Z525E, Z535M, Z535R, Z540M
and Z540R ZTrak™
OPERATOR'S MANUAL
Z500 Series ZTrak™
OMGX26263 ISSUE F5 (ENGLISH)
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
birth defects, and other reproductive harm.
If this product contains a gasoline engine:
WARNING
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects or other reproductive harm.
The State of California requires the above two warnings.
Additional Proposition 65 Warnings can be found in this manual.
John Deere Power Products
North American Edition
Printed in U.S.A.
Contents
Contents
Product Identification
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Product Identification . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety Labels Text . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety Labels No Text . . . . . . . . . . . . . . . . . . . . . . . 7
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Machine Cleanout . . . . . . . . . . . . . . . . . . . . . . . . . 14
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Operating Controls. . . . . . . . . . . . . . . . . . . . . . . . . 17
Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Service Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Service Lubrication . . . . . . . . . . . . . . . . . . . . . . . . 29
Service Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Service Transmission. . . . . . . . . . . . . . . . . . . . . . . 38
Service Mower. . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Service Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . 46
Service Miscellaneous . . . . . . . . . . . . . . . . . . . . . . 47
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Getting Quality Service. . . . . . . . . . . . . . . . . . . . . . 57
Service Record . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Slope Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Record Identification Numbers
Zero Turn Mowers
PIN (010001-)
If you need to contact an Authorized Service Center for information on
servicing, always provide the product model and identification numbers.
You will need to locate the model and serial number for the machine,
engine and transmission/transaxle of your machine and record the
information in the spaces provided below.
DATE OF PURCHASE:
_________________________________________
DEALER NAME:
_________________________________________
DEALER PHONE:
_________________________________________
GXT002512—UN—15JUL15
Product Identification Number (A):
__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
Engine Serial Number:
All - On engine blower housing.
__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
Original Instructions. All information, illustrations and specifications in this
manual are based on the latest information available at the time of
publication.
Transaxle Serial Numbers:
S/N tag on forward side of each transaxle housing.
LEFT SIDE:
The right is reserved to make changes at any time without notice.
__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
RIGHT SIDE:
__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
Register Your Product and Warranty Online
To register your product through the Internet, simply go to www.
JohnDeereWarrantyRegistration.com. Completing the information,
either online or with the product warranty card, will ensure the customer
COPYRIGHT © 2015
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION © Manual
3
Safety Labels Text
that their product receives all post sales service and important product
information.
Safety Labels Text
Safety Label Location
GXT002421—UN—15JUL15
Z540R Model Shown
D — DANGER M139128
A — WARNING M146577
B — DANGER, CAUTION, WARNING M172427
C — DANGER M118610
E — DANGER M156388
On your machine safety labels, the words DANGER, WARNING, and
CAUTION are used with this safety-alert symbol. DANGER identifies
the most serious hazards.
Understanding The Machine Safety Labels
The operator’s manual also explains any potential safety hazards
whenever necessary in special safety messages that are identified with
the word, CAUTION, and the safety-alert symbol.
Replace missing or damaged safety labels. Use this operator’s manual
for correct safety label placement.
There can be more safety information contained on parts and
components sourced from suppliers that is not reproduced in this
operator’s manual.
MXAL42363—UN—22MAY13
The machine safety labels shown in this section are placed in important
areas on your machine to draw attention to potential safety hazards.
4
Safety Labels Text
French or Spanish Safety Labels and Operator’s Manual
Operator’s manuals and safety labels with content in French or Spanish
are available for this machine through authorized John Deere dealers.
See your John Deere dealer.
NOTE: Both text and no-text labels are shown. Your machine is only
equipped with one of these types of labels.
WARNING
MXAL42769—UN—09APR13
•
To avoid injury from loaded spring, read operator’s manual before
changing attachments.
DANGER
GXT002171—UN—04JUN15
ROTATING BLADES CUT OFF ARMS AND LEGS
•
•
•
•
Do not mow when children or others are around.
Do not mow in reverse.
Look down and behind before and while backing.
Never carry children even while blades are off.
5
Safety Labels Text
CAUTION
DANGER
Avoid equipment fires.
Accumulation of grass, leaves and debris on or near hot or moving
parts can cause a fire.
Inspect machine before, during and after use.
Shut off engine and allow machine to cool before cleaning.
For clean-out locations refer to service label.
MXAL42773—UN—09APR13
To avoid injury from rotating blades and thrown objects:
WARNING
•
Keep hands and feet away from rotating blades. Keep bystanders a
safe distance away. Do not operate mower without discharge chute
or entire grass catcher in place.
DANGER
MXAL42770—UN—09APR13
ROTATING BLADE
•
Do not put hands or feet under or into mower when engine is
running.
THROWN OBJECTS
GXT002172—UN—04JUN15
•
•
Before mowing, clear area of objects that may be thrown by blade.
AVOID SERIOUS INJURY OR DEATH
Do not operate mower without discharge chute or entire grass
catcher in place.
•
•
•
•
Read operator’s manual.
Drive across slopes, not up and down.
If machine stops going uphill, stop blade and back down slowly.
DO NOT OPERATE MOWER WITHOUT DISCHARGE CHUTE OR
THE ENTIRE GRASS CATCHER IN PLACE.
Keep safety devices (guards, shields, and switches) in place and
working.
•
•
•
Remove objects that can be thrown by blade.
Avoid sudden turns.
When leaving machine:
- Stop engine
- Lock park brake
- Remove key
DANGER
MXAL42774—UN—09APR13
ROTATING BLADE
•
Do not put hands or feet under or into mower when engine is
running.
6
Safety Labels No Text
Safety Labels No Text
Safety Label Location
GXT002330—UN—15JUL15
A — Avoid Injury From Loaded Spring M146577
B — Read Operator’s Manual, Avoid Injury From Thrown Objects, Keep Children Away
From Mower, Avoid Injury From Tipping M172428
C — Avoid Injury From Thrown Objects, Avoid Injury From Rotating Blades M138631
D — Prevent Equipment Fires GX24573
Understanding The No-Text Machine Safety
Labels
Avoid Injury From Loaded Spring
TCT005498—UN—11SEP12
At several important places on this machine safety signs are affixed
intended to signify potential danger. The hazard is identified by a
pictorial in a warning triangle. An adjacent pictorial provides information
how to avoid personal injury. These safety signs, their placement on the
machine and a brief explanatory text are shown in this Safety section.
MXAL42777—UN—09APR13
There can be additional safety information contained on parts and
components sourced from suppliers that is not reproduced in this
operator’s manual.
•
•
Keep fingers and hands away from pinch point.
Read operator’s manual.
7
Safety Labels No Text
Read Operator’s Manual
Avoid Injury From Tipping
MXAL42776—UN—09APR13
MXAL42779—UN—09APR13
•
•
This operator’s manual contains important information necessary for
safe machine operation.
•
•
Do not drive where machine could slip, tip, or rollover.
In some configurations, do not drive or operate on a slope of more
than 10 degrees.
Carefully read operator’s manual before operating machine.
Observe all safety rules to avoid accidents.
•
Refer to the Operating on Slopes section for more information.
Avoid Injury From Thrown Objects
Avoid Injury From Rotating Blades
MXAL42784—UN—09APR13
•
•
Do not put hands or feet under or into mower when engine is
running.
MXAL42780—UN—09APR13
Do not operate mower without discharge chute or entire grass
catcher in place.
•
Keep a safe distance from the machine as long as the engine is
running.
Prevent Equipment Fires
Keep Children Away from Mower
MXAL42778—UN—09APR13
MXAL42781—UN—09APR13
•
•
•
Mower can cause dismemberment or death.
Stay a safe distance from the machine.
•
•
Clean and inspect the entire machine.
Carefully read Operator’s Manual Machine Cleanout section for
details.
Make sure that children stay clear of mower at all times when the
engine is running.
8
Safety
•
•
•
Make sure spark plug, muffler, fuel cap and air cleaner are in place
before starting the engine.
Safety
Be sure all drives are in neutral and parking brake is locked before
starting engine. Only start engine from the operator’s position.
Operating Safely
Do not change the engine governor settings or overspeed the
engine. Operating the engine at excessive speed can increase the
hazard of personal injury.
•
•
If you hit an object or if abnormal vibration occurs, stop the machine
and inspect it. Make repairs before you operate.
Use only accessories and attachments approved by the
manufacturer of the machine. Keep safety labels visible when
installing accessories and attachments.
GXAL42347—UN—04MAR13
This cutting machine is capable of amputating hands and feet and
throwing objects. Failure to observe the following safety instructions
could result in serious injury or death.
•
•
Do not wear radio or music headphones. Safe service and operation
requires your full attention.
When machine is left unattended, stored, or parked, lower the
mower deck unless a positive mechanical lock is used.
•
Read, understand and follow all instructions on the machine and in
manuals provided, and view safety video, before starting. Be
thoroughly familiar with the controls and the proper use of the
machine before starting.
Using a Spark Arrestor
The California Public Resources Code, section 4442.5 provides as
follows:
•
•
Do not put hands or feet near rotating parts or under the machine.
Keep clear of the discharge opening at all times.
Only allow responsible adults, who are familiar with the instructions,
to operate this machine. Local regulations may restrict the age of the
operator.
No person shall sell, offer for sale, lease, or rent to any person any
internal combustion engine subject to Section 4442 or 4443, and not
subject to Section 13005 of the Health and Safety Code, unless the
person provides a written notice to the purchaser or bailee, at the time
of sale or at the time of entering into the lease or rental contract, stating
that it is a violation of Section 4442 or 4443 to use or operate the engine
on any forest-covered, brush-covered, or grass-covered land unless
the engine is equipped with a spark arrestor, as defined in Section
4442, maintained in effective working order or the engine is
•
•
Clear the area of objects such as rocks, wire and toys which could
be thrown by the blades.
Be sure the area is clear of bystanders before operating. Stop
machine if anyone enters the area.
•
•
Never carry passengers.
Do not mow in reverse unless absolutely necessary. Always look
down and behind before and while backing.
constructed, equipped, and maintained for the prevention of fire
pursuant to Section 4443. Cal. Pub. Res. Code 4442.5.
•
•
Never direct discharged material toward anyone. Avoid discharging
material against a wall or obstruction. Material may ricochet back
toward the operator. Stop the blades when crossing gravel surfaces.
Other states or jurisdictions may have similar laws. A spark arrestor for
your machine may be available from your authorized dealer. An
installed spark arrestor must be maintained in good working order by
the operator.
Do not operate the machine without the entire grasscatcher,
discharge guard, or other safety devices in place and working. Never
operate with the discharge deflector raised, removed, or altered,
unless using a grasscatcher.
Checking Mowing Area
•
•
Slow down before turning.
Never leave a running machine unattended. Always turn off blades,
lock park brake, stop engine and remove key before dismounting.
•
Disengage blades when not mowing. Shut off engine and wait for all
parts to come to a complete stop before cleaning the machine,
removing the grasscatcher, or unclogging the discharge chute.
•
•
Operate machine only in daylight or good artificial light.
Do not operate the machine while under the influence of alcohol or
drugs.
MXAL41932—UN—22MAY13
•
•
•
•
Watch for traffic when operating near or crossing roadways. Stop
blades before crossing roads or sidewalks.
•
•
Clear mowing area of objects that might be thrown. Keep people and
pets out of mowing area.
Use extra care when loading or unloading the machine into a trailer
or truck.
Low-hanging branches and similar obstacles can injure the operator
or interfere with mowing operation. Before mowing, identify potential
obstacles such as low-hanging branches, and trim or remove those
obstacles.
Always wear safety goggles or safety glasses with side shields when
operating machine.
Data indicates operators 60 years and above are involved in a large
percentage of riding mower-related injuries. These operators should
evaluate their ability to operate the riding mower safely enough to
protect themselves and others from serious injury.
•
•
•
Study mowing area. Set up a safe mowing pattern. Do not mow
where traction or stability is doubtful.
Test drive area with mower lowered (if equipped) but not running.
Slow down when you travel over rough ground.
•
•
Follow the manufacturer’s recommendation for wheel weights or
counterweights.
Survey all mowing sites to determine which slopes are safe for
machine operation and which slopes should be maintained through
other maintenance techniques.
Inspect machine before you operate. Be sure hardware is tight.
Repair or replace damaged, badly worn, or missing parts. Be sure
guards and shields are in good condition and fastened in place.
Make any necessary adjustments before you operate.
Parking Safely
•
Before using, always visually inspect to see that the blades, blade
bolts and the mower assembly are not worn and damaged. Replace
worn and damaged blades and bolts in sets to preserve balance.
1. Stop machine on a level surface, not on a slope.
2. Disengage mower blades or any other attachments.
3. Lower attachments to the ground.
9
Safety
4. Lock the park brake.
5. Stop the engine.
6. Remove the key.
•
Never carry children on a machine or attachment, even with the
blades off. Do not tow children in a cart or trailer. They can fall off and
be seriously injured or interfere with safe machine operation.
•
•
Never use the machine as a recreational vehicle or to entertain
children.
7. Wait for engine and all moving parts to stop before you leave the
operator’s seat.
Never allow children or an untrained person operate the machine.
Instruct all operators not to give children a ride on the machine or in
an attachment.
8. Close fuel shut-off valve, if your machine is equipped.
9. Disconnect the negative battery cable or remove the spark plug
wire(s) (for gasoline engines) before servicing the machine.
•
•
•
Keep children indoors, out of the mowing area, and in the watchful
eye of a responsible adult, other than the operator, when a mower is
being operated.
Stay alert to the presence of children. Never assume that children
will remain where you last saw them. Turn the machine off if a child
enters the work area.
Rotating Blades are Dangerous
Use extreme care when approaching blind corners, shrubs, trees, or
other objects that may block your view of a child.
Operating on Slopes
MXAL41928—UN—18FEB13
NOTE: Use the Slope Gauge Template provided in the back of this
operators manual. Follow the instructions included with the
template.
HELP PREVENT SERIOUS OR FATAL ACCIDENTS:
•
•
•
Rotating blades can cut off arms and legs, and throw objects. Failure
to observe safety instructions could result in serious injury or death.
•
Slopes are a major factor related to loss-of-control and tipover
accidents, which can result in severe injury or death. Operation on all
slopes requires extra caution.
Keep hands, feet and clothing away from mower deck when engine
is running.
Identify Slopes for Safe Operation
Be alert at all times, drive forward and in reverse carefully. People,
especially children can move quickly into the mowing area before
you know it.
•
Follow safe procedures for operation on slopes. Measure slopes of
all moving sites to determine which slopes are safe for mowing with
a ride-on mower. Always use common sense and good judgement
when performing this survey.
•
Before backing up, stop mower blades or attachments and look
down and behind the machine carefully, especially for children.
•
•
•
Do not mow in reverse.
Measuring Slopes
Shut off blades when you are not mowing.
•
Suggested Method 1: Lay a straight piece of sturdy lumber 1.2 m (4
ft) long on the slope and measure the angle of the slope with an
angle indicator or protractor level.
Park machine safely before leaving the operator’s station for any
reason including emptying the grasscatchers or unplugging the
chute.
•
Suggested Method 2: Refer to the slope gauge provided at the end
of this manual.
•
The mower blades should stop in approximately five seconds when
the mower is disengaged. If you believe that your blades may not be
stopping in that period of time, take your machine to your authorized
dealer where they can safely check and service your machine.
Operate Safely on Slopes
•
Exceeding the recommended maximum slope angle increases the
risk of rollover accidents that can result in serious injury or death.
Protect Children
•
Never mow or operate ride-on mower on slope angles greater than
13° with the lawn ride-on mower in its basic configuration. The basic
configuration is the ride-on mower with mower deck and not other
attachments. (A 13° slope is a slope that rises 1.4 m (4.6 ft) over a
horizontal distance of 6.1 m (20 ft).)
•
When using attachments, never mow or operate the ride-on mower
on slope angles greater than 10°. The addition of a weather
enclosure, material collection system, or other attachments will
increase the risk of a rollover. (A 10° slope is a slope that rises 1 m
(3.5 ft) over a horizontal distance of 6.1 m (20 ft).)
•
•
On slope angles of 10° or less, the risk of rollover is low, but as the
slope angle increases to the recommended maximum, the risk
increases to a medium level.
MXAL41929—UN—18FEB13
•
•
•
•
Death or serious injury can occur when young children associate
having fun with a lawn mowing machine simply because someone
has given them a ride on a machine.
Always consider potential turf conditions and slope angles when
determining the risk of loss-of-control and tip-over accidents.
•
•
•
•
Drive slowly when mowing or operating on slopes.
If you feel uneasy on a hillside, do not mow or operate on it.
Mow across slopes, not up and down.
Children are attracted to lawn mowing machines and mowing
activities. They don’t understand the dangers of rotating blades or
the fact that the operator is unaware of their presence.
