Also make sure that the pulley grooves are free of debris build up. Reference Scag Fundamentals Belt Section for details on troubleshooting belts.

27

48

LANYARD PIN

15

43

STT & SSZ TECHNICAL REFERENCE MANUAL

SECTION 3 - ELECTRICAL SYSTEM (34:43)
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 orange wire is connected to the speed control lever switches. The test light should illuminate when both the levers are out in the neutral lock position, and should go out when either or both of the levers are moved inward. Be sure to test both steering levers. The seat switch is tested at the brown wire. The test light should illuminate when pressing down on the seat switch, and go out when releasing the switch. The pink wire is connected to the brake switch. The light will be on when the brake is on. Release the brake, and the test light should go out. The light blue wire is connected to the PTO switch. When the switch is moved to the off position, the test light will be on, and will go out when the PTO switch is pulled to the on position. The green wire supplies a ground to the starter relay to assist in completing the starting circuit. Reference the Engine Cranking Circuit for testing procedures.

The electrical system on the STT incorporates a solid state module, which controls the function of the engine crank and operator presence interlock circuits. The basic function of these circuits is the same as with other products. However the use of the module simplifies the wiring system because all basic switch and circuit tests can be performed at the interlock module connector. Two different interlock modules are used on the STT, determined by the engine option. The Kohler engine uses a magneto type ignition system, which requires an external grounding of the magneto kill wire to stop the engine. This ground is provided through the interlock module at the white wire. The Kawasaki engine uses a battery type ignition, which is supplied battery voltage to operate. The voltage supply for this ignition is provided through the interlock module from the white wire. These different modules each require a different method of testing the output from the white wire. 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. Remove the four bolts holding the top of the instrument panel in place. See Figure 3-1. Carefully tip the panel toward the seat until access is gained to the interlock module. Confirm that your test light is working by checking across the battery. Connect the test light clip to the battery positive terminal, and test for a good ground at the black wires in the interlock module connector. The test light should illuminate, indicating a ground, regardless of interlock switch positions. Next, confirm voltage to the module from the key switch. Verify the fuses in the fuse block are in good condition with a test light before continuing. Move the test light clip to the negative battery terminal, and test the red wires at the interlock module connector. The light should illuminate when the key switch is turned on.

Figure 3-1 Remove Top of Instrument Panel

INTERLOCK MODULE WIRE LEGEND
BLACK RED ORANGE BROWN LIGHT BLUE PINK GREEN WHITE Ground Power - 12 volts Speed Control Levers Seat Switch PTO Switch Parking Brake Switch Engine Crank Wire Ignition Voltage Wire (KA) Ignition Ground Wire (KH)

28

STT & SSZ TECHNICAL REFERENCE MANUAL

To test the ignition interlock circuits, reference the appropriate Interlock Module Section (Kohler or Kawasaki).

3.2

KOHLER INTERLOCK MODULE (39:33)

Proper operation of a Kohler powered STT machine provides that for the operator to leave the seat and the engine to stay running, the PTO must be disengaged, the speed control levers in the neutral lock position, and the parking brake applied. Two basic ignition interlock tests are performed while the test light is connected to the white wire. The first is a safety check to determine if the engine ignition will be stopped when the operator leaves the seat when either the brake is off, the PTO is on or the speed control levers are moved from the neutral lock position. The second is a drive system protection check to determine if the engine will be stopped if the speed control levers are moved to the drive position while the brake is applied. For the first check, place the test light clip to the positive battery terminal. Test the light at the negative battery terminal to verify proper connection. Place the test light probe at the white wire in the interlock module connector. The ignition switch must be in the on position, the brake must be in the engaged position, the speed control levers in the neutral lock position, and the PTO switch off.

When testing the ignition circuit, white wire, on a Kohler powered STT, you will be testing for a ground to kill the engine. To begin, place a test light clip on the battery positive terminal. Place the probe on a known good ground to test the connection, then place the probe into the module connector with the white wire. The test light will illuminate when a ground is present to kill the engine. The test light will not illuminate if the following parameters are met: 1.) Ignition switch is in the "on" position. 2.) Seat switch is depressed. 3.) Steering control levers are in the outward, neutral lock position. 4.) PTO switch is in the off position. 5.) Brake in the engaged position. When the controls are moved from any of these positions, the ground through the module will be a closed circuit, and the test light will be on.

