Briggs Stratton Lawn Mower Accessory 500Z 26 User Manual

Dealer Setup  
& Adjustment Instructions  
500Z - 26 HP Briggs & Stratton  
48” Mower Deck  
This Dealer Setup Instruction covers the following products:  
TABLE OF CONTENTS:  
SETUP PROCEDURES  
Model No.  
Description  
5900731  
500ZB2648, 26HP Kawasaki w/ 48” Mower  
Quick Setup List................................................................2  
Uncrating............................................................................3  
Battery Installation ............................................................3  
Tractor Assembly ..............................................................4  
Ground Speed Control Lever Assembly..........................4  
Seat Assembly.................................................................4  
Check Fluid levels.............................................................5  
Check Engine Oil Level ...................................................5  
Check Hydraulic Oil Level................................................5  
Check Tire Pressure..........................................................5  
Check Mower Assembly ...................................................6  
Check Torque - Mower Blades........................................6  
Check Deck Rod Timing ...................................................7  
Deck Leveling Adjustment ...............................................8  
Check Deck Drive Belt ......................................................9  
Lubrication.......................................................................10  
Adding Fuel......................................................................11  
Starting The Engine ........................................................11  
Perform Safety Checks...................................................12  
Functional Tests.............................................................12  
Safety Interlock System.................................................12  
ADJUSTMENT PROCEDURES  
ATTENTION SETUP PERSONNEL:  
The safety warnings provided in this guide and in  
the operator's manual included with the unit contain  
important information that must be obeyed when  
assembling, setting-up, operating, servicing,  
transporting, or storing the unit.  
These warnings are highlighted by the safety alert triangle  
symbol shown above, which signifies that an important safety  
message is being provided.  
You must read, understand, and follow these warnings and  
instructions, and use safe shop and work practices at all  
times while working on or around this unit and all other  
outdoor power equipment.  
Sections and items denoted by the Setup symbol  
provide the information necessary to fully assemble,  
test, and prepare the units described above for  
delivery to your customers.  
A Quick Setup List is provided on page 2 of this booklet  
to help you identify and check that the items have been  
performed.  
Seat Adjustment ..............................................................13  
Ground Speed Control Lever Adjustment ....................13  
Return-To-Neutral Adjustment.......................................14  
Parking Brake Adjustment .............................................15  
Additional information concerning functional tests,  
general adjustment procedures, and the location of  
normal lubrication points are included in these  
instructions.  
Although all required lubrication and normal adjustments on  
factory-assembled components are done at the factory, this  
additional information is provided to assist you in ensuring that  
each unit is delivered to the customer in proper working order.  
5101454  
Rev. IR  
TP 300-7368-IR-ZT-N  
1/2008  
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500Z 26HP - 48” Mower Deck  
Uncrating  
1. Using a reciprocating utility saw or equivalent, cut the  
crate away from the bottom skid. Remove the crate.  
Remove the shrink-wrap plastic.  
2. Cut the nylon banding from the front of the frame and  
the rear of the bumper.  
IMPORTANT NOTE  
When cutting the crate from the bottom  
skid, use caution around tractor tires  
and mower rollers.  
A
B
C
3. Pull both transmission release levers (A, Figure 1)  
back and then down to lock the transmission release  
levers in the disengaged (free-wheel) position (C).  
4. Push down on the parking brake lever to release the  
parking brake.  
Figure 1. Transmission Release Levers (LH shown)  
A. Transmission Release Lever  
B. Engaged Position (Drive Position)  
5. Be sure there are no nails or sharp objects on the  
bottom skid to puncture the tractor’s tires. Roll the  
tractor forward off the bottom skid.  
C. Disengaged Position (Free-wheel Position)  
6. After moving the tractor, re-engage the transmissions  
by pulling the transmission release levers up and  
forward to the engaged (drive) position (B).  
Battery Installation  
C
WARNING  
BATTERY SAFETY RULES  
A
• Battery acid causes severe burns. Avoid contact  
with skin.  