Children who have been given rides in the past may suddenly
appear in the mowing area for another ride and be run over or
backed over by the machine.
Watch for holes, ruts, bumps, rocks, or other hidden objects. Uneven
terrain could overturn the ride-on mower. Tall grass can hide
obstacles.
Tragic accidents with children can occur if the operator is not alert to
the presence of children, especially when a child approaches a
machine from behind. Before and while backing up, stop mower
blades and look down and behind the machine carefully, especially
for children.
•
•
Drive slowly so you will not have to stop while on a slope.
Do not mow on wet grass. Tires may lose traction. Tires may slip on
slopes even though the brakes are functioning properly.
10
Safety
•
•
Avoid starting, stopping or turning on a slope. If the tires lose
traction, disengage the PTO and proceed slowly, straight down the
slope.
Keep all movement on slopes slow and gradual. Do not make
sudden changes in speed or direction, which could cause the ride-on
mower to roll over.
MXT005363—UN—10JUL13
11
Safety
Operating Near Hazards
•
Excessive towed load can cause loss of traction and loss of control
on slopes. Reduce towed weight when operating on slopes.
•
•
Never allow children or others in or on towed equipment.
Use only approved hitches. Tow only with a machine that has a hitch
designed for towing. Do not attach towed equipment except at the
approved hitch point.
•
•
•
•
Follow the manufacturer’s recommendations for weight limits for
towed equipment and towing on slopes.
Towed attachments will increase the risk of rollover. Refer to the
“Operating on Slopes” section for more information.
Do not turn sharply. Use additional caution when turning or operating
under adverse surface conditions. Use care when reversing.
Do not shift to neutral and coast downhill.
Wear Appropriate Clothing
MXAL41935—UN—18FEB13
•
•
Always wear eye protection when operating the machine.
Wear close fitting clothing and safety equipment appropriate for the
job.
GXAL41966—UN—04MAR13
Example side view of slope and hazards, showing areas (A), (B), and (C).
•
•
While operating this machine, always wear substantial footwear and
long trousers. Do not operate the equipment when barefoot or
wearing open sandals.
•
•
Do not mow or operate machine in areas adjacent to hazards that
may cause the machine to roll over. The machine could suddenly
lose traction, slide, and/or roll over if a wheel goes over the edge or if
the edge breaks away.
Wear a suitable protective device such as earplugs. Loud noise can
cause impairment or loss of hearing.
Hazards (A) include but are not limited to:
- Drop-offs, ditches, embankments, or bodies of water.
Driving Safely on Public Roads
- Areas of unsafe slope, soft ground, edges along bodies of water,
or area with holes, ruts, bumps, or other hidden objects.
•
•
•
Maintain a buffer area (B) at least as wide as the machine between
hazards (A) and the mowing area (C). Do not mow or operate the
machine in the hazard area or buffer area.
Only mow or operate the machine in the mowing area (C). Do not
exceed the recommended slope operating angle. Refer to the
"Operate Safely on Slopes" section.
MXAL42880—UN—26MAR13
Use a walk-behind mower or string trimmer in and around areas (A)
and (B).
Avoid personal injury or death resulting from a collision with another
vehicle on public roads:
•
Use safety lights and devices. Slow moving machines when driven
on public roads are hard to see, especially at night.
Keep Riders Off
•
Whenever driving on public roads, use flashing warning lights and
turn signals according to local regulations. Extra flashing warning
lights may need to be installed.
Practice Safe Maintenance
MXAL41930—UN—18FEB13
•
•
Only allow the operator on the machine. Keep riders off.
Riders on the machine or attachment may be struck by foreign
objects or thrown off the machine causing serious injury.
•
Riders obstruct the operator’s view resulting in the machine being
operated in an unsafe manner.
MXAL41933—UN—18FEB13
•
•
•
Only qualified, trained adults should service this machine.
Understand service procedure before doing work.
Towing Loads Safely
•
Stopping distance increases with speed and weight of towed load.
Travel slowly and allow extra time and distance to stop.
Never operate machine in a closed area where dangerous carbon
monoxide fumes can collect.
•
Total towed weight must not exceed combined weight of pulling
machine, ballast and operator. Use counterweights or wheel weights
as described in the attachment or pulling machine operator’s
manual.
Keep all nuts and bolts tight, especially blade attachment bolts, to be
sure the equipment is in safe working condition.
12
Safety
•
•
Never tamper with safety devices. Check their proper operation
regularly.
•
If an accident occurs, see a doctor immediately. Any fluid injected
into the skin must be surgically removed within a few hours or
gangrene may result. Doctors unfamiliar with this type of injury
should reference a knowledgeable medical source. Such information
is available from Deere & Company Medical Department in Moline,
Illinois, U.S.A. Information may be obtained in the United States and
Canada only by calling 1-800-822-8262.
Keep machine free of grass, leaves or other debris build-up. Clean
up oil or fuel spillage and remove any fuel-soaked debris. Allow the
machine to cool before storing.
•
•
If you strike a foreign object, stop and inspect the machine. Repair, if
necessary, before restarting.
Never make any adjustments or repairs with the engine running.
Wait for all movement to stop on machine before adjusting, cleaning
or repairing.
Prevent Fires
•
Please review these recommendations with all operators. See your
John Deere dealer with questions.
•
•
Check grasscatcher components and the discharge guard frequently
and replace with manufacturer’s recommended parts, when
necessary. Grasscatcher components are subject to wear, damage,
and deterioration which could expose moving parts or allow objects
to be thrown.
•
Always follow all safety procedures posted on the machine and in
this operator manual. Before carrying out any inspection or cleaning
always shut off engine, set parking brake and remove ignition key.
•
•
Besides routine maintenance, one of the best ways to keep your
John Deere equipment running efficiently and to reduce fire risk is to
regularly remove debris buildup from the machine.
Mower blades are sharp. Wrap the blade or wear gloves, and use
extra care when servicing them. Only replace blades. Never
straighten or weld them.
After operating, allow machine to cool in an open area before
cleaning or storing. Do not park machine near flammable materials
such as wood, cloth or chemicals, or near an open flame or other
sources of ignition, such as a water heater or furnace.
•
•
•
Check brake operation frequently. Adjust and service as required.
Maintain or replace safety and instruction labels, as necessary.
On multi-bladed machines, take care as rotating one blade can
cause other blades to rotate.
•
•
Completely remove any combustible materials from equipment
before storing, by emptying any grass catcher bags, containers and
cargo boxes.
•
•
Keep hands, feet, clothing, jewelry, and long hair away from any
moving parts, to prevent them from getting caught.
Debris can accumulate anywhere on the machine, especially on
horizontal surfaces. Remove grass and debris completely from
engine compartment, muffler area, and from on top of the mower
deck both before and after operating machine. Additional cleaning
may be necessary when mowing or mulching in dry conditions.
Lower any attachments to the ground before cleaning or servicing
machine. Disengage all power and stop the engine. Lock park brake
and remove the key. Let machine cool.
•
•
•
Securely support any machine elements that must be raised for
service work. Use jack stands or lock service latches to support
components when needed.
•
•
In addition to cleaning machine before using and storing, keeping
engine area clean provides the greatest impact on fire prevention.
Other areas requiring regular inspection and cleaning include behind
wheel rims, wire harness, hose or line routing, mowing attachments,
etc. Compressed air, leaf blowers, or high pressured water assists in
keeping these areas clean.
Disconnect battery or remove spark plug wire (for gasoline engines)
before making any repairs. Disconnect negative terminal first and
positive last. Install positive terminal first and negative last.
Before servicing machine or attachment, carefully release pressure
from any components with stored energy, such as hydraulic
components or springs.
Frequency of these inspections and cleaning will vary depending on
a number of factors including operating conditions, machine
configuration, operating speeds and weather conditions particularly
dry, hot and windy conditions. When you are operating in these
conditions, inspect and clean these areas frequently throughout the
day.
•
•
Keep all parts in good condition and properly installed. Fix damage
immediately. Replace worn or broken parts.
Charge batteries in an open, well-ventilated area, away from sparks.
Unplug battery charger before connecting or disconnecting from the
battery. Wear protective clothing and use insulated tools.
•
•
Excess lubrication or fuel/oil leaks or spills on the machine can also
serve as collection sites for debris. Prompt machine repair and oil
and fuel clean-up reduces the potential for debris collection.
•
•
Do not strike the flywheel with a hammer or hard object because the
flywheel may later shatter during operation.
Bearing failures or overheating can result in a fire. To reduce this
risk, always follow the instructions in the machine operator’s manual
regarding lubrication intervals and locations. Contact your local
dealer if you have any questions about the lubrication intervals or
location and if any unusual noises are coming from areas where
bearings might be located. Washing the machine while warm may
also reduce bearing life and increase potential for premature bearing
failure.
If equipped with hydraulic lift - release hydraulic pressure by lowering
attachment or cutting units to the ground or to a mechanical stop and
move hydraulic control levers back and forth.
Avoid High Pressure Fluids
•
•
Always shut off fuel when storing or transporting machine, if the
machine has a fuel shutoff.
Check fuel lines, tank, cap, and fittings frequently for cracks or leaks.
Replace if necessary.
MXAL41927—UN—18FEB13
•
Hydraulic hoses and lines can fail due to physical damage, kinks,
age, and exposure. Check hoses and lines regularly. Replace
damaged hoses and lines.
•
•
Hydraulic fluid connections can loosen due to physical damage and
vibration. Check connections regularly. Tighten loose connections.
Escaping fluid under pressure can penetrate the skin causing
serious injury. Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten all connections before
applying pressure.
•
Search for leaks with a piece of cardboard. Protect hands and body
from high pressure fluids.
13
Machine Cleanout
•
Always maintain the correct tire pressure. Do not inflate the tires
Handling Fuel Safely
above the recommended pressure. Never weld or heat a wheel and
tire assembly. The heat can cause an increase in air pressure
resulting in a tire explosion. Welding can structurally weaken or
deform the wheel.
•
•
When inflating tires, use a clip-on chuck and extension hose long
enough to allow you to stand to one side and NOT in front of or over
the tire assembly.
Check tires for low pressure, cuts, bubbles, damaged rims or
missing lug bolts and nuts.
Checking Wheel Hardware
•
•
•
A serious accident could occur causing serious injury if wheel
hardware is not tight.
Check wheel hardware tightness often during the first 100 hours of
operation.
MXAL41938—UN—18FEB13
Wheel hardware must be tightened to specified torque using the
proper procedure anytime it is loosened.
To avoid personal injury or property damage, use extreme care in
handling fuel. Fuel is extremely flammable and fuel vapors are
explosive:
Handling Waste Product and Chemicals
Waste products, such as, used oil, fuel, coolant, brake fluid, and
batteries, can harm the environment and people:
•
•
Extinguish all cigarettes, cigars, pipes, and other sources of ignition.
Use only an approved fuel container. Use only non-metal, portable
fuel containers approved by the Underwriter’s Laboratory (U.L.) or
the American Society for Testing & Materials (ASTM). If using a
funnel, make sure it is plastic and has no screen or filter.
•
•
•
Do not use beverage containers for waste fluids - someone may
drink from them.
See your local Recycling Center or authorized dealer to learn how to
recycle or get rid of waste products.
•
•
•
Never remove the fuel tank cap or add fuel with the engine running.
Allow engine to cool before refueling.
A Material Safety Data Sheet (MSDS) provides specific details on
chemical products: physical and health hazards, safety procedures,
and emergency response techniques. The seller of the chemical
products used with your machine is responsible for providing the
MSDS for that product.
Never add fuel to or drain fuel from the machine indoors. Move
machine outdoors and provide adequate ventilation.
Clean up spilled fuel immediately. If fuel is spilled on clothing,
change clothing immediately. If fuel is spilled near machine, do not
attempt to start the engine but move the machine away from the area
of spillage. Avoid creating any source of ignition until fuel vapors
have dissipated.
•
•
•
•
•
Never store the machine or fuel container where there is an open
flame, spark, or pilot light such as on a water heater or other
appliance.
Machine Cleanout
Cleanout Areas
Prevent fire and explosion caused by static electric discharge. Static
electric discharge can ignite fuel vapors in an ungrounded fuel
container.
NOTE: Also see machine Service Label.
Never fill containers inside a vehicle or on a truck or trailer bed with a
plastic liner. Always place containers on the ground away from your
vehicle before fueling.
Primary areas that must be inspected and cleaned on the machine
include:
Remove fuel-powered equipment from the truck or trailer and refuel it
on the ground. If this is not possible, then refuel such equipment with
a portable container, rather than from a fuel dispenser nozzle.
1. Exhaust manifold, muffler pipes, muffler and muffler shield.
Keep the nozzle in contact with the rim of the fuel tank or container
opening at all times until the fueling is complete. Do not use a nozzle
lock-open device.
•
•
•
Never overfill fuel tank. Replace fuel tank cap and tighten securely.
Replace all fuel container caps securely after use.
For gasoline engines, do not use gas with methanol. Methanol is
harmful to your health and to the environment.
Tire Safety
MXAL41937—UN—18FEB13
Explosive separation of a tire and rim parts can cause serious injury or
death:
•
Do not attempt to mount a tire without the proper equipment and
experience to perform the job.
14
Assembly
GXT002176—UN—05JUN15
GXT002174—UN—05JUN15
4. On or near transaxles (F) and belt drives and fins.
2. Engine intake screens, both rotating (A) and fixed (B). Cooling fins
(C), and oil cooler (if equipped).
GXT002177—UN—05JUN15
5. Under the seat and near fuse block (G), including the battery (H) and
wiring harness.
GXT002175—UN—05JUN15
3. Top of mower deck, under shields (D), including spindle and belt area
(E).
Assembly
Charge and Connect Battery
CAUTION: Avoid injury! The battery produces a flammable
and explosive gas. The battery may explode:
•
•
•
Do not smoke or have open flame near battery.
Wear eye protection and gloves.
Never check battery charge by placing a metal object
across the posts. Use a voltmeter or hydrometer.
•
Do not jump start or charge a frozen battery. Warm
battery to specification.
Specification
Battery — Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16°C (60°F)
1. Remove and discard the red positive (+) protective cap from the
positive (+) battery terminal.
2. Charge the battery.
•
Battery is fully charged at 12.6 volts.
15
Assembly
3. Connect positive (+) battery cable to battery.
4. Connect negative (–) battery cable.
5. Apply general purpose grease or silicone spray to terminal to help
prevent corrosion.
6. Slide red cover over positive battery cable.
Install Seat
Z535M and Z540M Models
NOTE: Z535M and Z540M models are shipped with back of seat in a
horizontal position for shipping only. Do not operate machine
with seat in this horizontal position.
GXT002178—UN—05JUN15
1. Move the left (A) and right (B) motion levers toward the outside of
the machine.
2. Rotate the seat until the seat bottom (C) is in a vertical position.
3. Lift the L-pin handle (D) up and slide it toward the outside of the
machine. Insert the free end of the seat tether into the opening slot
(E) of the machine cover.
4. Push the L-pin through the tether loop and push the L-pin handle
down into the snap-lock groove in the cover.
GXT002404—UN—15JUL15
1. Remove rear bolt (A) and discard plastic washer from each side of
seat bracket (B).
Check Tire Pressure
Check tire pressure. (See Checking Tire Pressure in the SERVICE
MISCELLANEOUS section.)
2. Loosen front bolt (C) on each side of seat bracket.
3. Lift seat back to operating position and insert bolts removed earlier
into holes (D) on each side of seat.
Install Hitch (Z535R and Z540R Only)
Install hitch. See HITCH KIT INSTALLATION INSTRUCTIONS included
with kit.
4. Tighten four bolts to specification.
Specification
Seat Hardware — Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N·m (18 lb-ft)
Z535R and Z540R Models
Install and Level Mower Deck
Install and level mower deck. See Mower, Installing Deck in the
SERVICE MOWER Section and Mower, Adjusting Level in the
OPERATING Section.
NOTE: Z535R and Z540R models are shipped with the seat rotated
forward and resting on the front platform for shipping only. Do
not operate machine with seat in this rotated position.
Adjust Mower Deck Level
Adjust mower deck level. (See Adjusting Mower Deck Level in the
OPERATING section.)
Check Engine Oil Level
Check engine oil level. (See Checking Engine Oil Level in the
SERVICE ENGINE section.)
Check Machine Safety System
Perform safety system check to make sure the electronic safety
interlock circuit is functioning properly. Perform all tests. (See Testing
Safety System in the OPERATING section.)
16
Operating Controls
Check Transmission Oil Level
Check Transmission Oil Level (see Checking Transaxle Oil Level in the
SERVICE TRANSMISSION section)
Operating Controls
17
Operating
Operator Station Controls
GXT002420—UN—15JUL15
A — Park Brake Lever
G — Ignition Key Switch
H — Mower Engagement Switch
— Choke Control Lever
J — Throttle Control Lever
K — Hourmeter
B — Left Motion Control Lever
C — Right Motion Control Lever
D — Mower Deck Lift Pedal (If Equipped)
E — Mower Deck Lift Lever
F — Deck Height Pin
I
L — Fuel Tank Cap
❏ Check engine oil level.