INTERLOCK BLOCK DIAGRAM
INTERLOCK MODULE RED GRN MAGNET O WHT BLK +12V STARTER KILL GROUND ARMS-OUT SEAT -ON BRAKE-ON PTO-OFF ORG SEA T BRN BRAKE PINK PTO LT BLUE

LH CTRL ARM

RH CTRL ARM

RUN CRANK KEYSWITCH

+

SWITCH POSITIONS
LH CTRL ARM RH CTRL ARM CLOSED WHEN ARMS ARE OUT

BATTER Y

SEAT - CLOSED WHEN SITTING ON SEAT BRAKE - CLOSED WHEN BRAKE IS ON

STARTER RELA Y
PTO - CLOSED WHEN PTO IS OFF

KOHLER INTERLOCK MODULE - PART NUMBER 481623
29

STT & SSZ TECHNICAL REFERENCE MANUAL

The light in the engine ignition wire will be off with the seat switch up or down. Allow the seat switch to remain in the up position. Moving any one of the controls to its opposite position while the seat switch is up will cause the light at the white ignition wire to go on. For the second test, press the seat switch down with the brake on, and the speed control levers in the neutral lock position. The test light should be off. Move either speed control lever out of neutral lock. The light should go on. Leave the speed control lever moved inward, and move the brake to the off position. The light will turn off. Moving any one switch to its opposite position will cause the light to go out. Be sure to test each switch for a complete test of the interlock circuit.

2.) Seat switch is either engaged or disengaged. 3.) Steering control levers are in the outward neutral lock position. 4.) PTO switch is in the disengaged position. 5.) Brake in the engaged position. When the controls are moved from any of these positions, the 12 volt supply will be interrupted, causing the engine to die. Proper operation of a Kawasaki powered STT machine provides that the engine will stop anytime the operator leaves the seat without stopping the PTO, engaging the parking brake, and placing the steering control levers in the neutral lock position. Two basic ignition interlock tests are performed while the test light is connected to the white wire at the interlock module connector. The first is a safety check to determine if the engine ignition will be stopped when the operator leaves the seat anytime the parking brake is disengaged, the PTO is on or the speed control levers are moved from the neutral lock position. The second is a drive system protection check to determine if the engine will be stopped if the speed

3.3 KAWASAKI INTERLOCK MODULE (38:27)
When testing the interlock module on a Kawasaki powered unit, begin by checking for 12 volts through the white wire in the module. Attach the test light clip to a good ground. Place the test light probe on the white wire at the module connection. The test light will light, indicating 12 volts through the module, only when all of the following parameters are met: 1.) Ignition switch is in the "on" position.

INTERLOCK BLOCK DIAGRAM
INTERLOCK MODULE RED GRN IGNITION WHT BLK +12V STARTER KILL GROUND ARMS-OUT SEAT -ON BRAKE-ON PTO-OFF ORG SEA T BRN BRAKE PINK PTO LT BLUE

LH CTRL ARM

RH CTRL ARM

RUN CRANK KEYSWITCH

+

SWITCH POSITIONS
LH CTRL ARM RH CTRL ARM CLOSED WHEN ARMS ARE OUT

BATTER Y

SEAT - CLOSED WHEN SITTING ON SEAT BRAKE - CLOSED WHEN BRAKE IS ON

STARTER RELA Y
PTO - CLOSED WHEN PTO IS OFF

KAWASAKI INTERLOCK MODULE - PART NUMBER 481668
30

STT & SSZ TECHNICAL REFERENCE MANUAL

control levers are moved to the drive position while the brake is applied. For the first check, the ignition key must be in the on position, the brake must be in the engaged position, the speed control levers in the neutral lock position, and the PTO switch off. The test light in the white, ignition wire will illuminate with the seat switch up or down. Allow the seat switch to remain in the up position. Moving any of the controls to its opposite position while the seat switch is up will cause the test light to turn off. Note: The Kawasaki engine allows for a slight delay before cutting off ignition to prevent backfiring if the operator bounces in the seat on rough terrain. For the second test, press the seat switch down with the brake on, and the speed control levers in the neutral lock position. The light should illuminate. Move either speed control lever out of neutral lock. The light should go out. Leave the speed control lever inward, and move the brake to the off position. The test light should illuminate. Moving any one switch to its opposite position will cause the light to go out. Be sure to test each switch for a complete test of the interlock circuit.