B
• Wear eye protection while handling the battery.  
• To avoid an explosion, keep flames and sparks  
away from the battery, especially while charging.  
• When installing the battery cables, CONNECT  
THE POSITIVE (+) CABLE FIRST and the negative  
(-) cable last. If not done in this order, the  
positive terminal can be shorted to the frame by a  
tool.  
Figure 2. Connect the Battery  
A. Positive (+) Cable, Terminal & Boot  
B. Negative (-) Cable & Terminal  
C. Insulator Pad  
Connect Battery  
1. Connect the red positive battery cable (A, Figure 2)  
to the positive battery post. Make sure that the cable  
boot completely covers the positive terminal, so the  
terminal cannot touch the insulator pad (C).  
2. Connect the black negative battery cable (B) to the  
negative battery post.  
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500Z 26HP - 48” Mower Deck  
Tractor  
A
Assembly  
Install Ground Speed Control Levers  
C D  
E
1. Install the ground speed control levers (A, Figure 3)  
onto the control lever base (B) using the 5/16-18 x  
3/4” bolts, 5/16” lock washers and 5/16” flat washers  
(C, D & E). Prior to tightening the bolts, align the  
handles with each other.  
B
NOTE: There is a LEFT-HAND and a RIGHT-HAND  
control lever. When assembled to the base, the lever  
base should be pointing towards the rear as shown in  
Figure 3.  
Figure 3. Install the Control Levers  
A. Ground Speed Control Levers  
B. Control Base  
C. 5/16-18 x 3/4” Bolt(s)  
D. 5/16” Lock Washer(s)  
E. 5/16” Flat Washer(s)  
Seat Assembly  
1. Unpack the seat.  
A
2. Install the seat onto the seat mount plate (C, Figure  
4) and secure with the 5/16-18 nylock flange nuts (A).  
B
D
3. Connect the wire harness (B) to the seat switch (D)  
that is located in the bottom of the seat.  
C
A
Figure 4. Remove The Existing Seat  
A. 5/16-18 Nylock Flange Nuts  
B. Wire Harness  
C. Seat Mount Plate  
D. Seat Switch  
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500Z 26HP - 48” Mower Deck  
Check  
Fluid Levels  
A
Check the Engine Oil Level  
1. Use the engine oil dipstick (A, Figure 5) to check the  
engine oil level. If necessary add engine oil. Check  
the engine manufacturer’s owner’s manual for the oil  
recommendations.  
B
Check / Fill Transmission Oil  
Oil Type: 20W-50 conventional detergent motor oil  
1. Check the oil level when the unit is cold. Raise the  
seat plate to gain access to the transmission oil  
reservoirs (B, Figure 5). The oil should be up to the  
“FULL COLD” mark (C). If the oil is below this level,  
proceed to step 2.  
C
Figure 5. Checking the Fluid Levels  
A. Engine Oil Dipstick  
B. Hydraulic Oil Reservoir  
C. “FULL COLD” Mark  
2. Before removing the reservoir cap, make sure the  
area around the reservoir cap and fill neck of the  
reservoir is free of dust, dirt and other debris.  
Remove the transmission oil caps.  
3. Add oil up to the “FULL COLD” mark (C).  
4. Reinstall the reservoir cap.  
Check Tire Pressures  
Tire pressure should be checked periodically, and  
maintained at the levels shown in the chart. Note that  
these pressures may differ slightly from the “Max  
Inflation” stamped on the side-wall of the tires. The  
pressures shown provide proper traction, improve the  
cut quality, and extend the tire life.  
Tire  
Front  
Rear  
Pressure  
Figure 6. Checking Tire Pressure  
40 psi (2,76 bar)  
15 psi (1,03 bar)  
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500Z 26HP - 48” Mower Deck  
Check the Mower  
Assembly  
B
A
Check Torque - Mower Blades  
WARNING  
Mower blades are sharp. For your personal  
safety, do not handle mower blades with bare  
hands. Careless or improper handling of blades  
may result in serious injury. Blade mounting  
bolts must each be installed with a flat washer  
then securely tightened. Torque blade mounting  
bolts to 70 ft.lbs. (94 N.m.)  