❏ Remove grass and debris from engine compartment and muffler
area, and on top of mower deck, before and after operating machine.
Operating
❏ Remove debris from engine fixed and rotating screens.
❏ Check transaxle oil level - sight on reservoir.
❏ Clean air intake screen.
Daily Operating Checklist
❏ Test safety systems.
❏ Check fuel level. (See SERVICE MISCELLANEOUS section, Using
Proper Fuel and Stabilizer)
❏ Check area below machine for leaks.
18
Operating
❏ Clean mower deck with water using washout port after each use.
2. Slide seat forward or rearward to desired position.
3. Release lever.
Avoid Damage to Plastic and Painted
Surfaces
Adjusting Armrests (If Equipped)
•
•
•
•
Do not wipe plastic parts unless rinsed first. Using a dry cloth may
cause scratches.
Insect repellent spray may damage plastic and painted surfaces. Do
not spray insect repellent near machine.
Be careful not to spill fuel on machine. Fuel may damage surface.
Wipe up spilled fuel immediately.
Prolonged exposure to sunlight will damage some surfaces.
Mounting and Dismounting Machine
GXT002181—UN—05JUN15
1. Raise each armrest (A).
2. Turn adjustment knob (B) clockwise to lower armrest and
counterclockwise to raise armrest. Lower armrests.
GXT002179—UN—05JUN15
•
Do not step on the mower deck when mounting and dismounting the
machine.
Adjusting Motion Control Levers
1. Park machine safely. (See Parking Safely in the SAFETY section.)
•
•
Mount the machine from front (A).
Park machine safely before dismounting (see Parking Safely in the
SAFETY section).
•
Keep the foot plate clean.
Adjusting Seat
GXT002159—UN—03JUN15
2. To adjust motion control lever height, refer to the operator
instruction label on the machine front panel and the instructions
that follow.
GXT002180—UN—30JUL15
1. Slide lever (A) sideways to the left.
19
Operating
•
Z500 Series with 48A, 54A or 62C Mower Decks: Lift slightly
on mower deck lift lever, pull lever slightly toward center, and
lower lift lever (A) onto pin (C).
•
Z500 Series with 48HC, 54HC or 60 HC Mower Decks: Place
foot on lift pedal (B) and release lift pedal rearward while
lowering mower deck lift lever (A) onto pin (C).
Adjusting Mower Level
CAUTION: Avoid injury! Rotating blades are dangerous.
Before adjusting or servicing mower:
• Disconnect spark plug wire(s) or battery negative (-) cable
to prevent engine from starting accidentally.
• Always wear gloves when handling mower blades or
working near blades.
NOTE: Mower wheels should not contact the ground when leveling the
deck.
1. Park machine safely. (See Parking Safely in the SAFETY section.)
2. Inflate tires to the correct pressure.
GXT002182—UN—05JUN15
3. Position caster wheels to the forward driving position.
3. Remove two bolts and nuts and raise or lower each control lever to
your comfort level.
4. Set mower to preferred cutting height, and lower deck into the
mowing position.
•
For highest lever position, use holes (A).
5. Measure mower level (side-to-side).
•
For lowest lever position, use holes (B).
4. You can also adjust each motion control lever slightly forward or
rearward (C) within slotted holes.
Adjusting Cutting Height
Cutting height can be adjusted from approximately 25-100 mm (1-4 in.).
When mower deck is in transport position cutting height is
approximately 100 mm (4 in.).
1. Check tire pressure and adjust as needed.
MXAL42797—UN—09APR13
A convenient leveling gauge (A) (AM130907) is available from your dealer.
a. Position mower blades as follows and measure from each
outside blade tip (B) to the level surface.
GXT002184—UN—05JUN15
2. Raise mower deck:
•
Z500 Series with 48A, 54A or 62C Mower Decks: Pull upward
on mower deck lift lever (A) and push lever outward to lock in
raised position.
•
Z500 Series with 48HC, 54HC or 60 HC Mower Decks: Push
down on lift pedal (B), and pull upward on mower deck lift lever
(A) until in fully raised position.
MXAL42798—UN—09APR13
b. Turn left blade (C) as shown. Hold belt and turn right blade (D)
as shown. Take measurement for both blades.
The difference between blade measurements must not be more
than 3 mm (1/8 in.).
3. Insert the pin (C) in the proper hole for the desired height of cut.
4. Lower mower deck:
20
Operating
c. 48A and 54A mower decks: Adjust front to rear mower level, if
necessary, by loosening rear nuts (G) on front lift rod. Turn front
nuts (H) clockwise to raise front of mower or counterclockwise
to lower it. Make sure front lift rod (I) contacts mower deck
bracket on both sides (J) to maximize stability of deck. Tighten
rear nut after adjustment is complete.
GXT002427—UN—16JUL15
c. Adjust mower level, if necessary, by turning rear nuts (E)
clockwise to raise the side of the mower deck, or
counterclockwise to lower the mower deck.
NOTE: Ensure that bottom of lock nut is engaged on threaded fitting to
avoid hardware from loosening during operation.
GXT002518—UN—17JUL15
d. 48HC, 54HC, 60HC and 62 in. mower decks: Adjust mower
level, if necessary, by loosening lower nut (K) on both sides of
deck. Turn top nut (L) on each side of deck clockwise to raise
front of mower or counterclockwise to lower front of mower.
Tighten lower nuts after adjustment is complete.
6. Measure mower level (front-to-rear).
NOTE: Verify that deck latches in transport position. If it does not latch,
turn both rear adjusting nuts counterclockwise equally to lower
rear of deck until deck latch engages. Check front lift rod
adjustment, adjust if necessary.
Adjusting Mower Wheels
CAUTION: Avoid injury! Rotating blades are dangerous.
Before adjusting or servicing mower:
• Disconnect spark plug wire(s) or battery negative (-) cable
to prevent engine from starting accidentally.
GXT002188—UN—08JUN15
• Always wear gloves when handling mower blades or
working near blades.
a. Turn right blade (F) so blade tip points straight forward.
b. Measure from blade tip to the surface. Take measurement for
both blades. The front blade tip must be 3 - 6 mm (1/8 - 1/4 in.)
lower than rear blade tip.
IMPORTANT: Avoid damage! The mower deck can be damaged if
mower wheels are adjusted wrong:
• Wheels must not ride on ground supporting mower
weight.
• Check wheel adjustment each time cutting height is
changed.
1. Park machine safely on a level surface. (See Parking Safely in the
SAFETY section).
2. Inflate tires to correct pressure.
3. Raise mower deck lift lever, and lock in transport position.
4. Adjust mower wheels to correct height:
GXT002517—UN—17JUL15
48 in. deck shown.
21
Operating
48A, 48HC, 54A, 54HC and 60HC Mower Decks
Testing Safety Systems
MXAL42804—UN—09APR13
GXT001459—UN—02JUN15
CAUTION: Avoid injury! Engine exhaust fumes contain
carbon monoxide and can cause serious illness or death.
Position 1 (A)
Position 2 (B)
Position 3 (C)
Position 4 (D)
25 - 38 mm (1 - 1-1/2 in.) Height of Cut
38 - 50 mm (1-1/2 - 2 in.) Height of Cut
50 - 76 mm (2 - 3 in.) Height of Cut
76 - 101 mm (3 - 4 in.) Height of Cut
Do not run an engine in an enclosed area, such as a garage,
even with doors or windows opened.
Move the machine to an outside area before running the
engine.
The safety systems installed on your machine should be checked
before each machine use. Be sure you have read the machine operator
manual and are completely familiar with the operation of the machine
before performing these safety system checks.
•
Remove nut (E) using height-of-cut tool or 13 mm wrench. Pull
carriage bolt (F) out until end of bolt clears the outer wall of the
gauge wheel bracket (G), then slide bolt and wheel assembly to the
desired position. Push bolt back through outer wall of bracket. Install
nut (E) and tighten to specification.
Use the following checkout procedures to check for normal operation of
machine.
Specification
Mower Wheel Nut — Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N·m (18 lb.-ft.)
If there is a malfunction during one of these procedures, do not operate
machine. See your authorized dealer for service.
62C Mower Deck
Perform these tests in a clear open area. Keep bystanders away.
Testing Park Brake Switch
1. Park machine safely. (See Parking Safely in the SAFETY section.)
2. Sit on seat.
3. Unlock the park brake.
4. Try to start engine.
Result: Engine must not crank. If engine cranks, there is a problem
with your safety interlock circuit.
Testing Park Brake
1. Park machine safely. (See Parking Safely in the SAFETY section.)
2. Lock the park brake.
3. Engage bypass valve control.
MXAL47055—UN—16APR13
4. Try to push machine manually.
Result: Park brake must prevent machine from moving. If machine
moves, see your authorized dealer for service.
Position 1 (A)
Position 2 (B)
Position 3 (C)
25—44 mm (1—1-3/4 in.) Height of Cut
50—69 mm (2—2-3/4 in.) Height of Cut
76—101 mm (3—4 in.) Height of Cut
NOTE: When testing is complete, disengage bypass valve control prior
to returning machine to service.
• Remove carriage bolt (D) and nut (E). Move wheel (F) and axle (G) to
proper hole position. Secure with carriage bolt and nut. Tighten nut to
specification.
Testing Mower Engagement (PTO) Switch
1. Park machine safely. (See Parking Safely in the SAFETY section.)
2. Sit on seat.
Specification
3. Lock the park brake.
Mower Wheel Nut — Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N·m (18 lb.-ft.)
4. Engage the mower.
22
Operating
5. Try to start engine.
Releasing Park Brake
Result: Engine must not crank. If engine cranks, there is a problem
1. Lower park brake lever to unlock park brake.
with your safety interlock circuit.
Using Key Switch
Testing Seat Switch
1. Park machine safely. (See Parking Safely in the SAFETY Section.)
2. First test:
a. Lock park brake.
b. Start engine.
c. Move throttle lever up to maximum engine speed.
d. Engage mower.
e. Raise up off seat. Do not get off machine.
Result: Engine and mower blades should stop. If engine and
mower blades do not stop, there is a problem with your safety
interlock circuit.
3. Second test:
a. Disengage mower.
MXAL42805—UN—09APR13
A - STOP (off) position - With key in the STOP position, all switched
power is off, and engine should not run.
b. Start engine.
c. Unlock park brake.
B - Run (on) position - Turn key from STOP to this position, and all
switched power circuits will be on.
d. Raise up off seat. Do not get off machine.
Result: Engine should stop. If engine does not stop, there is a
problem with your safety interlock circuit.
C - Start position - Turn key to start position to crank the engine.
Release key after engine has started and it will automatically return to
the on position. The engine will continue to run.
4. Third test:
a. Lock park brake.
Using Mower Engagement Switch
b. Disengage mower.
•
To Engage Mower - Pull mower engagement knob up.
c. Start engine.
•
To Disengage Mower - Push mower engagement knob down.
d. Raise up off seat. Do not get off machine.
Result: Engine should continue to run. If engine stops, there is a
problem with your safety interlock circuit.
Using the Hour Meter
•
The hour meter shows the number of hours the engine has run. The
hour meter does not accumulate hours with the engine off when the
key is in the run position. Use the hour meter to determine when your
machine has reached the recommended service intervals.
Testing Motion Control Lever Switch
1. Park machine safely. (See Parking Safely in the SAFETY Section.)
2. Sit on seat.
•
•
Turn the key to STOP position when not using the machine.
Hour meter cannot be reset.
3. First test:
a. With the park brake locked, start engine.
Using the Motion Control Levers
b. Move right motion control lever inward.
CAUTION: Avoid injury! Learn use of the motion control
levers and practice at half throttle until becoming proficient
and comfortable with the operation of the machine.
Result: Engine should stop. If engine does not stop, there is a
problem with your safety interlock circuit.
4. Second test:
a. Start engine.
Do not move motion control levers from forward to reverse
or reverse to forward position rapidly. Sudden direction
changes could cause loss of control or damage the
machine.
b. Release park brake.
c. Move right motion control lever inward.
Result: Engine should continue to run. If engine stops, there is a
problem with your safety interlock circuit.
Before using the machine, become familiar with the motion control
levers and how they respond. It is essential to know how the machine
accelerates, steers and stops.
5. Repeat first and second test using left motion control lever.
The functions of the motion control levers are:
Using Park Brake
•
•
•
•
Dual function neutral position.
Steering.
CAUTION: Avoid injury! Children or bystanders may attempt
to move or operate an unattended machine.
Acceleration.
Braking.
Always lock the park brake and remove the key before
leaving the machine unattended.
Setting Park Brake
1. Raise park brake lever to lock park brake.
23
Operating
Start/shutdown Position
1. Move throttle lever to the mow position.
2. Unlock park brake.
3. Move both motion control levers from the start/shutdown position
inward to the neutral position.
4. Move the motion control levers forward to begin forward travel.
5. Move the motion control levers rearward to begin reverse travel.
6. To stop travel, move motion control levers back to the neutral
position.
Forward Travel
GXT002196—UN—08JUN15
•
•
•
Motion control levers must be in the start/shutdown position (A) and
the park brake locked (B) to start the engine.
Forward and reverse movement of the motion control levers is
prevented when levers are moved to the start/shutdown position.
Operator can exit mower with the engine running when the mower
engagement switch is disengaged, the motion control levers are in
the start/shutdown position and the park brake is locked.
•
Motion control levers must be in the start/shutdown position to safely
enter and exit the operator seat.
GXT002190—UN—08JUN15
Neutral Position
1. Gradually move both motion control levers evenly forward (A) from
neutral. To speed up, move the levers farther forward. To slow down
smoothly, slowly move the levers toward neutral.
Reverse Travel
GXT002189—UN—08JUN15
•
•
Machine speed, motion, and direction can be controlled when the
engine is running, motion control levers are in the neutral position
(C), and the park brake is unlocked (D).
To stop the machine for an emergency, move the motion control
levers quickly back to the neutral position.
Forward and Reverse Travel
GXT002191—UN—08JUN15
Straight forward and reverse travel takes practice. If the machine does
not track in a straight line when going forward or reverse, the motion
control lever tracking may need adjusting.
1. Look down and behind, then gradually move both motion control
levers evenly rearward (B) from neutral. To speed up, move the
24
Operating
levers farther rearward. To slow down smoothly, slowly move the
Right Turn
levers toward neutral.
Left Turn
GXT002194—UN—08JUN15
1. To turn slightly to the right, push left control lever (D) further forward
than the right control lever (C).
GXT002192—UN—08JUN15
1. To turn slightly to the left, push right control lever (C) further forward
than the left control lever (D).
GXT002195—UN—08JUN15
2. To turn sharply to the right, push left control lever (D) forward and
pull right control lever (C) rearward at the same time.
GXT002193—UN—08JUN15
2. To turn sharply to the left, push right control lever (C) forward and
pull left control lever (D) rearward at the same time.
Starting the Engine
CAUTION: Engine exhaust fumes contain carbon monoxide
and can cause serious illness or death.
Do not run an engine in an enclosed area, such as a garage,
even with doors or windows opened.
Move the machine to an outside area before running the
engine.
1. Sit on the operator seat.
2. Lock park brake.
3. Push the mower engagement knob down to disengage the mower.
25
Operating
4. Set both motion control levers to the start/shutdown position.
5. Move throttle lever to set engine speed:
Moving Machine by Hand
CAUTION: Avoid injury! When the bypass valve is open, the
machine will have unrestricted motion.
•
Cold start: Set throttle lever to the start position. Use the choke
control as necessary (if equipped).
•
Warm start: Set throttle lever to the mow position.
• Do not open the bypass valve when the machine is stopped
on an incline to prevent it from going downhill out of control.
IMPORTANT: Starter may be damaged if starter is operated for
more than 20 seconds at a time:
IMPORTANT: Transmission damage may occur if the machine is
towed or moved incorrectly:
•
Wait two minutes before trying again if engine does not
start.
• Move machine by hand only.
6. Turn key switch to the start position.
• Do not use another vehicle to move machine.
• Do not tow machine.
7. After engine starts, release key switch to the run position,
disengage the choke control (if equipped) and move throttle to mow
position.
IMPORTANT: Unnecessary engine idling may cause engine
damage. Excessive idling can cause engine overheating,
carbon build-up, and poor performance.
When the machine needs to be moved without starting the engine, use
the bypass valves:
NOTE: Do not operate bypass control levers while machine is running.
Do not operate the machine with controls in bypass position.