green wire to test the engine cranking circuit. The test light should illuminate, indicating a ground is present. Next, with the ignition key in the start position, place the test light probe at the green wire on the back of the ignition switch. The test light should illuminate. Follow the green wire from ignition switch to the starter relay. Place the test light probe at the green wire (A) going into the starter relay. See diagram below. The test light should illuminate with the ignition key in the start position. Test the green wire (B) on the opposite side of the relay with the test light to confirm that the circuit is completed through the relay. The test light may illuminate dimly on the green-white wire leaving the relay. This is normal. It is being caused by resistance in the coil inside of the relay. The starter relay has a constant twelve volt supply of electricity from the battery and is dependant upon the relay to complete the engine cranking circuit. If all the circuits test correctly, move the test light clip to a ground to begin checking for voltage in the circuit. Using the test light probe, test both of the fuses. Test for twelve volts at the red-yellow wire (C) going into the starter relay. Twelve volts should pass through the relay from the redyellow wire into the green-white wire (D) energizing the starter solenoid if the conditions listed at the begining of Section 3.4 are met. Moving any of the switches to their opposite position will cause the light to go out. Be sure to test each switch for a complete test of the cranking circuit. Reference the flowcharts on pages 35, 36 and 37 for assistance in troubleshooting the engine cranking system.

3.4

ENGINE CRANKING CIRCUIT (42:45)

In order for the engine to crank and to test the engine cranking circuit, all of the following parameters must be met: 1.) The brake lever in the engaged position.

red/yellow (C)

2.) The speed control levers in the outward, neutral lock position. 3.) PTO switch in the disengaged position.
green (A) green (B)

4.) The seat switch depressed. 5.) The ignition switch in the start, engine crank, position. Start by testing at the interlock module connector. Place the test light clip on the positive battery terminal to test for a ground at the green, engine crank wire. Place the test light probe at the interlock module connector at the 31
green/white (D)

STARTER RELAY

STT & SSZ TECHNICAL REFERENCE MANUAL

3.5

PTO CIRCUIT

In order for the PTO to engage and to test the PTO electrical circuit, the following parameters must be met: 1.) The ignition switch in the on position. 2.) PTO switch in the engaged position. 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.

WARNING:
Never operate the mower with the interlock system disconnected or malfunctioning. Do not disengage or bypass any switch; injury to yourself and others or property damage could result.

3.6

OPERATOR PRESENCE CIRCUIT

The following switches are involved in the operators presence circuit: 1.) Parking brake switch. 2.) Steering control lever switches. 3.) PTO switch. 4.) Seat switch. The safety interlock circuit on the STT machine prevents the mower from starting unless the PTO is disengaged, the parking brake is engaged, the speed control levers are in the neutral lock position, and the operator is in the seat. 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. Reference the flowchart on page 38 for assistance in troubleshooting the operator presence circuit.