D
1. Park the machine on a flat, level surface and engage  
the parking brake.  
Figure 7. Tightening the Mower Blade for  
Installation  
A. Mower Blade Mounting Bolt  
B. Flat Washer  
C. Mower Blade Air Lift (Points Up For Installation)  
D. 4 X 4 Wooden Block  
2. Lock the deck lift pedal in the 4-1/2” (11,47 cm)  
position.  
3. Check that blades are installed with the tabs pointing  
up toward the deck as shown in Figure 7. Torque  
the bolts to 70 ft.lbs. (94 N.m.).  
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500Z 26HP - 48” Mower Deck  
Check Deck Rod Timing  
1. Park machine on a flat, level surface. Disengage the  
PTO, stop the engine and engage the parking brake.  
Rear tires must be inflated to 15 psi (1,03 bar); front  
tires to 40 psi (2,76 bar).  
2. To check the lift rod timing, measure and record the  
distance between the lift pivots and the rod pivots.  
Repeat for the other side of the machine. See Figure  
8.  
Figure 8. Check Lift Rod Timing  
3. If the measurements for the rods are equal, no  
further adjustment is required. If the measurements  
are NOT equal (greater than 1/8” (3,17mm)  
difference), adjustment is required, continue with  
Step 5.  
4. Lock the deck lift pedal in the 4-1/2” (11,47cm)  
position. Remove the cutting height adjustment pin  
and lower the mower deck.  
5. To ensure that the deck is in the lowest position,  
push the pedal by hand towards the rear of the  
machine and install the height adjustment pin in the  
3” (7.6cm) position to hold in place.  
6. Block up the mower deck until all hanger chains are  
slack.  
Figure 9. Adjust Lift Rod Timing  
7. See Figure 9. To adjust the lift rod, loosen the jam  
nut on the clevis then remove the 1/2” clevis pin  
fastening the clevis the the lift pivot arm. Turn the  
clevis clockwise to shorten the distance between the  
rod pivots or counterclockwise to lengthen the  
distance between the rod pivots. Reinstall the clevis  
on the lift pivot arm and secure with the 1/2” clevis  
pin previously removed. Tighten the jam nut against  
the clevis.  
8. Remove the blocks from under the mower deck.  
9. Remove the the cutting height adjustment pin from in  
front of the deck lift pedal arm. Lift the mower deck  
and reinstall the adjustment pin in the desired  
mowing height.  
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500Z 26HP - 48” Mower Deck  
Deck Leveling  
Adjustment  
NOTE: Before adjusting the deck level, the deck lift rod  
timing must be checked and/or adjusted.  
1. Park machine on a flat, level surface. Disengage the  
PTO, stop the engine and engage the parking brake.  
Rear tires must be inflated to 15 psi (1,03 bar); front  
tires to 40 psi (2,76 bar).  
2. Lock the deck lift pedal in the 4-1/2” (11,47 cm)  
position. Place the deck height adjustment pin in the  
4" position and lower the deck lift pedal until the arm  
contacts the pin.  
Figure 10. 2 x 4 Locations  
3. Place the 2 x 4 blocks under each corner of the  
mower deck with the 3-1/2” sides being vertical.  
Place a 1/4” (0,64cm) thick spacer on top of the rear  
2 x 4’s. See Figure 10.  
6. Adjust the front eyebolts until the chains are tight and  
the deck is still resting on the 2 x 4’s. Tighten the  
jam nuts. See Figure 11.  
7. Loosen the nuts and allow the rear of the deck to rest  
on the 2 x 4’s and 1/4” spacers. Slide the chains  
down in the slots until the chains are tight and tighten  
the nuts. See Figure 11.  