8. Allow the engine to warm up for 20 seconds.
9. Release park brake.
10. Set both motion control levers to the neutral position.
Engaging Mower
CAUTION: Clear mowing area of all bystanders when
operating this machine. Thrown objects could cause serious
injury or death.
Keep hands and feet away from blades and discharge
opening.
Do not mow in reverse unless absolutely necessary.
1. Adjust mower to desired cutting height.
2. Start engine.
3. Release park brake.
4. Move both motion control levers to the neutral position.
5. Set throttle lever to the RUN position.
NOTE: For smoother engagement, deck can be engaged at transport
position and then lowered to desired cut height.
6. Pull mower engagement switch up to engage mower.
GXT002403—UN—30JUL15
NOTE: The travel speed and turn rate will vary with the amount that the
control levers are moved.
1. Rotate levers (A) inward until lever hits a stop.
2. Release park brake.
7. Push motion control levers forward slowly. Mow at a safe travel
speed.
3. Push machine to desired location and lock park brake.
4. Rotate bypass levers (A) outward to the disengaged position.
Stopping the Engine
1. Stop machine on a level surface, not on a slope.
2. Push the mower engagement switch down to disengage mower.
3. Move the motion control levers to the start/shutdown position.
4. Lock park brake.
Unplugging Mower, Bagger, or Material
Collection System
CAUTION: Avoid injury! Do not attempt to unplug
attachment with machine running.
5. Move throttle lever to the shutdown position.
6. Allow the engine to cool down for 20 seconds.
7. Turn ignition key to STOP (off) position.
•
Rotating blades are dangerous. Shut off the engine and
remove the key before getting off the seat to inspect the
machine and attachment.
•
Thrown objects can cause serious injury. Make sure all
machine parts are stopped before raising hopper top or
removing chutes.
CAUTION: Children or bystanders may attempt to move or
operate an unattended machine.
Always lock the park brake and remove the key before
leaving the machine unattended.
Checking For Plugging While Driving
If grass builds up in front of mower discharge chute, check for plugged
chute or problems with blower assembly (if equipped).
8. Remove key.
26
Operating
If there is a trail of clippings behind mower or clippings blow to the side,
check for plugged chute, full collector bags, or problems with blower
assembly.
Be sure that trailer has all the necessary lights and signs required by
law.
CAUTION: Avoid injury! Use extra care when loading or
unloading the machine onto a trailer or truck. Machine
wheels can go off the ramp or trailer, causing the machine to
tip over.
Removing Debris From Inspection Points:
CAUTION: Avoid injury! Do not use hands or feet to clear
plugged mower deck or blower assembly. Stored energy can
cause blades to rotate.
• To load, back slowly and in a straight line. Keep wheels
away from drop-offs and edges.
• Do not use two separate loading ramps. Use a full width
loading ramp at least 30 cm (12 in.) wider than machine to
keep caster wheels from going off the ramp edge.
1. Park machine safely. Wait for all moving parts to stop before getting
off to inspect machine.
2. Open hopper cover. Check chute outlet.
• Use a trailer with sides.
3. Remove chute from mower deck or blower assembly. Check chute
inlet.
1. Park trailer on level surface.
4. Check under mower deck for debris.
2. Raise mower deck before driving machine onto trailer.
Using Wash Port to Clean Mower Deck
NOTE: Follow this procedure after each use to prevent buildup and
remove corrosive lawn chemicals.
1. Park machine safely. (See Parking Safely in the Safety section).
MXAL42817—UN—09APR13
3. Back machine onto heavy-duty trailer with full-width ramp.
4. Lower mower deck completely.
5. Lock park brake.
MXT005333—UN—22MAY13
2. Attach quick-coupler to garden hose.
3. Attach garden hose with quick-coupler to wash port (A) on the
mower deck.
4. Turn on water.
5. Start engine.
6. Run at full throttle.
7. Engage mower blades.
8. Flush water under deck for approximately one minute.
9. Disengage mower blades.
10. Stop engine.
11. Turn off water and remove garden hose and quick-coupler from
wash port.
GXT002198—UN—08JUN15
12. Remove quick-coupler from garden hose and store for future use.
6. Fasten front of machine at both sides of the frame at points (A) to
trailer with heavy-duty straps, chains, or cables. Straps must be
directed forward, down and outward from machine.
Transporting Machine on Trailer
7. Turn off machine and remove key.
NOTE: Trailer capacity must exceed combined machine weight and
attachment weight. (See Specifications section in operator’s
manual).
27
Service Intervals
Service Intervals
Servicing Your Machine
IMPORTANT: Avoid damage! Operating in extreme conditions may
require more frequent service intervals:
•
Engine components may become dirty or plugged when
operating in extreme heat, dust or other severe
conditions.
•
Engine oil can degrade if machine is operated constantly
at slow or low engine speeds or for frequent short
periods of time.
IMPORTANT: Avoid damage! High-pressure washing can cause
damage to machine components. It is recommended that
your vehicle be washed by hand or with a garden hose
using mild soap.
GXT002405—UN—16JUL15
Avoid spraying water with any great force near or into the
following places:
8. Fasten rear of machine at slots on each side of frame (B - right, C -
left) to trailer with heavy-duty straps, chains, or cables. Straps must
be directed rearward, down and outward from machine.
•
•
•
•
•
•
•
•
•
•
•
•
Air intake
Electrical connections (including battery compartment)
Wheel bearings
Transporting Material Collection System (If
Equipped)
If the material collection system is left on the machine during transport,
follow these guidelines when trailering the unit:
Radiator (if equipped)
Warning labels
Other labels
Ignition switch
•
Empty the cloth bags and remove them from the hopper. Full bags
add extra weight which can overstress the hopper frame on rough
roads. At road travel speeds, wind can cause premature wear of the
cloth bags.
Instrument panel (gauges and switches)
Breather/tube vents
Mower spindles
Mower idler bearings
Transmission cooling fans
•
•
Make sure the hopper cover is latched securely to the hopper frame.
If the unit is transported over long distances or at high speeds,
remove the rear bagger or power flow chute before transport.
Please use the following timetables to perform routine maintenance on
your machine.
Mowing Tips
Park the vehicle safely. (See Park Safely in the SAFETY Section.)
•
•
•
•
•
•
•
Mow grass with throttle lever in the full fast / mow position.
Mow grass when it is dry.
Service Intervals
Keep mower deck and discharge chute clean.
Mow with sharp blades.
Break-In after 8 Hours
Properly level mower deck for a smooth cut.
Mow grass frequently.
•
•
•
Change engine oil.
Change engine oil filter.
Check mower deck level.
Use a travel speed that fits the conditions:
- Mow tall or wet grass twice. Cut grass at half desired height – then
cut at desired height.
Every 50 Hours or Annually (Whichever Comes First)
- Travel slow when mowing tall or thick grass.
•
•
•
•
•
•
Change engine oil.
- Avoid damaging grass by slipping or skidding machine drive
wheels. Practice smooth control lever movements.
Change engine oil filter.
Clean air intake screens.
- When performing sharp turns, do not allow inside machine drive
wheel to stop and twist on grass.
Lubricate mower deck spindles.
Lubricate mower deck idler arm (HC decks and 62C)
Check mower deck level.
Blade Choices
Several types of blades are available for ZTrak Z500 series mowers:
Every 100 Hours or Annually (Whichever Comes First)
•
Side discharge blades. These blades are designed for optimal
performance when side discharging and are installed on Z500 series
mowers when shipped from the factory.
•
•
•
•
•
•
•
•
Replace spark plugs.
Replace air filter element(s).
Replace fuel filter.
•
Mulching blades. These blades are designed for optimal
performance when used with a mulch cover or mulch plug installed.
Check mower belt.
Sharpen / replace mower blades.
Clean underside of deck.
Check tire pressure.
Clean engine cooling fins.
28
Service Lubrication
Every 200 Hours
Check / adjust engine valve clearance. See your John Deere dealer
for this service.
48HC, 54HC, 60HC and 62C Mower Deck
•
Service Lubrication
Grease
IMPORTANT: Avoid Damage! Use recommended John Deere
greases to avoid component failure and premature wear.
The following grease is recommended for service:
•
•
John Deere Multi-Purpose HD Lithium Complex Grease
Grease-Gard™ Premium Plus
GXT002201—UN—08JUN15
Not all grease types are compatible; John Deere does not recommend
mixing greases. If using any product other than the recommended
grease in service, purge any remaining grease from the system prior to
application. If this is not practical, grease twice as often until all old
grease is purged from the system.
•
Lubricate three spindle grease fittings (A).
NOTE: For 48HC, it may be necessary to raise deck to transport height
to rotate idler arm for grease access to center spindle.
Lubricating Front Lift Arm
Lubricating Mower Deck Spindles
NOTE: Removal of belt shields is not necessary to lubricate the
spindles.
1. Remove mower deck foot plate.
2. Lubricate each mower deck spindle with two pumps of grease at
specified intervals as indicated:
48A and 54A Mower Decks
GXT002202—UN—08JUN15
48A deck shown.
Lubricate the front lift arm at the points (A) where it pivots in the mower
deck bracket as needed to prevent or minimize squeaking during
operation.
Service Engine
GXT002200—UN—08JUN15
Emissions Service Information
•
Raise spindle cover (A) and lubricate spindle grease fitting (B).
A qualified repair shop or person of the owner’s choosing may maintain,
replace, or repair emission control devices and systems with original or
equivalent replacement parts. However, warranty, recall and all other
services paid for by John Deere must be performed at an authorized
John Deere service center.
•
•
Raise opposite spindle cover and lubricate spindle grease fitting.
Lubricate center spindle grease fitting (C).
Within the warranty period, John Deere will reimburse reasonable
service costs incurred at service providers outside the John Deere
authorized network only in an unsafe, emergency condition if an
authorized John Deere dealer is not available and the failure does not
arise from the owner’s misuse or failure to perform required
maintenance. An emergency situation exists under this section if, after
30 days, the authorized John Deere network is unable to perform the
repairs or source replacement parts.
29
Service Engine
Emission Control System Certification Label
Other oils may be used if above John Deere oils are not available,
provided they meet the following specification:
NOTE: Tampering with emission controls and components by
unauthorized personnel may result in severe fines or penalties.
Emission controls and components can only be adjusted by
EPA and/or CARB authorized service centers. Contact your
John Deere Retailer concerning emission controls and
component questions.
•
API Service Classification SJ or higher
Checking Engine Oil Level
IMPORTANT: Failure to check the oil level regularly could lead to
serious engine problems if oil level is out of the operating
range:
The presence of an emissions label signifies that the engine has been
certified with the United States Environmental Protection Agency (EPA)
and/or California Air Resources Board (CARB).
• Check oil level before operating.
• Check oil level when the engine is cold and not running.
• Keep oil level between the dipstick marks.
• Shut off engine before adding oil.
The emissions warranty applies only to those engines marketed by
John Deere that have been certified by the EPA and/or CARB; and
used in the United States and Canada in off-road mobile equipment.
NOTE: Check oil twice a day if you run engine over 4 hours in a day.
Make sure that engine is cold when checking engine oil level.
Altitude Adjustment (Gasoline Engines Only)
If your engine features a carburetor it is calibrated by the engine
manufacturer and is not adjustable.
1. Park machine safely. (See Parking Safely in the SAFETY section.)
If your engine is operated at altitudes below 1006 m (3,300 ft.), a high
altitude carburetor jet kit is not required. If your engine is operated at
altitudes above 1006 m (3,300 ft.), a high altitude carburetor jet kit may
be required for proper engine performance and emissions control.
Operating the engine with the wrong carburetor configuration at a given
altitude may increase the engine’s emissions and decrease fuel
efficiency and performance.
IMPORTANT: Dirt and contamination can enter engine when
checking oil level. Clean area around dipstick before
loosening or removing.
2. Clean area around dipstick to prevent debris from falling into
crankcase.
See a qualified service provider for details on jet kit requirements for
your specific product.
Avoid Fumes
CAUTION: Avoid injury! Engine exhaust fumes contain
carbon monoxide and can cause serious illness or death.
Do not run an engine in an enclosed area, such as a garage,
even with doors or windows opened.
Move the machine to an outside area before running the
engine.
Engine Oil
Use oil viscosity based on the expected air temperature range during
the period between oil changes.
GXT002409—UN—15JUL15
Model Z525E
MXAL42826—UN—09APR13
The following John Deere oils are preferred:
•
•
•
John DeereTurf-Gard™
John DeerePlus-4™
John DeerePlus-50™ II
™Turf-Gard is a trademark of Deere & Company
™Plus-4 is a trademark of Deere & Company
™Plus-50 is a trademark of Deere & Company
30
Service Engine
Changing Engine Oil and Filter
IMPORTANT: Operating in extreme conditions may require more
frequent service intervals:
• Engine components may become dirty or plugged when
operating in extreme heat, dust, or other severe conditions.
• Engine oil can degrade if machine is operated constantly
at slow or low engine speeds or for frequent short periods
of time.
1. Run engine to warm oil.
2. Park machine safely on level surface. (See Parking Safely in the
SAFETY section.)
IMPORTANT: Dirt and contamination can enter engine when
checking oil level. Clean area around dipstick before
loosening or removing.
GXT002424—UN—15JUL15
3. Clean area around dipstick to prevent debris from falling into
crankcase.
Models Z535M and Z535R
GXT002410—UN—15JUL15
GXT002415—UN—15JUL15
Model Z525E
Models Z540M and 540R
3. To check oil level on dipstick:
Models Z525E, Z535M and Z535R
a. Remove dipstick (A). Wipe with clean cloth.
b. Install and tighten dipstick.
c. Remove dipstick.
d. Check oil level on dipstick. Oil must be between ADD and FULL
marks.
Models Z540M and Z540R
a. Remove dipstick (A). Wipe with clean cloth.
b. Insert dipstick fully in tube, but do not tighten.
c. Remove dipstick.
d. Check oil level on dipstick. Oil must be between ADD and FULL
marks.
4. If oil level is low, add oil to bring oil level no higher than FULL mark
on dipstick. Do not overfill.
5. Install and tighten dipstick.
GXT002425—UN—15JUL15
Models Z535M and Z535R
31
Service Engine
Cleaning Engine Screen Guard
Model Z525E
The Z525E engine incorporates a removable guard over the rotating
flywheel cover at the top of the engine. The guard should be removed
to check for and remove any debris daily in conjunction with checking
engine oil level.
GXT002416—UN—15JUL15
Models Z540M and Z540R
4. Prepare to drain oil:
•
Models Z525E, Z535M and Z535R — Disconnect oil drain hose
(A) from the side of the engine and lower hose, routing the oil
drain hose down through the opening behind the transmission oil
reservoir bottle. Ensure that the drain valve will not drain onto
the transmission housing, transmission fan and frame.
GXT002411—UN—15JUL15
•
Models Z540M and Z540R — Put drain pan under drain valve
(A).
1. Locate rotating screen guard (A) at top of engine, and the two
retaining tabs (B), embossed with a finger symbol.
5. Drain oil:
•
Models Z525E, Z535M and Z535R — Loosen dipstick (C).
Remove the oil drain cap (B) and drain the oil into an approved
container until the oil has drained completely.
2. Remove screw (C) (if equipped). Push in on the two retaining tabs
(B) and lift off guard (A).
3. Clean guard and flywheel cover of debris.
4. Install guard after cleaning.
•
Models Z540M and Z540R — Do not loosen dipstick (C) until the
oil drain valve is partially open. Partially open drain valve and
slowly loosen dipstick cap to ensure oil flow control. Once oil
begins draining, loosen dipstick cap and oil drain valve cap
completely. Drain the oil into an approved container until the oil
has drained completely.
Models Z535M and Z535R
Removal of engine screen guard is not necessary.
Models Z540M and Z540R
6. Wipe dirt from around oil filter (D). Place a drain pan under oil filter,
and remove filter.
7. Put a light coat of fresh, clean oil on the new filter gasket.
8. Install replacement oil filter by turning oil filter to the right
(clockwise) until the rubber gasket contacts filter base. Tighten filter
an additional one-half turn.
9. After oil has drained, install the drain cap (B) on all models.
10. Models Z525E, Z535M and Z535R — Attach drain hose assembly
(A) to side of engine
11. Add oil no higher than FULL mark on dipstick. Begin with per
specification, do not overfill.
Specification
Models Z525E, Z535M and Z535R Beginning Oil — Capacity . . . . . . . . . . . . . . . 1.6 L
(1.75 qt)
Models Z540M and Z540R Beginning Oil — Capacity . . . . . . . . . . . . . . . . . . . . . 2.1 L
(2.2 qt)
12. Tighten dipstick.
13. Start and run engine at idle to check for leaks. Stop engine. Fix any
leaks before operating.
GXT002417—UN—15JUL15
14. Check oil level. Add oil if necessary.
32
Service Engine
MXAL47081—UN—16APR13
MXT005379—UN—31JUL13
3. Locate rotating screen guard (A) at top of engine, and the two
retaining tabs (B), embossed with a finger symbol. Remove screw
at front of screen guard (if equipped).