32

WHITE GREEN RED BLACK IGNITION SWITCH AMMETER PTO SWITCH BLUE GREEN

RED/YELLOW

BLACK FUSE

RED/ YELLOW

YELLOW FUSE YELLOW BLACK HOURMETER WHITE

WHITE

YELLOW

GREEN

RED-YELLOW

STT & SSZ TECHNICAL REFERENCE MANUAL

BLACK

RED

RED

BLACK

RED PINK PINK

BLACK

BLACK

LIGHT BLUE

ENGINE CONNECTOR RELAY GREEN

GREEN/ WHITE

RED-YELLOW

GREEN/WHITE

ALTERNATOR IGNITION (WHITE) BLACK

BROWN RED RED

ORANGE

INTERLOCK MODULE

BROWN

BLACK

BRAKE SWITCH

RED

3.7 STT WIRING DIAGRAM - KOHLER ENGINE

BLACK

LEFT NEUTRAL LOCK SWITCH

RED

RIGHT NEUTRAL LOCK SWITCH

BLUE

BLUE

BLUE SEAT SWITCH

PINK

BLUE

BATTERY

RED

33

WHITE GREEN RED BLACK IGNITION SWITCH AMMETER
RED/YELLOW

GREEN BLUE

RED / YELLOW

GREEN

FUSE

RED

PTO SWITCH

RED YELLOW BLACK RED WHITE

BLACK

BATTERY BLACK WATER TEMP HOURMETER RED PINK RED RED / YELLOW B/W GREEN

WHITE

RED

RED

RED

YELLOW

PINK PINK RED BLUE BROWN ORANGE

GREEN RELAY BLACK WHITE

RED / YELLOW

ENGINE CONNECTOR WHITE

BLACK

ALTERNATOR IGNITION RED RED

INTERLOCK MODULE RED RED RED RED

LIGHT BLUE

GREEN / WHITE

BRAKE BRAKE SWITCH SWITCH

BLACK

RED

RED

3.8 STT WIRING DIAGRAM - KAWASAKI ENGINE

SEAT SWITCH RED LEFT NEUTRAL LOCK SWITCH FUEL PUMP BLUE BLUE RIGHT NEUTRAL LOCK SWITCH

BLACK

STT & SSZ TECHNICAL REFERENCE MANUAL

BLACK

RED

FUSE

34

STT & SSZ TECHNICAL REFERENCE MANUAL

START
Does the battery have at least 12.0 volts? YES

3.9 STT - ENGINE CRANKING SYSTEM NO START, ENGINE DOES NOT CRANK
Parameters =

NO

Charge or replace the battery.

Perform Basic Electrical Checklist PTO switch off Ignition switch in start position Seat switch depressed Parking brake engaged Steering control levers in neutral lock position

red/yellow (C)

green (A)

green (B)

Replace the ignition switch. Does the battery have at least 9.0 volts NO with the ignition key in the start position? YES Replace faulty fuse. Test all fuses with the test light. Are any YES of the fuses blown? NO YES Is there voltage at the Red wires on the Ignition switch?

Starter Relay

green/white (D)

Repair or replace connection or wiring.

NO Perform the following procedures using a test light. Place the test light clip to ground to test for 12 volts.

Consult the Operator Presence Circuit Flowchart

Perform the following procedures using a test light. Place the test light clip to the positive battery terminal to test for ground. Is there voltage present at the RedNO Yellow (C) wire at the starter relay? With the key in the start position, is there voltage NO at the Green wire at the ignition switch? YES Replace or repair wiring harness. YES

Replace or repair wiring harness.

Consult the Operator Presence Circuit Flowchart for testing of the Interlock Module.

Is there voltage present at the GreenNO White (D) wire at the starter relay? YES

Unplug the Green (B) wire from the relay.

Replace relay.

Is there a ground present at the Green NO (A) wire at the starter relay? YES Replace relay.

Is there voltage present at the GreenNO White wire at the starter solenoid? YES

Is there voltage present at the Green YES wire at the interlock module? NO

Is there voltage present at theGreen NO (B) wire at the starter relay? YES

Consult the Engine Manufacturers manual.

Repair Green-White wire between the relay and the starter solenoid.

Replace the interlock module.

35

STT & SSZ TECHNICAL REFERENCE MANUAL

3.10

STT - KOHLER - ENGINE CRANKING SYSTEM NO START, ENGINE DOES CRANK

Parameters =

Does the battery have at least 12.0 volts? YES

NO

Charge or replace the battery.

Perform Basic Electrical Checklist PTO switch off Ignition switch in start position Seat switch depressed Parking brake engaged Steering control levers in neutral lock position

Does the battery have at least 9 volts with the ignition key in the start position? YES

NO Perform the following procedures using a test light as noted.

Does the starter crank the engine YES fast enough to start? NO

Does the White wire at the interlock module show ground with the key in the crank and run position? YES Consult the Operator Presence Circuit for further testing.

NO

Consult the Engine Manufacturer's Manual for further testing.

Does the White wire at the engine connector show ground with the key in the crank and run position? YES Replace or repair wiring harness.

NO

Kohler Engine
Consult the Engine Manufacturer's Manual for further testing.

36

STT & SSZ TECHNICAL REFERENCE MANUAL

3.11

STT - KAWASAKI - ENGINE CRANKING SYSTEM NO START, ENGINE DOES CRANK

Parameters =

Does the battery have at least 12.0 volts? YES

NO

Charge or replace the battery.

Perform Basic Electrical Checklist PTO switch off Ignition switch in start position Seat switch depressed Parking brake engaged Steering control levers in neutral lock position

Does the battery have at least 9 volts with the ignition key in the start position? YES

NO Perform the following procedures using a test light as noted.

Does the starter crank the engine YES fast enough to start? NO

Does the White wire at the interlock module show voltage with the key in the YES crank and run position? NO Consult the Operator Presence Circuit for further testing.

Consult the Engine Manufacturer's Manual for further testing.

Does the White wire at the engine connector show voltage with the key in the crank and run position? NO Replace or repair wiring harness.

YES

Kawasaki Engine
Consult the Engine Manufacturer's Manual for further testing.

37

STT & SSZ TECHNICAL REFERENCE MANUAL

3.12
START

STT - OPERATOR PRESENCE CIRCUIT
Test Black wire between Module and Switch for continuity. Repair or replace.