8. Remove all the 2 x 4’s and spacers from under the  
mower deck.  
9. For your safety, DO NOT handle mower blades  
with bare hands. Position the outside mower blades  
so that they face front-to-back (Figure 12).  
10. Measure from the front tip of the blade from the  
cutting edge to the ground. Measure from the rear  
tip of the blade from the cutting edge to the ground.  
Repeat this process for the other side of the  
machine. The front measurements should be 4” (10,2  
cm), the back measurements should be 4-1/4” (10,8  
cm). If the measurements are greater than 1/8” (3,17  
mm) of what they should be adjust the deck height  
until they are correct.  
Figure 11. Hanger Chain Adjustment  
Figure 12. Checking The Blade Height Measurement  
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500Z 26HP - 48” Mower Deck  
48” Models  
B
A
Check Deck Drive Belt  
1. Lower the mower deck to its lowest cutting position.  
2. Remove the mower deck guards.  
3. Make sure the V-side of the belt runs in the pulley  
grooves (Figures 14).  
WARNING  
B
Use extreme caution when rotating the idler arm  
with the breaker bar, due to the increased tension  
in the spring as the idler arm is being rotated.  
Injury may result if the breaker bar is prematurely  
released while the spring is under tension.  
Figure 13. Mower PTO Belt  
A. Idler Arm  
B. Stationary Idler Pulley  
4. If the belt is not properly seated, use a 1/2” breaker  
bar, and place the square end in the square hole  
located in the end of the idler arm (A, Figure 13).  
Carefully rotate the breaker bar CLOCKWISE, which  
will relieve the tension on the belt exerted from the  
idler arm.  
B
48” Models  
D
C
5. Re-seat belt and carefully release the tension on the  
breaker bar.  
6. Reinstall the mower deck guards.  
A
A
D
A
Figure 14. Mower PTO Belt Routing  
A. Spindle Pulley  
B. Deck Drive Belt  
C. Spring-loaded Idler Pulley  
D. Stationary Idler Pulley  
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500Z 26HP - 48” Mower Deck  
Lubrication  
Lubricate the unit at the locations shown in Figure 15  
through18 as well as the following lubrication points.  
Grease:  
• front caster wheel axles and yokes  
• deck lift pivot blocks  
• mower deck spindles  
• mower deck idler arm  
Figure 15. Deck Lubrication  
Use grease fittings when present. Disassemble parts to  
apply grease to moving parts when grease fittings are  
not installed.  
Not all greases are compatible. Red Grease (p/n  
5022285) is recommended, automotive-type high-  
temperature, lithium grease may be used when this is  
not available.  
Oil:  
• control handle pivots  
• seat plate pivots  
• deck lift pivots  
• discharge chute hinge  
Figure 16. Control Handle Pivots & Seat Plate  
Pivots  
Generally, all the moving metal parts should be oiled  
where contact is made with other parts. Keep oil and  
grease off belts and pulleys. Remember to wipe the  
fittings and surfaces clean both before and after  
lubrication.  
Lubricating the Front Casters:  
NOTE: Front casters should be lubricated annually.  
1. Remove the 1/4-28 bolt (A, Figure 18) screwed into  
the front caster and install a 1/4-28 grease fitting.  
2. Grease the front caster.  
Figure 17. Deck Lift Linkage Pivots  
3. Remove the 1/4-28 grease fitting and reinstall the  
1/4-28 bolt.  
4. Repeat the process for the other side of the  
machine.  
A
Figure 18. Front Caster & Wheel  
A. 1/4-28 Bolt  
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500Z 26HP - 48” Mower Deck  
A
Adding Fuel  
To add fuel:  
1. Remove the fuel cap (A, Figure 19).  
2. Fill the tank to about 1-1/2” (3,81 cm) of the bottom of  
the filler neck. This will allow for fuel expansion.  
NOTE: Do not overfill. Refer to your engine manual for  
specific fuel recommendations.  