1. Locate rotating screen guard (A) at top of engine. Remove three
rivets (B) by prying up using a screwdriver under head until it pops
up. Lift off screen guard.
4. Push in on the two retaining tabs and lift off guard (A).
5. Clean guard and flywheel cover of debris.
2. Clean guard, flywheel cover, and the rotating flywheel screen of
debris.
IMPORTANT: Be careful to maintain position of fuel pump
assembly (D), clips, (E) and fuel line. Also any other
attached components when removing parts from side of
engine.
3. Install guard after cleaning. Rivets can be reinstalled by pushing
them into the fastened position.
Cleaning Engine Shroud
6. Remove bolts and engine shroud (C).
CAUTION: Avoid injury! Compressed air can cause debris to
fly a long distance.
7. Remove four bolts and rotating screen (F).
• Clear work area of bystanders.
• Wear eye protection when using compressed air for
cleaning purposes.
• Reduce compressed air pressure to 210 kPa (30 psi).
IMPORTANT: An obstructed air intake screen can cause engine
damage due to overheating. Keep air intake screens and
other external surfaces of the engine, including cooling
fins, clean at all times to allow adequate air intake.
For models Z535M and Z535R, also clean fins on oil cooler.
CAUTION: Avoid injury! Touching hot surfaces can burn
skin. The engine, components, and fluids are hot if the
engine has been running. Allow the engine to cool before
servicing or working near the engine and components.
Model Z525E
MXAL47082—UN—16APR13
1. Park machine safely. (See Parking Safely in the SAFETY Section.)
2. Clean air intake screen and external engine surfaces (see Cleaning
Air Intake Screen and Engine Fins in ENGINE Section).
8. Clean debris from:
•
•
•
•
Fan areas (G)
Cylinder head cooling fins (H)
Engine cooling fins
Area between engine and frame
9. Install rotating screen with four bolts.
IMPORTANT: Engine shroud must be assembled so that slots in
shroud align with ridge in air intake and mating surfaces
along sides of engine. Failure to assemble correctly will
prevent the air filter from sealing and may cause engine
damage.
33
Service Engine
10. Install shroud with hardware.
Models Z535M and Z535R
1. Park machine safely. (See Parking Safely in the SAFETY Section.).
2. Clean air intake screen and external engine surfaces (see Cleaning
Air Intake Screen and Engine Fins in ENGINE Section).
3. Remove air cleaner cover.
GXT001684—UN—17SEP14
10. Clean fins on oil cooler (D) (if equipped) as needed.
Models Z540M and Z540R
1. Park machine safely. (See Parking Safely in the SAFETY Section.)
2. Clean air intake screen and external engine surfaces (see Cleaning
Air Intake Screen and Engine Fins in ENGINE Section).
GXT001680—UN—16SEP14
4. Loosen clean out port screws (A) until the cover can be removed.
5. Remove port covers (B).
GXT002418—UN—15JUL15
3. Loosen two knobs and remove air cleaner cover (A) and air filter.
GXT001681—UN—27OCT14
6. Clean debris from clean out ports (C) on either side of air cleaner.
7. Install port covers.
8. Secure with screws that were previously loosened.
9. Install air cleaner cover.
34
Service Engine
9. Install shroud, fuel pump, rotating screen and any other
components removed earlier.
10. Install rotating screen guard with three rivets. Rivets can be
reinstalled by pushing them into the fastened position.
11. Install air filter and air cleaner cover.
Checking and Cleaning Air Cleaner Element
Models Z525E, Z535M, Z535R, Z540M and Z540R
1. Park machine safely. (See Parking Safely in the SAFETY section.)
2. Let engine cool.
MXT005379—UN—31JUL13
4. Remove three rivets (B) by prying them up using a screwdriver
under the head until it pops up.
5. Remove the rotating screen guard (C).
IMPORTANT: Be careful to maintain position of fuel pump
assembly (D), clips for fuel line, and any other attached
components when removing parts from side of engine.
6. Remove two screws holding fuel pump (D) to side of engine.
7. Remove bolts, the rotating screen, (F) and engine shroud (E).
GXT002412—UN—15JUL15
Model Z525E
GXT002426—UN—15JUL15
Models Z535M and Z535R
MXT005356—UN—31JUL13
8. Clean debris from:
•
•
•
Fan areas (G)
Cylinder head cooling fins (H)
Area between engine and frame
IMPORTANT: Engine shroud must be assembled so that the slots
in the shroud align with ridge in air intake and mating
surfaces along sides of engine. Failure to assemble
correctly will prevent the air filter from sealing and may
cause engine damage.
35
Service Engine
GXT002419—UN—15JUL15
Models Z540M and Z540R
GXT001683—UN—16SEP14
Models Z535M and Z535R
3. Clean dirt and debris from the air cleaner cover (A).
4. Loosen two knobs (B) and remove cover.
IMPORTANT: To prevent engine damage, do not allow any foreign
objects to fall into the carburetor air intake.
NOTE: During filter cartridge removal, any material or foreign object
that enters the air intake must be removed before replacement
of the cartridge.
MXT005354—UN—08JUN13
Models Z540M and Z540R
5. Lift out filter cartridge (C) and inspect it for damage.
IMPORTANT: Dirt and debris can enter the engine through a
damaged filter element:
• Do not wash paper element.
• Do not attempt to clean paper element by tapping against
another object.
• Do not use pressurized air to clean element.
MXAL47088—UN—16APR13
Model Z525E
• Replace element only if it is dirty, damaged or the seal is
cracked.
6. Inspect the foam precleaner (D) (If Equipped) without removing it. If
the foam precleaner is dirty:
a. Remove it from the filter carefully.
b. Wash precleaner in a solution of warm water and liquid
detergent.
NOTE: Do not put engine oil on pre cleaner. Engine oil may wick into
the paper filter element and result in poor engine performance.
c. Rinse precleaner thoroughly. Squeeze out excess water in a dry
cloth until pre cleaner is dry.
d. Replace the precleaner if damaged or missing.
7. Inspect paper filter element. Replace the filter element if damaged
or dirty.
36
Service Engine
8. Clean air cleaner base carefully. Prevent any dirt from falling into
7. Check plug gap (C) with a wire feeler gauge. To change gap, move
the outer electrode. Gap must be set to specification.
Specification
carburetor or air intake tube.
9. Install foam precleaner (D) mesh side up on paper filter element.
Position air filter in air filter base:
Spark Plug — Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.75 mm (0.030 in.)
•
Model Z525E install cartridge. Make sure that cartridge and seal
are properly seated and sealing the carburetor air intake area.
8. Install spark plugs and tighten to specification.
Specification
Spark Plug — Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 N·m (180 lb-in.)
•
Models Z535M, Z535R, Z540M and Z540R, install also on air
intake tube (E). Align air filter clamp on intake tube groove and
tighten clamp by turning thumbscrew clockwise until secure.
9. Connect spark plug wire(s).
10. Install air cleaner cover and tighten knobs. Do not overtighten.
Replacing Fuel Filter
Checking Spark Plug
CAUTION: Avoid injury! Fuel vapors are explosive and
flammable:
CAUTION: Touching hot surfaces can burn skin. The engine,
components, and fluids will be hot if the engine has been
running. Allow the engine to cool before servicing or
working near the engine and components.
• Do not smoke while handling fuel.
• Keep fuel away from flames or sparks.
• Shut off engine before servicing.
• Cool engine before servicing.
1. Park machine safely (See Parking Safely in the SAFETY section).
• Work in a well-ventilated area.
• Clean up spilled fuel immediately.
NOTE: Change filter when fuel is low.
1. Park machine safely. (See Parking Safely in the SAFETY section).
2. Let engine cool.
3. Raise operator’s seat if required.
4. Put a drain pan under fuel filter.
GXT002413—UN—15JUL15
Standard twin cylinder engine shown.
2. Disconnect spark plug wire (A). For the twin cylinder engines, there
is a spark plug on each side of engine.
3. Remove each spark plug.
4. Clean spark plug carefully with a wire brush.
5. Inspect spark plug for:
•
•
•
Cracked porcelain.
Pitted or damaged electrodes.
Other wear or damage.
NOTE: In Canada, replace spark plug with resistor plug only.
GXT002414—UN—15JUL15
6. Replace spark plug(s) as necessary.
5. Slide hose clamps on both sides of fuel filter (A) away from fuel
filter ends using pliers.
6. Disconnect hoses from filter.
IMPORTANT: Incorrect installation of fuel filter may cause engine
damage. Install the filter with the arrow pointing in the
direction of fuel flow (towards the engine) for proper
operation.
7. Connect hoses to new filter making sure the filter arrow is pointing
in the direction of the fuel flow.
8. Install clamps and check for leaks.
Spark Arrestor Maintenance (if equipped)
MXAL47092—UN—16APR13
Spark arrester assemblies include a screen element which should be
inspected and cleaned periodically. Visually inspect the screen for
tears, broken wires, or loose welds. Replace the spark arrester
assembly if any of these conditions exist. If the screen is determined to
37
Service Transmission
be intact and in good condition, proceed with cleaning the screen by
4. Remove screws (H), spark arrestor cover (I) and spark arrestor
brushing away loose dirt or carbon.
from engine.
5. Inspect, clean, or if necessary, replace the screen if damaged.
6. Install spark arrestor and cover on muffler with original screws.
7. Install muffler shield and tighten hardware.
Z525E, Z535M, Z535R
NOTE: If muffler sustains damage during the removal or installation
process, replace muffler.
Z540M, Z540R
GXT002406—UN—16JUL15
1. Remove two push retainers (A), four bolts (B, C) and rear cover (D)
from machine.
2. Remove four bolts (E) and frame tube (F).
GXT002203—UN—09JUN15
1. Remove screw and spark arrestor from end of muffler exhaust pipe
(A).
NOTE: Observe direction of arrestor inside exhaust pipe for
reassembly.
2. Inspect, clean, or if necessary, replace the screen if damaged.
3. Install spark arrestor on muffler exhaust pipe with original screw.
NOTE: If muffler sustains damage during the removal or installation
process, replace muffler.
Service Transmission
GXT002407—UN—16JUL15
Transmission Oil
Use only 10W-30.
3. Remove muffler shield (G).
DO NOT use type “F” automatic transmission fluid.
Checking Transaxle Oil Level
1. Park machine safely on a level surface. (See Parking Safely in the
SAFETY section.)
IMPORTANT: Hot hydraulic oil will expand and show incorrect oil
level. Check oil level:
• When oil is cold.
• With engine not running.
2. Allow machine to cool.
IMPORTANT: Contamination can damage the hydraulic system.
Clean thoroughly around reservoir fill cap before opening.
GXT002422—UN—16JUL15
38
Service Transmission
GXT002204—UN—09JUN15
GXT002408—UN—30JUL15
Right side of machine shown with machine parts removed for a clearer image.
3. Locate the left-hand and right-hand reservoirs at the rear of the
machine. Each transmission has its own reservoir.
3. On linkage side needing adjustment (right side shown), remove
spring locking clip (A) and rod end (B) from pivot pin (C). Turn rod
end (B) on rod (D) in (clockwise) to decrease forward creep and out
(counterclockwise) to decrease reverse creep. Repeat procedure,
as necessary, on opposite side. Install rod ends back onto arms
and secure with spring locking clips.
4. The reservoirs have two marks, FULL (A) and ADD (B). Check
level with fluid cold.
5. If oil level is below the ADD line (B), clean area around reservoir
cap and remove cap (C).
6. Remove foam insert.
7. Add oil until level is at FULL mark (A) on reservoir.
8. Install foam insert.
Adjusting Tracking
If the machine does not track in a straight line while going in full forward
position, the tracking requires adjustment.
9. Install cap (C).
1. Park machine safely. (See Parking Safely in the SAFETY section.)
10. Start engine.
11. Operate machine forward and in reverse several times.
12. Park machine safely on a level surface. (See Parking Safely in the
SAFETY section.)
13. Wait for hydraulic oil to cool.
14. Check oil level again. Add oil if necessary.
Changing Transaxle Oil and Filter
The transaxles on these models require no maintenance. If you suspect
transmission problems, contact your authorized dealer.
Checking and Adjusting Neutral Creep
Check neutral creep with engine running, motion control levers in the
start/shutdown position, park brake off, and machine on level ground.
If the machine creeps forward or reverse while motion control levers are
in the start/shutdown position, adjust the motion control lever linkages:
1. Park machine safely. (See Parking Safely in the SAFETY section.)
GXT002205—UN—09JUN15
2. Remove style panel for better access to adjustment components (if
desired). (See Removing and Installing Style Cover in the
SERVICE MISCELLANEOUS section.):
2. Adjust tracking with the 13 mm socket on the free end of the deck
height adjustment lock pin (A) as follows:
NOTE: Tracking bolts limit top forward speed. If both levers hit against
the tracking bolts, turn both bolts counterclockwise equal
amounts until only one bolt contacts the lever. This will achieve
maximum forward speed.
•
•
If machine tracks to the left, turn tracking bolt (B) clockwise.
If machine tracks to the right, turn tracking bolt (C) clockwise.
39
Service Transmission
Cleaning Transaxle Cooling Fans
CAUTION: Avoid injury! Compressed air can cause debris to
fly a long distance.
• Clear work area of bystanders.
• Wear eye protection when using compressed air for
cleaning purposes.
• Reduce compressed air pressure to 210 kPa (30 psi).
IMPORTANT: To ensure proper cooling, keep the transaxle cooling
fins and surrounding area clean at all times. Operating the
transaxle with obstructed cooling fins could cause damage
due to overheating.
GXT002208—UN—09JUN15
Components viewed from top front.
2. Inspect drive belt (A) for excessive wear, damage or stretching
while in position on all machine sheaves.
1. Park machine safely. (See Parking Safely in the SAFETY section.)
Replacing Transaxle/Transmission Drive Belt
1. Park machine safely. (See Parking Safely in the SAFETY section.)
2. Remove style panel. (See Removing and Installing Style Cover in
the SERVICE MISCELLANEOUS section.)
3. Remove mower deck.
4. Disconnect electric clutch wiring connector from main wiring
harness connector.
CAUTION: Avoid injury! Components are installed under
spring tension. Wear eye protection and use proper tools
when installing and removing components with spring
tension.
GXT002207—UN—09JUN15
View from front of machine.
2. Clean transaxle fan fins (A) and around exterior of each fan with a
rag, brush or compressed air.
Checking and Replacing
Transaxle/Transmission Drive Belt
CAUTION: Avoid injury! Entanglement in a belt or sheave
can cause serious injury. Stop engine and wait for all moving
parts to stop.
GXT002514—UN—30JUL15
Components viewed from top front.
5. Insert 3/8 in. ratchet into hole in the idler arm (B) and rotate the
spring-loaded idler arm to relieve belt tension. Work belt off the
transmission sheaves (C) and over the top of the cooler fans (D).
NOTE: The transmission drive belts are self-adjusted using a spring
tensioner and do not require a tension adjustment.
6. Remove belt from drive sheave on engine.
7. Disconnect spring (E) from rockshaft
Checking Transaxle/Transmission Drive Belt
1. Park machine safely. (See Parking Safely in the SAFETY section.)
8. Remove belt from underneath the machine.
40
Service Mower
GXT002515—UN—30JUL15
9. Position replacement belt around drive sheave on engine and route
belt through idler sheaves (F).
10. Route belt on transmission sheaves (G) and tension belt by
attaching spring (H) to rockshaft.
GXT002215—UN—10JUN15
11. Insert electric clutch wiring harness connector (I) to main wiring
harness.
2. Remove bolt (A).
3. Rotate foot plate up using finger pull (B).
4. Remove foot plate.
12. Install mower deck.
13. Install style cover.
Installing Foot Plate
1. Place tabs (C) of foot plate into slots in frame.
2. Lower foot plate.
Service Mower
3. Install bolt (A) to secure foot plate.
Mower Deck Identification
Mower decks in the following instructions are identified by a code
designation. The codes are as follows:
Removing Mower Deck (48A, 48HC, 54A,
54HC, 60HC and 62C)
1. Park machine safely. (See Parking Safely in the SAFETY section.)
Code
48A
Description
2. Allow engine and muffler to cool completely.
48 inch Accel Deep™
CAUTION: Avoid injury! Rotating blades are dangerous.
Before adjusting or servicing mower:
48HC
54A
48 inch Edge™ High Capacity
54 inch Accel Deep™
• Disconnect spark plug wire(s) or battery negative (-) cable
to prevent engine from starting accidentally.
54HC
60HC
62C
54 inch Edge™ High Capacity
60 inch Edge™ High Capacity
62 inchEdge™ Convertible
• Always wear gloves when handling mower blades or
working near blades.