Perform the following procedure using a test light at the Interlock Module connector. Place the test light clip to the positive battery terminal to test for ground.

Does the test light illuminate at the Black wire in the Interlock Module connector? YES

NO

Does the test light illuminate at the YES Black wire at the Ignition switch? NO

Perform the following procedures using a test light at the Interlock Module connector. Place the test light clip to ground to test for voltage.

Test ground circuit for continuity. Repair or replace harness or faulty connector. NO Test the fuses. Are they defective? NO Test the Ignition switch. Does it YES test correctly?

Replace the Ignition switch.

Does the test light illuminate at the Red wire in the Interlock Module connector? YES

YES NO Test wiring harness for continuity. Repair or replace harness or faulty connector. Replace the faulty fuse(s). Test the Speed Control Interlock switches. Do they test correctly? NO

Does the test light illuminate at the Orange NO wire in the Interlock Module connector? YES

YES Test wiring harness for continuity. Repair or replace harness. YES Test the PTO switch. Does it test NO correctly?

Replace the faulty Steering Control Lever Switch.

Does the test light illuminate at the Light Blue NO wire in the Interlock Module connector? YES

Replace the PTO Switch.

Test the Parking Brake Switch. Does NO it test correctly? Does the test light illuminate at the Pink wire in the Interlock Module connector. YES YES NO Test wiring harness for continuity. Repair or replace harness. YES Test the Seat Switch. Does it test correctly? NO Unhook the White wire from the Ignition switch. Perform continuity and ohms testing on the White wire in the harness. YES Is there a short or loss of continuity in the White wire? NO

Replace the Parking Brake Switch.

Replace the Seat Switch.

Does the test light illuminate at the Brown wire in the Interlock Module connector? YES

Repair or replace faulty wire.

NO

Replace the Interlock Module

38

START
Parameters = All basic electrical checks performed PTO switch on Ignition switch on Airgap adjusted on PTO clutch to .015".

Perform the following procedures using a test light. Place the Ignition switch in the on position. Is there power at the LIGHT BLUE wire at the PTO switch?
NO

Replace the PTO switch.

YES

Test the fuses. Is there a blown fuse? Replace the faulty fuse(s). Repair or replace the Light Blue wire between the Interlock module and the PTO switch as needed. Is there power at the Light Blue wire at the YES NO interlock module connector?
YES

YES

NO

STT & SSZ TECHNICAL REFERENCE MANUAL

3.13

Is there power at the single RED wire going into the rear of the Ignition switch? Replace the PTO switch.

NO

Test the wiring harness between the fuse block and the Ignition switch. Repair or replace as needed. Is there power at the BLUE wire YES NO at the PTO switch?

Replace the PTO clutch assembly.

YES

STT - PTO CIRCUIT

39
YES YES

Is there power at the double RED wire at YES the rear of the Ignition switch?
NO

Is there power at the RED wire going into the rear of the PTO switch?

YES

Is there a ground and voltage at the PTO clutch?
NO

NO

Replace the Ignition switch.

Is there power at both sides of the Blue wire at the PTO clutch connector?
NO

YES

Is there a good ground at the Black wire on YES both sides of the PTO clutch connector?
NO

Test the red wire between the PTO switch and the Ignition switch. Repair or replace as needed.

Repair faulty connection or wiring at PTO connector.

STT & SSZ TECHNICAL REFERENCE MANUAL

4.1

GREASE FITTING LUBRICATION CHART INDEX (Reference Figure 4-3, page 41)
LUBRICATION LOCATION INTERVAL 500 Hours/Yearly 100 Hours/Bi-Weekly 200 Hours/Monthly 100 Hours/Bi-Weekly 100 Hours/Bi-Weekly 40 Hours/Weekly 40 Hours/Weekly 200 Hours/Monthly 100 Hours/Bi-Weekly LUBRICANT Chassis Grease Chassis Grease Chassis Grease Chassis Grease Chassis Grease +Lithium MP White Grease 2125 +Lithium MP White Grease 2125 Chassis Grease Chassis Grease NO. OF PLACES 2 2 2 4 2 1 3 1 3

1 2 3 4 5 6 7 8 9

Caster Wheel Pivot Caster Wheel Bearings Brake Actuator Cutter Deck Bellcranks Cutter Deck Pusharms PTO Spindle Cutter Deck Spindle Brake Handle Cutter Deck Drive Shaft

+

Compatible Greases:

Mobilix #2 found at Mobil Service Stations Ronex MP found at Exxon Service Stations Super Lube MEP #2 & Super Stay-M #2 found at Conoco Stations Shell Alvania #2 found at Shell Service Stations Lidok EP #2 found at industrial shops

4.2

CUTTER DECK GEARBOX
3. Re-install the drain plug and add EP-80/90 lubricant through the check plug hole in the gearbox until it is level with the bottom of the check plug hole. Install the check plug and tighten securely.