3. Install and hand tighten the fuel cap.  
Figure 19. Adding Fuel  
A. Fuel Cap  
Starting The Engine  
1. While sitting in the operator’s seat, engage the  
parking brake and make sure the PTO switch is  
disengaged and the ground speed control levers are  
locked in the NEUTRAL position.  
2. Set the engine throttle control to FULL throttle  
position. Then fully close the choke by pulling the  
knob OUT fully.  
3. Insert the key into the ignition switch and turn it to  
START.  
4. After the engine starts, gradually open the choke  
(push knob down fully). Reduce to half throttle speed  
and allow to warm up.  
Warm up the engine by running it for at least a minute  
before engaging the PTO switch or driving the rider.  
5. After warming the engine, ALWAYS operate the unit  
at FULL THROTTLE when mowing.  
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500Z 26HP - 48” Mower Deck  
Perform the  
Safety Checks  
SAFETY INTERLOCK  
SYSTEM  
WARNING  
This unit is equipped with safety interlock switches.  
These safety systems are present for your safety, do  
not attempt to bypass the safety switches, and never  
tamper with the safety devices. Check their operation  
regularly.  
Disengage the PTO, stop the engine, set the parking  
brake, and wait for moving parts to stop before  
leaving operator's position for any reason.  
If the tractor does not pass the test, do not  
operate tractor. Under no circumstance should  
you attempt to defeat the purpose of the safety  
system.  
Operational SAFETY Checks  
Test 1 — Engine should NOT crank if:  
Functional Tests  
1. Check the tractor for loose bolts, screws, nuts, etc.  
• PTO switch is engaged, OR  
• Parking brake is not engaged, OR  
2. Start the engine and check all the controls for proper  
operation: ground speed control levers, parking  
brake, throttle cable, electric PTO clutch, etc.  
• Ground speed control levers are not in the  
NEUTRAL position.  
Test 2 — Engine SHOULD crank if:  
3. Stop the engine and check for fluid leaks: oil, fuel  
and hydraulic oil.  
• PTO switch is NOT engaged, AND  
• Parking brake is engaged, AND  
4. If any control fails to operate properly during testing  
or seems to be out of adjustment, check and readjust  
it according to the following Adjustments section.  
• Ground speed control levers are locked in the  
NEUTRAL position.  
Test 3 — Engine should SHUT OFF if:  
• Operator rises off seat with PTO engaged, OR  
• Operator rises off seat with parking brake  
disengaged.  
• Operator moves ground speed control levers out of  
their neutral positions before disengaging parking  
brake.  
Test 4 — Blade Brake Check  
Mower blades and the mower drive belt should come to  
a complete stop within seven (7) seconds after the  
electric PTO switch is turned off (or the operator rises  
off seat). If the mower drive belt does not stop within  
seven (7) seconds, see your dealer.  
NOTE: Once the engine has stopped, PTO switch must  
be turned off, parking brake must be engaged, and the  
ground speed control levers must be locked in the  
NEUTRAL position after the operator returns to the seat  
in order to start the engine.  
WARNING  
If the unit does not pass a safety test, do not  
operate it. See your authorized dealer. Under no  
circumstance should you attempt to defeat the  
purpose of the safety interlock system.  
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500Z 26HP - 48” Mower Deck  
Adjustment  
Procedures  
Seat Adjustment  
See Figure 20. The seat can be adjusted forward and  
backward. Move the seat adjustment lever towards the  
left, position the seat as desired, and release the seat  
adjustment lever to lock the seat into position.  
A
Figure 20. Seat Adjustment  
A. Seat Adjustment Lever  
Ground Speed Control  
Adjustment  
B
The ground speed control levers can be adjusted in  
three ways. The alignment of the control levers, the  
placement of the levers (how close the ends are to one  
another) and the height of the levers can be adjusted.  
A
TO ADJUST THE HANDLE ALIGNMENT  
Loosen the mount bolts (A, Figure 21) and pivot the  
ground speed control lever(s) (B) to align with each  
other.  