™Accel Deep is a trademark of Deere & Company
™Edge is a trademark of Deere & Company
3. Raise mower deck to the transport lock position.
Removing and Installing Mower Deck Foot
Plate
CAUTION: Avoid injury! Always operate the mower with the
foot plate installed. Operating with the foot plate removed
can cause serious injury.
Removing Foot Plate
1. Park machine safely. (See Parking Safely in the SAFETY section.)
GXT002216—UN—10JUN15
41
Service Mower
4. Remove lock pin, push handle to its lowest position (A) and install
pin just above lever (B) to lock deck in lowered position.
5. Disconnect mower drive belt:
CAUTION: Avoid injury! Component is spring-assisted and
under tension. Injury can occur if spring-assisted
component is released suddenly.
GXT002429—UN—16JUL15
6. 48HC, 54HC, 60HC and 62C Mower Deck Only: Remove locking
clip (F) from front draft link (G) and remove draft link from mower
deck bracket (H) and draft bracket (I). Repeat on opposite side.
GXT002516—UN—31JUL15
Mower deck shown removed from machine for better view.
•
From the left side of machine, insert a 3/8 inch ratchet into
square hole (C) in tension arm and pull clockwise and hold to
release tension on belt.
GXT002430—UN—16JUL15
7. 48A and 54A Mower Deck Only: Remove locking clips (J), and
remove front draft rod (K) from deck brackets (L) and mower
hanger brackets (M).
GXT002519—UN—31JUL15
Mower deck shown removed from machine for better view.
•
•
Raise left spindle cover (D) and remove belt (E) from spindle.
Remove belt from clutch sheave.
GXT002431—UN—31JUL15
42
Service Mower
8. Remove spring clip (N) and pin (O) from each side of rear hanger
bracket.
9. Raise draft arms to transport position:
a. Pull and raise mower lift lever fully upward.
b. Install pin just below lift lever to lock into raised position.
10. Rotate front caster wheels to maximize clearance.
11. Slide mower out from under the machine.
•
Do not operate the machine without the mower deck: Machine
may become unstable without the mower deck attached. Move
machine only by hand. (See Moving Machine by Hand in
OPERATING section.)
Installing Mower Deck (48A, 48HC, 54A,
54HC, 60HC and 62C)
1. Park machine safely. (See Parking Safely in the SAFETY section.)
GXT002433—UN—16JUL15
2. Allow engine and muffler to cool completely.
CAUTION: Avoid injury! Rotating blades are dangerous.
Before adjusting or servicing mower:
6. 48A and 54A Mower Only: Install front hanger rod (C) onto mower
deck bracket (D) and onto draft bracket (E). Secure each stud end
with locking clip (F).
• Disconnect spark plug wire(s) or battery negative (-) cable
to prevent engine from starting accidentally.
• Always wear gloves when handling mower blades or
working near blades.
3. Raise mower lift lever fully upward into transport lock position.
4. Slide mower deck under machine.
GXT002429—UN—16JUL15
7. 48HC, 54HC, 60HC and 62C Mower Only: Install front hanger rod
(J) onto mower deck brackets (K) and onto draft brackets (L).
Secure each stud end with locking clip (M).
GXT002432—UN—31JUL15
5. Lower mower lift lever, and install pin (A) and spring clip (B) onto
each side of rear mower bracket.
43
Service Mower
1. Park machine safely. (See Parking Safely in SAFETY section.)
2. Allow engine and muffler to cool completely.
3. Remove mower deck.
CAUTION: Avoid injury! Component is spring-assisted and
under tension. Injury can occur if spring-assisted
component is released suddenly.
4. Remove deck drive belt as follows:
CAUTION: Avoid injury! Components are installed under
spring tension. Wear eye protection and use proper tools
when installing and removing components with spring
tension.
GXT002218—UN—31JUL15
8. Connect mower drive belt:
Install belt onto engine sheave.
•
NOTE: Left and right spindle sheaves are hidden by belt covers. Failure
to seat belt properly on sheaves may result in belt damage.
GXT002436—UN—16JUL15
•
Insert 3/8 inch ratchet onto square hole (G) in tension arm.
Rotate arm clockwise and hold to release spring tension on idler
sheave.
•
Unhook spindle cover (A) torsion spring (B) from wire form on
each side of deck.
GXT002437—UN—16JUL15
GXT002520—UN—31JUL15
•
Lift each spindle cover (C) to align the wire form index tab with
the mating key hole in the cover. Slide each cover forward (D) on
wire form to remove from deck.
•
•
Lift left spindle cover (H) and install mower belt (I) onto left
spindle sheave. Release spindle cover and tension arm.
Flip up left and right spindle covers to check that belt is correctly
routed on all sheaves.
Replacing Mower Drive Belt (Z500 Series
with 48A, 48HC, 54A, 54HC, 60HC and 62C
Mowers)
NOTE: A 48HC deck has been used in the illustrations below. All
mower decks listed above use a similar configuration of
sheaves.
44
Service Mower
MXAL42867—UN—09APR13
Mower deck with side discharge used for illustration
3. Measure distance (A) between blade tip and flat ground surface.
GXT002511—UN—31JUL15
4. Rotate blade 180° and measure distance between other blade tip
and flat ground surface.
•
•
Remove spring from welded spring hook (E) on deck.
5. Install new blade if the difference between the two measurements
is more than 3 mm (1/8 in.).
Remove nut (F) on tension sheave and lower bolt to remove
guide (G). Remove belt (H) from all sheaves.
6. Repeat for all blades.
5. Inspect belt for wear or damage; replace as necessary.
6. Clean top surface of mower deck and sheaves.
7. Install belt on mower deck as shown.
Servicing Mower Blades
8. Make sure belt guide (G) is indexed as shown, and tighten nut (F)
CAUTION: Avoid injury! Rotating blades are dangerous.
Before adjusting or servicing mower:
to specification.
Specification
• Disconnect spark plug wire(s) or battery negative (-) cable
to prevent engine from starting accidentally.
Sheave Nut — Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 N·m (35 lb-ft)
9. Install spring on welded spring hook (E) on deck.
• Always wear gloves when handling mower blades or
working near blades.
NOTE: Failure to seat belt properly on sheaves may result in belt
damage.
10. Make sure belt is properly seated on all sheaves, and install belt
shields:
Removing Mower Blades
1. Park machine safely. (See Parking Safely in the SAFETY section.)
a. Hold shield perpendicular to deck shell, and place spring
between mounting holes.
2. Raise mower deck to gain access to mower blades. If necessary,
remove mower deck.
b. Aligning key hole in shield with index tab on wire form, slide
shield, and spring fully onto wire form.
3. Block mower blade with a piece of wood to prevent it from spinning.
c. Lower shield to deck, and pull curved leg of torsion spring down
and around wire form.
11. Install mower deck.
Checking for Bent Mower Blades
CAUTION: Avoid injury! Blades are sharp. Always wear
gloves when handling blades or working near blades.
Replace blades if defective. Never straighten or weld them.
1. Park machine safely. (See Parking Safely in the SAFETY section.)
2. Raise mower deck to highest position to access blades.
MXAL47131—UN—16APR13
Z500 Series 62 in. deck shown. Other decks are similar.
4. Loosen and remove bolt (A), washer (B), and blade (C).
5. Inspect blades; sharpen, balance or replace blades as necessary.
Installing Mower Blades
1. Make sure deflector cup (D) is seated properly between mower
spindle and blade.
45
Service Electrical
2. Position mower blade (C) with cutting edge toward ground onto
mower spindle.
3. Install washer (B), with cupped side towards blade, and install bolt
(A) to secure blade onto spindle shaft.
4. Block mower blade with a piece of wood to prevent spinning and
tighten bolt to specification.
Specification
Mower Blade Bolt — Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 N·m (50 lb-ft)
Service Electrical
Electrical
WARNING: Battery posts, terminals and related accessories contain
lead and lead components, chemicals known to the State of California
to cause cancer and reproductive harm. Wash hands after handling.
GXT002423—UN—15JUL15
Service the Battery Safely
4. Disconnect negative (-) battery cable (A).
5. Push red cover (B) away from positive (+) battery terminal and
remove cable (C) from battery.
6. Remove battery.
Installing
1. Place battery into battery tray as shown.
2. Connect positive (+) cable to battery first, then negative (-) cable.
3. Apply general-purpose grease or silicone spray to terminals to help
prevent corrosion.
4. Slide red cover over positive battery terminal.
5. Install battery compartment cover.
6. Lower operator seat.
MXAL42869—UN—09APR13
Cleaning Battery and Terminals
1. Park machine safely. (See Parking Safely in the SAFETY section.)
2. Disconnect and remove battery.
CAUTION: Avoid injury! The battery produces a flammable
and explosive gas.
To prevent the battery from exploding:
3. Wash battery with solution of four tablespoons of baking soda to
one gallon of water. Be careful not to get the soda solution into the
cells.
•
•
•
•
•
Do not smoke or have open flame near battery.
Wear eye protection and gloves.
Do not allow direct metal contact across battery posts.
Remove negative cable first when disconnecting.
Install negative cable last when connecting.
4. Rinse the battery with plain water and dry.
5. Clean terminals and battery cable ends with wire brush until bright.
6. Install battery.
Removing and Installing the Battery
7. Attach cables to battery terminals, beginning with the positive
cable, using washers and nuts.
Removing
8. Apply spray lubricant to terminal to prevent corrosion.
1. Park machine safely. (See Parking Safely in the SAFETY section.)
2. Rotate operator seat forward.
3. Remove battery compartment cover.
46
Service Miscellaneous
5. Remove the fuse and check metal strip in fuse window. Discard
Using Booster Battery
fuse(s) if strip is broken.
CAUTION: Avoid injury! The battery produces a flammable
and explosive gas.
6. Push new, correct amp, fuse into correct socket.
7. Lower operator’s seat.
To prevent the battery from exploding:
•
•
•
Do not smoke or have open flame near battery.
Wear eye protection and gloves.
Service Miscellaneous
Do not jump-start or charge a frozen battery. Warm
battery to specification.
Specification
Using Proper Fuel and Stabilizer
Battery — Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16°C (60°F)
•
Do not connect the negative (-) booster cable to the
negative (-) terminal of the discharged battery. Connect at
a good ground location away from the discharged battery.
IMPORTANT: Avoid damage! Using stale, contaminated, or
improper fuel can result in engine and fuel system damage.
Repairs caused by stale, contaminated, or improper fuel
are not covered by warranty.
Use regular grade unleaded fuel with an octane rating of 87 octane or
higher. Fuel blends containing up to 10% ethanol or up to 15% MTBE
reformulated fuel are acceptable. Do not use fuel or additives
containing methanol as engine damage can occur.
Always use fresh, clean fuel that is purchased in a quantity that can be
used within approximately 30 days. Fuel stabilizer should always be
added to the fuel each time fuel is purchased. Add stabilizer before
filling the fuel container to insure proper mixing. Such practice helps
prevent engine performance problems and allows fuel storage in the
machine all year without draining.
Store fuel in plastic containers to reduce condensation. Make sure that
the cap on the fuel container is tight to reduce fuel contamination and
evaporation. For best fuel storage life, use a self-sealing gas can.
MXAL42872—UN—09APR13
Fuel is blended to give best seasonal performance. To avoid engine
performance problems such as hard starting or vapor lock, use in-
season fuel. Use fuel during warm weather that was purchased during
that season, and use fuel during cold weather that was purchased
during that season.
A — Booster Battery
B — Disabled Vehicle Battery
C — Positive (+) Post
D — Positive (+) Post
E — Negative (-) Post
F — Negative (-) Booster Cable End
Fuel can become stale in machines with engines that are used
seasonally or infrequently during a season. Stale fuel can produce
varnish and plug carburetor or EFI components which can affect engine
performance.
1. Connect positive (+) booster cable to booster battery (A) positive
(+) post (C).
2. Connect the other end of positive (+) booster cable to the disabled
vehicle battery (B) positive (+) post (D).
Keep fuel storage container tightly covered and in a cool area out of
direct sunlight. Fuel can break down and degrade if not sealed properly
or exposed to sun and heat.
3. Connect negative (–) booster cable to booster battery negative (–)
post (E).
Condensation may collect in the fuel tank because of a variety of
operating or environmental conditions and, over time, may affect your
machine’s operation. Fill machine fuel tank at the end of the day.
IMPORTANT: Avoid damage! Electric charges from the booster
battery damages machine components. Do not install
negative booster cable to machine frame. Install only to the
engine block.
Install negative booster cable away from moving parts in
the engine compartment, such as belts and fan blades.
4. Connect the other end (F) of negative (–) booster cable to a metal
part of the disabled machine engine block away from battery.
5. Start the engine of the disabled machine and run machine for
several minutes.
6. Carefully disconnect the booster cables in the exact reverse order:
negative cable first and then the positive cable.
Replacing Fuse
1. Park machine safely. (See Parking Safely in the SAFETY section.)
2. Raise operator’s seat.
3. Remove battery compartment cover.
4. Refer to the service label behind the operator’s seat for fuse circuit
identification and location.
47
Service Miscellaneous
Filling Fuel Tank
CAUTION: Avoid injury! Fuel vapors are explosive and
flammable:
•
•
•
•
•
•
•
Shut engine off before filling fuel tank.
Allow engine to cool before refueling.
Do not smoke while handling fuel.
Keep fuel away from flames or sparks.
Fill fuel tank outdoors or in ventilated area.
Clean up spilled fuel immediately.
To prevent static electric discharge, use clean approved
non-metal container.
IMPORTANT: Avoid damage! Dirt and water in fuel causes engine
damage:
•
•
•
Clean dirt and debris from the fuel tank opening.
Use clean, fresh, stabilized fuel.
GXT002211—UN—09JUN15
To keep condensation out of the fuel tank, fill the fuel
tank at the end of each days operation.
2. Safely lift rear of machine frame points (A). Place jack stands or
other stable supports onto transaxle locations (B).
•
Use a non-metallic funnel with a plastic mesh strainer
when filling the fuel tank or container.
To prevent condensation and freezing during cold weather, fill fuel tank
at the end of each days operation.
1. Park machine safely. (See Parking Safely in the SAFETY section.)
2. Allow engine to cool.
3. Remove any trash from area around fuel tank cap.
4. Remove fuel tank cap slowly to allow any pressure built up in tank
to escape.
5. Fill fuel tank only to bottom of filler neck. Do not overfill.
6. Install fuel tank cap.
•
Gas models: Turn cap until clicks.
Lifting Machine
1. Park machine safely. (See Parking Safely in the SAFETY section.)
CAUTION: Avoid injury! The machine can fall or slip from an
unsafe lifting device or supports.
•
•
Use a safe lifting device rated for the load to be lifted.
GXT002212—UN—09JUN15
Lower machine onto jack stands or other stable supports
and block wheels before servicing.
3. Safely lift front of machine at machine frame point (C). Place jack
stands or other stable supports onto machine frame locations (D).
NOTE: Remove any material collection system attachments prior to
lifting machine.
4. If only lifting front of machine, block rear wheels remaining on
ground to avoid movement of machine.
5. To lower machine, lift front and/or rear of machine, and remove jack
stands or supports. Lower machine.
48
Service Miscellaneous
5. Take wheel assembly to an authorized service dealer for repairs.
Checking Tire Pressure
Installing
CAUTION: Avoid injury! Explosive separation of tire and rim
parts is possible when they are serviced incorrectly:
1. Install wheel assembly with valve stem to the outside.
2. Tighten wheel nuts evenly in alternating sequence until snug.
3. Lower machine completely to the ground.
•
Do not attempt to mount a tire without the proper
equipment and experience to perform the job.
•
Make sure that all tires are inflated to the recommended
pressure, especially when operating on slopes. Low
pressure can cause machine to become unstable on
slopes.
4. Tighten wheel nuts to specification.
Specification
Wheel Nuts — Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 N·m (75 lb.-ft.)
•
•
Do not weld or heat a wheel and tire assembly. Heat can
cause an increase in air pressure resulting in an
explosion. Welding can structurally weaken or deform the
wheel.
Removing and Installing Front Caster
Wheels
Do not stand in front or over the tire assembly when
inflating. Use a clip-on chuck and extension hose long
enough to allow you to stand to one side.
Disassembly:
1. Park machine safely. See “Park Machine Safely” in the Safety
section.
1. Check tires for damage.
2. Jack up front of machine and place on safety stands.
2. Check tire pressure with an accurate low-pressure gauge. (See
SPECIFICATIONS Section for correct tire pressure.)
3. A lower pressure will improve traction and performance depending
on turf conditions or if transport areas have steep inclines.
4. Add or remove air, if necessary.
Removing and Installing Wheel Assembly
Removing
1. Park machine safely. (See Parking Safely in the Safety section.)
CAUTION: Avoid injury! The machine can fall or slip from an
unsafe lifting device or supports.