The fluid level in the cutter deck gearbox (Figure 4-2) should be checked after every 100 hours of operation or bi-weekly, whichever occurs first. 1. Lower the cutter deck to to its lowest position to gain access to the cutter deck gearbox. 2. Clean and remove the check plug from the side of the gearbox. See Figure 4-2. Visually check that the lubricant level is to the bottom edge of the check plug hole. If lubricant is low, add SAE 80W90 lubricant through the check plug hole in the gearbox until it is level with the bottom of the check plug hole. Install the check plug and tighten securely. The lubricant in the cutter deck gearbox should be changed after every 500 hours of operation or yearly, whichever occurs first. 1. Place a suitable container beneath the cutter deck gearbox and locate the gearbox drain plug. 2. Remove the drain plug and drain the lubricant into the container and properly discard it. 40

CAUTION:
The cutter deck gearbox can reach high operating temperatures. Allow the cutter deck gearbox to cool before servicing.

CUTTER DECK GEARBOX CHECK PLUG
390S0161

Figure 4-2

Cutter Deck Drive Gearbox

STT & SSZ TECHNICAL REFERENCE MANUAL

4-3

STT LUBRICATION CHART
GREASE FITTING LUBRICATION
LUBRICANT / INTERVAL LITHIUM MP WHITE GREASE 2125 ( 40 HOURS / WEEKLY ) CHASSIS GREASE ( 100 HOURS / BI-MONTHLY ) CHASSIS GREASE ( 200 HOURS / MONTHLY ) CHASSIS GREASE ( 500 HOURS / YEARLY )

4

1

6

3

5

7

2

8

1

2

4

5

9

3

9

390S0145

41

STT & SSZ TECHNICAL REFERENCE MANUAL

5.1
Grade Number

APPENDIX GENERAL TORQUE SPECIFICATION CHART 5 8

Standard
COARSE THREAD Number Threads /

Bolt Size
Inches 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 Grade Number

TORQUE
Foot Pounds
Average 10 19 39 59 88 121 165 297

TORQUE
Foot Pounds
Average 14 27 50 77 121 176 242 418

Inch

Newton-Meters
Average 13.5 25.5 52.3 80.0 119.4 164.1 223.8 402.7

Newton-Meters
Average 18.3 35.9 67.1 104.4 164.1 238.7 328.2 566.8

20 18 16 14 13 12 11 10

5

8

Standard
FINE THREAD Number Threads /

Bolt Size
Inches 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 Grade Number

TORQUE
Foot Pounds
Average 11 21 43 54 96 132 180 324 8.8
8.8 8.8 10.9

TORQUE
Foot Pounds
Average 15 29 55 84 132 192 264 456 12.9
10.9 12.9 12.9

Inch

Newton-Meters
Average 14.7 27.8 57.0 87.2 130.1 178.9 243.9 438.9 10.9

Newton-Meters
Average 20.5 39.1 73.1 113.8 178.9 260.2 357.7 617.8 SAE GRADE 8 CAPSCREW

28 24 24 20 20 18 18 16

Metric
Thread

# 8-32
TORQUE TORQUE TORQUE
Pitch Mm

Bolt Size
Mm M6 M8 M10 M10 M12

Ft. Lb.

Nm

Ft. Lb.

Nm

Ft. Lb.

Nm

42 - Inch Lbs. 4.7 - Nm
SAE GRADE 8 CAPSCREW

1.0 1.25 1.25 1.50 1.75

Average 7 10 18 25 36 49 40 54 63 86

Average 10 14 26 35 51 69 55 85 88 120

Average 13 17 30 41 61 83 86 115 107 145

# 10-32
60 - Inch Lbs. 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

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TECHNICIAN CERTIFICATION

The contents of this video-based training program are the property of Scag Power Equipment and may not be reproduced in any manner without the written permission of Scag Power Equipment. © 1998 Scag Power Equipment Division of Metalcraft of Mayville, Inc.

Part No. 02001-07

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