TO ADJUST THE HANDLE PLACEMENT  
Loosen the jam nuts and adjust the placement bolt (C) in  
or out to properly adjust the ground speed control lever  
end spacing.  
C
TO ADJUST THE HANDLE HEIGHT  
Remove the mounting hardware and reposition the  
ground speed control lever either up or down from its  
original position. You will need to readjust the ground  
speed control lever alignment as described above.  
Figure 21. Control Lever Adjustment  
A. Placement Hardware  
B. Ground Speed Control Lever  
C. Alignment Hardware  
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500Z 26HP - 48” Mower Deck  
Return-To-Neutral  
Adjustment  
To determine if it is necessary to adjust the neutral  
return, perform the following steps.  
A
1. Disengage the PTO, engage the parking brake and  
turn off the engine.  
2. Move the ground speed control levers into the  
operating position, pull levers rearward and release.  
B
3. Move the ground speed control levers out towards  
the neutral position. If the levers do not align with  
the notches in the neutral lock plate, it is necessary  
to adjust the neutral return rod (B, Figure 22).  
It is important to note that after every adjustment of the  
neutral return rod, the lever must be pulled rearward and  
released to properly check the neutral position.  
Figure 22. Return-to-Neutral Adjustment  
A. Jam Nuts  
B. Neutral Return Rod  
WARNING  
To avoid serious injury, perform adjustments only  
with the engine stopped, the key removed and the  
tractor on level ground.  
ADJUSTMENT  
NOTE: Perform this adjustment on a hard, level surface  
such as a concrete floor.  
1. Disengage the PTO, engage the parking brake and  
turn off the engine.  
2. There are three nuts (B, Figure 22) on the neutral  
return rod. The first two are to be used together to  
turn the neutral return rod and the third (towards the  
front of the machine) is used to lock the neutral  
return rod in place. Loosen the jam nut that locks  
against the ball joint (B) and turn the neutral return  
rod (A) to adjust. If the machine creeps forward, turn  
the neutral return rod CLOCKWISE (while standing  
at the rear of the machine, facing forward), if the  
machine creeps backward, turn the neutral return rod  
COUNTER-CLOCKWISE.  
3. Lock the jam nut (B) against the ball joint when  
neutral is achieved.  
NOTE: This adjustment should not be performed while  
the machine is running. It may take several attempts to  
achieve neutral, depending upon how much the machine  
creeps.  
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500Z 26HP - 48” Mower Deck  
Parking Brake  
Adjustment  
C
B
D
1. Disengage the PTO, stop the engine, engage the  
parking brake, and remove the key from the ignition.  
E
A
2. Raise the seat plate to gain access to the parking  
brake components.  
3. Measure the distance from the top of the brake  
spring rod (C, Figure 23) to the top of the lock nut  
(D) on both sides of the unit. The measurement  
should be .50” (1,27 cm). If not, adjust the locknut to  
achieve the measurement of .50” (1,27 cm)  
G
F
4. Measure the distance between the bottom of the  
brake shaft weldment (G) and the top of the set  
collar (F). The measurement should be .375” (0,95  
cm). If not, position the set collar until the  
measurement equals .375” (0,95 cm).  
Figure 23. Parking Brake Adjustment  
A. Brake Spring  
B. First Measurement - .50” (1,27 cm)  
C. Brake Spring Rod  
D. Lock Nut  
E. Second Measurement - .375” (0,95 cm)  
F. Set Collar  
G. Brake Shaft Weldment  
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500Z 26HP - 48” Mower Deck  
PRODUCTS, INC.  
535 Macon Street  
McDonough, GA., 30253  
The Snapper logo is a trademark of Briggs & Stratton  
Corporation, Milwaukee, WI, USA  
Briggs & Stratton Yard Power Products Group  
Copyright © 2008 Briggs & Stratton Corporation  
Milwaukee, WI, USA. All rights reserved.  
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