•
•
Use a safe lifting device rated for the load to be lifted.
Lower machine onto jack stands or other stable supports
and block wheels before servicing.
IMPORTANT: Avoid damage! Place jack stands under frame, not
under transmission or engine, when raising or supporting
machine.
MXAL47137—UN—16APR13
2. Raise machine with a safe lifting device and lower machine onto
jack stands or other stable supports. Block wheels remaining on
the ground to prevent machine movement.
3. Support caster assembly and remove flange bolt (A) and cap (B).
4. Remove caster from machine.
MXAL42875—UN—09APR13
3. Remove the wheel nuts (A).
4. Remove the wheel assembly.
MXAL47138—UN—16APR13
CAUTION: Avoid injury! Explosive separation of tire and rim
parts is possible when they are serviced incorrectly:
5. Inspect bearings (C) at top and bottom of frame. Replace worn or
damaged bearings.
•
Do not attempt to mount a tire without the proper
equipment and experience to perform the job.
49
Service Miscellaneous
•
Tighten caster locknut and bolt to specification.
Specification
Caster Locknut — Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 N·m (35 lb-ft)
•
Tighten flange bolt securing yoke to specification.
Specification
Flange Bolt — Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 N·m (35 lb-ft)
Removing and Installing Style Cover
1. Park machine safely. (See Parking Safely in the SAFETY section.)
MXAL47139—UN—16APR13
6. Remove nut (D) and pull bolt out of caster.
7. Remove wheel assembly (E).
GXT002438—UN—15JUL15
2. Remove two bolts and motion control lever (A) from either side of
machine.
3. Raise seat and rotate forward. Remove battery cover (B).
MXAL47140—UN—16APR13
4. Disconnect seat switch wiring harness connector (C). Lift switch
harness from channel in cover, and place in battery compartment.
8. Remove shield (F) and bearing (G). Inspect shields, wheel, and
bearings for wear or damage. Replace worn or damaged parts.
5. Remove pin and seat lanyard (D) from cover. Remove two L-pins
and seat (E).
6. Remove three push retainers (F) on each side of style panel.
7. Remove fuel tank cap (G) and cover tank opening.
8. Lift style panel to remove from machine and immediately install cap
(G) on fuel tank.
9. Repeat steps in reverse order to install style panel on machine.
Cleaning and Repairing Metal Surfaces
Cleaning:
Follow automotive practices to care for your vehicle painted metal
surfaces. Use a high-quality automotive wax regularly to maintain the
factory look of your vehicle’s painted surfaces.
Repairing Minor Scratches (surface scratch):
GXT002156—UN—02JUN15
1. Clean area to be repaired thoroughly.
9. Inspect bearing wear areas (H), and bolt holes (I) for wear or
damage. Replace if necessary.
IMPORTANT: Avoid damage! Do not use rubbing compound on
painted surfaces.
Assembly
2. Use automotive polishing compound to remove surface scratches.
3. Apply wax to entire surface.
•
•
Apply grease to caster shaft and bolt.
Assemble in the reverse order of disassembly.
50
Troubleshooting
Repairing Deep Scratches (bare metal or primer showing):
IF
CHECK
1. Clean area to be repaired with rubbing alcohol or mineral spirits.
Engine Vapor Locks
Fuel tank vent plugged.
Dirt in fuel filter.
2. Use paint stick with factory-matched colors available from your
authorized dealer to fill scratches. Follow directions included on
paint stick for use and for drying.
Cooling fins plugged.
Loose hose connection at fuel filter or fuel
pump.
3. Smooth out surface using an automotive polishing compound. Do
not use power buffer.
Engine Overheats
Engine air intake screen plugged.
Cooling fins plugged.
Engine oil low or too high.
Engine operated too long at a slow idle
speed.
4. Apply wax to surface.
Engine Will Not Idle
Engine Knocks
Spark plug not gapped correctly.
Faulty spark plug.
Troubleshooting
Operator raising off the seat.
Stale or low octane fuel.
Engine overloaded.
Low engine speed.
Oil level low.
Using Troubleshooting Chart
If you are experiencing a problem that is not listed in this chart, see your authorized dealer for
service.
Engine Stops Or Misses When Operating On Fuel tank less than half full of fuel.
Hillsides
Operator raising off of the seat.
When you have checked all the possible causes listed and you are still experiencing the
problem, see your authorized dealer
Engine Backfires
Faulty spark plug.
Operator raising off of the seat.
Engine Loses Power
Engine overheating.
Too much oil in engine.
Dirty air cleaner.
Engine
Faulty spark plug.
IF
CHECK
Travel speed is too fast for conditions.
Improper fuel.
Poor Engine Performance
Dirt in fuel system or fuel is old. Replace fuel
with fresh stabilized fuel. Obtain fuel from
another supplier before suspecting machine
problems. Suppliers blend fuels differently
and changing suppliers will generally solve
any performance problems
Excessive Fuel Consumption
Black Exhaust Smoke
Choke is not fully open.
Air filter is dirty or oil soaked.
Electrical
Fuel blended with alcohol or ether may
contribute to performance problems by
causing gum and varnish deposits,
IF
CHECK
especially if fuel is stored for several weeks
or more. Obtain fresh fuel.
Starter Does Not Work Or Will Not Turn
Engine
Park brake not locked.
Mower is engaged.
Engine Will Not Start - No Crank
Park brake not locked.
Battery terminals are corroded.
Battery not charged.
Motion control levers not in Start/Shutdown
position.
Motion control levers not in outward position.
Mower is engaged.
Defective brake, mower engagement, or key
switch.
Blown fuse.
Electrical problem - See Electrical
Troubleshooting Section
Defective key switch
Battery Will Not Charge
Lights Do Not Work
Dead cell in the battery.
Engine Cranks But Will Not Start
Spark plug wire is loose or disconnected.
Improper fuel.
Blown charging fuse.
Battery cables and terminals are dirty.
Low engine speed or excessive idling.
Plugged fuel filter.
Electrical problem - See Electrical
Troubleshooting Section
Light plug disconnected.
Loose or burned out bulb.
Blown headlight fuse.
Engine Is Hard To Start
Carburetor is not adjusted properly or dirty.
Choke not fully closing.
Plugged fuel filter.
Faulty spark plug.
Machine
Stale or improper fuel.
Loose or corroded electrical connections.
Engine oil viscosity.
IF
CHECK
Engine Runs Unevenly
Cooling fins plugged.
Machine Vibrates Too Much Or Rattles
Excessively
Attachment drive belts worn or damaged.
Mower blades not balanced.
Loose electrical connections.
Choke or throttle cable sticking.
Choke not fully open.
Traction drive belt damaged or worn.
Dirt on drive sheaves.
Fuel line or fuel filter plugged.
Stale or dirty fuel.
Machine Will Not Move With Engine Running Transmission hydraulic oil level low.
Transmission belt broke.
Improper fuel.
Air cleaner element plugged.
Bypass valve levers are engaged.
Engine Misses Under Load
Faulty spark plug.
Stale or dirty fuel.
Plugged fuel filter.
Machine Moves With Engine Running And
Hydrostatic Control In Neutral
Linkage out of adjustment.
Transmission neutral out of adjustment.
Mower Lift Will Not Latch in Transport
Deck is adjusted too high.
51
Storage
Storage
IF
CHECK
Front of machine squeaks while driving
Lubricate mower front draft rod at front and
rear pivot points.
Storing Safety
CAUTION: Avoid injury! Fuel vapors are explosive and
flammable.
Mower
Engine exhaust fumes contain carbon monoxide and cause
serious illness or death:
IF
CHECK
Discharge Chute Plugged
Travel speed too fast.
Grass too long.
•
Run the engine only long enough to move the machine to
or from storage.
Grass too wet.
•
If a machine is stored before allowing it to cool, machine
fires and structure fires can occur. Fires can occur if
debris is not removed from around the engine and muffler,
or if stored near combustible materials.
Engine rpm not at mow position.
Restricted air flow.
Belt installed incorrectly.
Adjust cutting height to remove only 1/3 of
grass at a time.
•
•
Do not store vehicle with fuel in the tank inside a building
where fumes reach an open flame or spark.
Patches Of Grass Uncut
Belt Slipping
Travel speed too fast.
Allow the engine to cool before storing the machine in any
enclosure.
Engine rpm not at mow position.
Mower deck needs cleaning.
Debris in sheaves.
Worn belt.
Preparing Machine for Storage
1. Repair any worn or damaged parts. Replace parts if necessary.
Tighten loose hardware.
Belt tension is incorrect.
Too Much Vibration
Debris on mower deck or in sheaves.
Damaged drive belt.
2. To prevent rust, repair scratched or chipped metal surfaces.
3. Remove grass and debris from machine.
Damaged sheaves or sheaves out of
alignment.
Blades out of balance.
4. Clean under the deck and remove grass and debris from inside
chute and bagger, if applicable.
Front Tires Vibrate
Set front tire pressure to 10 psi. If vibration
continues, reduce tire pressure by 1 psi until
vibration stops. Do not reduce tire pressure
below 6 psi.
5. Wash the machine and apply wax to metal and plastic surfaces.
6. To dry belts and pulleys, run machine for five minutes.
Blades Scalping Grass
Cutting too low.
7. To prevent rust, apply light coat of engine oil on pivot and wear
points.
Mower wheels not adjusted correctly.
Turning speed too fast.
Ridges in terrain.
8. Lubricate grease points and check tire pressure.
Rough or uneven terrain.
Low tire pressure.
Preparing Fuel and Engine For Storage
Mower Loads Down Tractor
Engine rpm too low.
Fuel:
Travel speed too fast.
Debris wrapped around mower spindles.
Adjust cutting height to remove only 1/3 of
grass at a time.
If you have been using “Stabilized Fuel,” add stabilized fuel to tank until
the tank is full.
NOTE: Filling the fuel tank reduces the amount of air in the fuel tank
and helps reduce deterioration of fuel.
Uneven Cut
Mower deck not leveled properly.
Travel speed too fast.
Blades dull.
Mower wheels not adjusted correctly.
Tire pressure unequal.
If you are not using “Stabilized Fuel:”
1. Park machine safely in a well-ventilated area. (See Parking Safely
in the SAFETY section.)
Adjust cutting height to remove only 1/3 of
grass at a time.
NOTE: Try to anticipate the last time the machine will be used for the
season so very little fuel is left in the fuel tank.
Excessive Clippings are Expelled from Front Conditions may be too dry or terrain too
of Mower Deck
uneven to provide good seal between front of
com or contact dealer to purchase dry
condition kit.
2. Turn on engine and allow to run until it runs out of fuel.
3. For machines equipped with key switch, turn key to off position.
IMPORTANT: Avoid damage! Stale fuel can produce varnish and
plug carburetor or injector components and affect engine
performance.
•
Add fuel conditioner or stabilizer to fresh fuel before
filling tank.
4. Mix fresh fuel and fuel stabilizer in separate container. Follow
stabilizer instructions for mixing.
5. Fill fuel tank with stabilized fuel.
6. Run engine for a few minutes to allow fuel mixture to circulate
through carburetor on gas engine or fuel injectors on diesel engine.
52
Specifications
Engine:
Valve Clearance (Cold) . . . . . . . . . . . . . . . . . . . . . . . . 0.10 - 0.15 mm (0.004 - 0.006 in.)
Spark Plug Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.76 mm (0.030 in.)
Spark Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (180 lb-in.)
Engine storage procedure should be used when vehicle is not to be
used for longer than 60 days.
1. Change engine oil and filter while engine is warm.
2. Service air filter if necessary.
Z535M, Z535R
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Briggs & Stratton
Model Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Cyclonic
Power Rating Information. . . . . . . . . . . . . . . . . . . . . . . http://www.briggsandstratton.com/
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.25 mm (3.12 in.)
Stroke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.40 mm (2.890 in.)
Displacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 724 cm3 (44.18 cu in.)
Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-Twin
Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Four
Valve Clearance (Cold) . . . . . . . . . . . . . . . . . . . . . . . . 0.10 - 0.15 mm (0.004 - 0.006 in.)
Spark Plug Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.76 mm (0.030 in.)
Spark Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (180 lb-in.)
3. Clean debris from engine air intake screen.
4. On gas engines:
•
Remove spark plugs. Put 30 mL (1 oz.) of clean engine oil in
cylinders.
•
•
Install spark plugs, but do not connect spark plug wires.
Crank the engine 5 or 6 times to allow oil to be distributed.
5. Clean the engine and engine compartment.
6. Remove battery.
7. Clean the battery and battery posts. Check the electrolyte level, if
your battery is not maintenance free.
8. Close fuel shutoff valve, if your machine is equipped.
9. Store the battery in a cool, dry place where it will not freeze.
NOTE: The stored battery should be recharged every 90 days.
Z540M, Z540R
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kawasaki
Model Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FS730V
Power Rating Information. . . . . . . . . . . . . . . . . . . http://www.kawasaki-criticalpower.com /
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 mm (3.070 in.)
Stroke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 mm (2.992 in.)
Displacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 726 cm3 (44.3 cu in.)
Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-Twin
Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Four
Valve Clearance (Cold) . . . . . . . . . . . . . . . . . . . . . . 0.075 - 0.125 mm (0.002 - 0.005 in.)
Spark Plug Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.75 mm (0.029 in.)
Spark Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (180 lb-in.)
10. Charge the battery.
IMPORTANT: Avoid damage! Prolonged exposure to sunlight
could damage surfaces. Store machine inside or use a
cover if stored outside.
11. Store the vehicle in a dry, protected place. If vehicle is stored
outside, put a waterproof cover over it.
Removing Machine From Storage
1. Check tire pressure.
2. Check engine oil level.
3. Check battery electrolyte level, if your battery is not maintenance
free. Charge battery if necessary.
Drivetrain
4. Install battery.
Transaxle Motors (Z525E, Z535M, Z540M) . . . . . . . . . . . . . . . . . . . . . . Tuff Torq TZT7 D
Transaxle Motors (Z535R, Z540R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tuff Torq TZT7 M
Number of Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic, Variable Speed
5. On gas engines: Check spark plug gap. Install and tighten plugs to
specified torque.
6. Lubricate all grease points.
7. Open fuel shut-off valve, if your machine is equipped.
Travel Speeds at Full Engine RPM
8. Run the engine 5 minutes without the mower or any attachments
running to allow oil to be distributed throughout engine.
9. Be sure all shields and guards or deflectors are in place.
Z525E, Z535M, Z540M (22 in. Tires)
Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-13.7 km/h (0-8.5 mph)
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-6.4 km/h (0-4.0 mph)
Specifications
Engine
Z535R, Z540R (23 in. Tires)
Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-14.5 km/h (0-9.0 mph)
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-7.25 km/h (0-4.5 mph)
Z525E
Electrical System
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Briggs & Stratton
Model Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 ELS
Power Rating Information. . . . . . . . . . . . . . . . . . . . . . . http://www.briggsandstratton.com/
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.25 mm (3.12 in.)
Stroke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.40 mm (2.890 in.)
Displacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 724 cm3 (44.18 cu in.)
Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-Twin
Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Four
Battery Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Volt
Cold Cranking Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 Amps
53
Specifications
Fuel System
Z540M
Height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1045 mm (41.1 in.)
Width (with 48A Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1587 mm (62.5 in.)
Width (with 54A Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1737 mm (68.4 in.)
Width (with 62C Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1920 mm (75.6 in.)
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1955 mm (77 in.)
Weight (with 48A Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289.4 kg (638 lb)
Weight (with 54A Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296.6 kg (654 lb)
Weight (with 62C Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311.7 kg (687 lb)
Fuel Types (Recommended):
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Regular Grade 87 Octane Unleaded Fuel
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ethanol Blended Fuel (Up to 10%)
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replaceable - paper element
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pulse
Fuel Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carburetor
Tires
Z540R
Height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1164 mm (45.8 in.)
Width (with 48HC Deck). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1586 mm (62.4 in.)
Width (with 54HC Deck). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1734 mm (68.3 in.)
Width (with 60HC Deck). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1868 mm (73.5 in.)
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1955 mm (77 in.)
Weight (with 48HC Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316.2 kg (697 lb)
Weight (with 54HC Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325.2 kg (717 lb)
Weight (with 60HC Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334.7 kg (738 lb)
Front (Z525E, Z535M, Z540M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13x5.00-6 (Ribbed)
Front (Z535R, Z540R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13x6.50-6 (Ribbed)
Rear (Z525E, Z535M, Z540M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22x9.5-10 (Turf)
Rear (Z535R, Z540R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23x10.5-12 (Turf)
Inflation - Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 kPa (10 psi)
Inflation - Rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 kPa (10 psi)
Capacities
Mower Decks
Crankcase with oil filter:
Z525E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 L (2.0 qt)
Z535M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 L (2.0 qt)
Z535R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 L (2.0 qt)
Z540M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 L (2.2 qt)
Z540R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 L (2.2 qt)
48A Mower (Z525E, Z535M, Z540M)
Cutting Width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22 m (48 in.)
Blades-Rotary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Blade Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 N•m (50 lb-ft)
Cutting Height (Approximately) . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 - 102 mm (1 - 4 in.)
Fuel Tank
54A Mower (Z525E, Z535M, Z540M)
All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 L (4.5 gal)
Cutting Width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.37 m (54 in.)
Blades-Rotary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Blade Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 N•m (50 lb-ft)
Cutting Height (Approximately) . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 - 102 mm (1 - 4 in.)
Dimensions
Z525E
Height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 980 mm (38.6 in.)
Width (48A Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1587 mm (70.4 in.)
Width (54A Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1737 mm (68.4 in.)
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1955 mm (77 in.)
Weight (with 48A Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .279 kg (615 lb)
Weight (with 54A Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286.2 kg (631 lb)
48HC High Capacity Mower (Z540R)
Cutting Width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22 m (48 in.)
Blades-Rotary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Blade Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 N•m (50 lb-ft)
Cutting Height (Approximately) . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 - 102 mm (1 - 4 in.)
54HC High Capacity Mower (Z535R, Z540R)
Z535M
Cutting Width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.37 m (54 in.)
Blades-Rotary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Blade Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 N•m (50 lb-ft)
Cutting Height (Approximately) . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 - 102 mm (1 - 4 in.)
Height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1045 mm (41.1 in.)
Width (with 48A Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1587 mm (70.4 in.)
Width (with 54A Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1737 mm (68.4 in.)
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1955 mm (77 in.)
Weight (with 48A Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .279 kg (615 lb)
Weight (with 54A Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286.2 kg (631 lb)
60HC High Capacity Mower (Z540R)
Cutting Width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.52 m (60 in.)
Blades-Rotary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Blade Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 N•m (50 lb-ft)
Cutting Height (Approximately) . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 - 102 mm (1 - 4 in.)
Z535R
Height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1164 mm (45.8 in.)
Width (with 54HC Deck). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1734 mm (68.3 in.)
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1955 mm (77 in.)
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322.1 kg (710 lb)
62C Mower (Z540M)
Cutting Width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.57 m (62 in.)
Blades-Rotary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
54
Warranty
smog standards. John Deere must warrant the emissions control
Blade Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 N•m (50 lb-ft)
Cutting Height (Approximately) . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 - 102 mm (1 - 4 in.)
system on your spark ignited off-road engine equipment for the period
listed below provided there has been no abuse, neglect or improper
maintenance of your equipment.
Recommended Lubricants
Your emissions control system may include parts such as: carburetors
or fuel-injection system, ignition system, catalytic converters, fuel tanks,
valves, filters, clamps, connectors, and other associated components.
Also included may be hoses, belts, sensors and other emission-related
assemblies.
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TURF-GARD® OR PLUS-4®
Grease
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GREASE-GARD™ Premium Plus
. . . . . . . . . . . . . . . . . . . . . . . . . . John Deere Multi-Purpose HD Lithium Complex Grease
Where a warrantable condition exists, John Deere will repair your spark
ignited off-road engine equipment at no cost to you including diagnosis,
parts and labor.
(Specifications and design subject to change without notice.)
Manufacturer’s Warranty Coverage
This emissions control system is warranted for two years for models
Z335E, Z355E, Z525E, D105, D110, D125, D130, D140, D155, D160,
D170 and three years for all other models referenced in this operator’s
manual. If any emissions related part on your equipment is defective,
the part will be repaired or replaced by John Deere.
Warranty
Product Warranty
Owner’s Warranty Responsibilities
John Deere offers a standard warranty on new John Deere products.
For a copy of the product warranty statement or for details on the
warranty terms and conditions for products purchased in the United
States and Canada, please contact your local John Deere Dealer or
utilize the following resources:
•
As the spark ignited off-road engine equipment owner, you are
responsible for the performance of the required maintenance listed
in your Operator’s Manual. John Deere recommends that you retain
all receipts covering maintenance on your spark ignited off-road
engine equipment, but John Deere cannot deny warranty solely for
lack of receipts or for your failure to ensure the performance of all
scheduled maintenance.
United States
Website:
•
•
As the spark ignited off-road engine equipment owner, you should
however be aware that John Deere may deny you warranty
coverage if your spark ignited off-road engine equipment or a part
has failed due to abuse, neglect, or improper maintenance or
unapproved modifications.
warranty/warranty.page
Toll Free: 1-800-537-8233
You are responsible for presenting your spark ignited off-road engine
equipment to a John Deere Turf and Utility distribution center or
service center as soon as a problem exists. The warranty repairs
should be completed in a reasonable amount of time, not to exceed
30 days. If you have a question about your emissions warranty
coverage, how to make an emissions warranty claim or how to make
arrangements for emissions-related authorized repairs, you should
contact your John Deere Turf and Utility retailer, or the John Deere
Customer Contact Center at 1-800-537-8233, or email John Deere
Dealer Locator:
Canada
Website (English):
service_plans_warranties/service_plans_
warranties.page
com/app/utils/login_form/redirect/ask.
Website (French):
service_plans_warranties/service_plans_
warranties.page
General Emissions Warranty Coverage
The warranty period begins on the date the equipment is delivered to
an ultimate purchaser. John Deere warrants to the ultimate purchaser
and each subsequent purchaser that the spark ignited off-road engine
equipment is:
Toll Free: 1-800-537-8233
Dealer Locator:
•
Designed, built and equipped so as to conform to all applicable
regulations adopted by the California Air Resources Board;
Emission-related warranties are included in this Operator’s
Manual, and applicable if required by law or regulation.
•
Designed, built and equipped so as to conform at the time of sale
with applicable U.S. Environmental Protection Agency regulations
under 40 CFR Parts 1054 and 1060: and,
For products purchased in a country other than the United States or
Canada, please contact your local John Deere dealer for assistance.
•
•
Free from defects in materials and workmanship which cause such
engine to fail to conform with applicable regulations for the
Emissions Control System Warranty period provided herein.
California and U.S. EPA Emissions Control
System Warranty Statement (Off-Road Gas
Engines)
For owners located more than 100 miles from a John Deere
authorized service center, John Deere will pay either for shipping
costs to and from an authorized service center, provide for a service
technician to come to the owner to make the warranty repair, or pay
for the repair to be made at a local non-authorized service center.
These provisions do not apply to Alaska, Hawaii, Arizona, Colorado,
Idaho, Montana, Nebraska, Nevada, New Mexico, Oregon, Texas,
Utah, and Wyoming.
Your Warranty Rights and Obligations
The California Air Resources Board, John Deere, and the United States
Environmental Protection Agency are pleased to explain the emissions
control system’s warranty on your model year 2016 or 2017 spark
ignited off-road engine equipment. In California, new equipment that
uses small or large (less than 1 liter) spark ignited off-road engines
must be designed, built and equipped to meet the State’s stringent anti-
Emissions Warranty Interpretation
•
Any warranted part that is not scheduled for replacement as required
by the maintenance instructions in the Operator’s Manual is
55
Warranty
warranted as provided herein. If any such part fails during the period
•
•
Electronic controls
Hoses, belts, connectors and assemblies
of warranty coverage it will be repaired or replaced by John Deere.
Any such part repaired or replaced under warranty is warranted for
the remaining warranty period.
Limited Liability
•
•
Any warranted part that is scheduled only for regular inspection in
the maintenance instructions in the Operator’s Manual is warranted
as provided herein. A statement in the Operator’s Manual to the
effect of “repair or replace as necessary” does not reduce the period
of warranty coverage. Any such part repaired or replaced under
warranty is warranted for the remaining warranty period.
a) The liability of John Deere under this Emissions Control System
Warranty is limited solely to the remedying of defects in materials or
workmanship. Except as otherwise expressly provided herein, this
warranty does not cover inconvenience or loss of use of the non-road
equipment or engine or transportation of the equipment or engine to or
from the John Deere Turf and Utility retailer. John Deere shall not be
liable for any other expense, loss, or damage, whether direct,
incidental, consequential (except as listed above under “coverage”) or
exemplary arising in connection with the sale or use of or inability to use
the non-road equipment or engine for any other purpose.
Any warranted part that is scheduled for replacement as required
maintenance in the Operator’s Manual is warranted for the period of
time prior to the first scheduled replacement point for that part. If the
part fails prior to the first scheduled replacement, the part will be
repaired or replaced by John Deere. Any such part repaired or
replaced under warranty is warranted for the remainder of the period
prior to the first scheduled replacement point for the part.
b) No express emissions control system warranty is given by John
Deere with respect to the equipment or engine except as specifically
set forth in this document. Any emissions control system warranty
implied by law, including any warranty of merchantability or fitness for a
particular purpose, is expressly limited to the emissions control system
warranty terms set forth in this document.
•
•
•
•
Repair or replacement of any warranted part under the warranty will
be performed at no charge to the owner at any authorized John
Deere Turf and Utility retailer.
The owner will not be charged for diagnostic labor which leads to the
determination that a warranted part is defective, provided such work
is performed by John Deere.
c) No dealer is authorized to modify this Federal, California and John
Deere Emissions Control System Warranty.
John Deere will repair damages to other engine components
proximately caused by a failure under warranty of any emissions-
related warranted part.
Tire Warranty
John Deere warranty applies for tires available through the John Deere
parts system. For tires not available through the John Deere parts
system, the tire manufacturer’s warranty applicable to your machine
may not apply outside the U.S. (See your John Deere dealer for specific
information.)
Add-on or modified parts that are not exempted by the California Air
Resources Board may not be used. The use of any non-exempted
add-on or modified parts will be grounds for disallowing a warranty
claim. John Deere will not be liable to warrant failures of warranted
parts caused by the use of a non-exempted add-on or modified part.
Limited Battery Warranty For Factory
Installed Batteries
Emission Warranty Parts List
Coverage under this warranty includes, but is not limited to, the parts
listed below (the emissions control system parts) to the extent these
parts were on the engine and equipment purchased.
NOTE: Applicable in North America only. For complete machine
warranty, reference a copy of the John Deere warranty
statement. Contact your John Deere dealer to obtain a copy.
Fuel Metering System:
•
•
•
Carburetor and internal parts (or fuel injection system)
Air/fuel ratio feedback and control system
Cold start enrichment system
TO SECURE WARRANTY SERVICE
The purchaser must request warranty service from a John Deere dealer
authorized to sell John Deere batteries, and present the battery to the
dealer with the top cover plate codes intact.
Evaporative System:
•
•
•
•
•
•
•
Fuel tank, fuel cap and tether
Fuel hose, line, fittings, clamps
Fuel pump, fuel shut-off valve
Fuel vapor hoses, fittings
Carbon canister
FREE REPLACEMENT PERIOD
Any new battery which becomes unserviceable (not merely discharged)
due to defects in material or workmanship within the FREE
REPLACEMENT PERIOD will be replaced free of charge. Installation
costs will be covered by warranty if the unserviceable battery was
installed by a John Deere factory or dealer and the replacement battery
is installed by a John Deere dealer.
Rollover/slant valve for fuel vapor control
Purge and vent line
Air Induction System:
PRO RATA ADJUSTMENT (batteries with letter code identification
only)
•
•
Air cleaner
Intake manifold
Any new battery which becomes unserviceable (not merely discharged)
due to defects in material or workmanship within the Pro Rata Warranty
Period will be replaced upon payment of the battery’s current list price
less a pro rata credit for unused months of service. The applicable
adjustment period is determined from the Warranty Code printed at the
top of the battery and table below. Installation costs are not covered
after the battery warranty period has ended.
Ignition System:
•
•
•
Spark plugs
Magneto or electronic ignition system
Spark advance/retard system
Exhaust System:
THIS WARRANTY DOES NOT COVER
•
•
Exhaust manifold
Catalyst muffler
A. Breakage of the container, cover, or terminals.
B. Depreciation or damage caused by lack of reasonable and
necessary maintenance or by improper maintenance.
Miscellaneous Items Used in Above Systems
C. Transportation, mailing, or service call charges for warranty service.
D. Batteries that are merely discharged.
•
Valves and Switches: vacuum, temperature, position, check, time-
sensitive
56
Getting Quality Service
LIMITATION OF IMPLIED WARRANTIES AND PURCHASER’S
REMEDIES
When you order parts, your John Deere dealer needs the serial number
or product identification number (PIN) for your machine or attachment.
These are the numbers that you recorded in the Product Identification
section of this manual.
To the extent permitted by law, neither John Deere nor any company
affiliated with it makes any warranties, representations, or promises as
to the quality, performance or freedom from defect of the products
covered by this warranty. IMPLIED WARRANTIES OF
Order Service Parts Online
ordering and information.
MERCHANTABILITYAND FITNESS FOR A PARTICULAR PURPOSE,
TO THE EXTENT APPLICABLE, SHALL BE LIMITED IN DURATION
TO THE APPLICABLE ADJUSTMENT PERIOD SET FORTH HERE.
THE PURCHASER’S ONLY REMEDIES IN CONNECTION WITH THE
BREACH OR PERFORMANCE OF ANY WARRANTY ON JOHN
DEERE BATTERIES ARE THOSE SET FORTH HERE. IN NO EVENT
WILL THE DEALER, JOHN DEERE OR ANY COMPANY AFFILIATED
WITH JOHN DEERE BE LIABLE FOR INCIDENTAL OR
CONSEQUENTIAL DAMAGES. (Note: Some states do not allow
limitations on how long an implied warranty lasts or the exclusion or
limitation of incidental or consequential damages. So these limitations
and exclusions may not apply to you.) This warranty gives you specific
legal rights, and you may also have some rights which vary from state
to state.
John Deere Quality Continues with Quality
Service
John Deere provides a process to handle your questions or problems,
should they arise, to ensure that product quality continues with your
John Deere dealer’s parts and service support.
Follow the steps below to get answers to any questions you may have
about your product.
1. Refer to the appropriate attachment, machine or equipment
operator manuals.
NO DEALER WARRANTY
2. Contact your John Deere dealer with unanswered questions.
The selling dealer makes no warranty of its own and the dealer has no
authority to make any representation or promise on behalf of John
Deere, or to modify the terms or limitations of this warranty in any way.
3. In North America or Canada, call the John Deere Customer
Contact Center.
•
Call 1-800-537-8233 and provide product serial number and
model number.
WARRANTY TERMS TABLE
NOTE: If your battery is not labeled with a warranty code, it is a
warranty code 6.
Warranty Code
Free Replacement Period
90 Days
Pro Rata Warranty Period
40 Months
A
B
90 Days
36 Months
C
D
E
90 Days
24 Months
12 Months
90 Days
48 Months
12 Months
F
90 Days
60 Months
G
H
6
12 Months
12 Months
6 Months
60 Months
60 Months
0 Months
12
18
12 Months
18 Months
0 Months
0 Months
The RSX850i original equipment battery will carry a 100% Full
Replacement for the duration of the complete machine warranty.
Getting Quality Service
Service Literature
If you would like a copy of the Parts Catalog or Technical Manual for
this machine call:
•
•
U.S. & Canada: 1-800-522-7448.
All Other Regions: Your John Deere dealer.
Parts
We recommend John Deere quality parts and lubricants, available at
your John Deere dealer.
Part numbers may change, use part numbers listed below when you
order. If a number changes, your dealer will have the latest number.
57
Service Record
Service Record
Record Service Dates
Oil Change
Oil Filter Change (If Equipped)
Lubricate Machine
Air Cleaner Element Check/Clean Fuel Filter Change
58
Slope Gauge
Slope Gauge
Slope Gauge Template
Hold up or copy this page and follow the directions below to use the Slope Gauge Template.
MXT013189—UN—22APR15
Use this slope gauge to determine if a slope is too steep for safe operation. Do not operate your machine on a slope greater than what is recommended in your Operator’s Manual. See Operating on
Slopes in the Safety Section.
• Fold along the appropriate line (A) to match the recommended slope.
• Align this edge (B) with a vertical surface, a tree, building, fence pole, etc.
• Compare slope (C) with folded edge.
59
Index
A
N
Adjustment, Altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Air Cleaner Elements, Checking and Cleaning. . . . . . . . . . . . . . . .35
Armrests, Adjusting (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . .19
Neutral Creep, Checking and Adjusting. . . . . . . . . . . . . . . . . . . . .39
O
Oil, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Oil Level, Checking Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Oil Level, Checking Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Oil, Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Operating Checklist, Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Operating safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Operator Station Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
B
Battery and Terminals, Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . .46
Battery, Charge and Connect at Assembly . . . . . . . . . . . . . . . . . .15
Battery, Removing and Installing. . . . . . . . . . . . . . . . . . . . . . . . . .46
Battery, Service Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Battery, Using Booster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Blades, Checking Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Blades, Servicing Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
P
Park Brake, Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Park Brake, Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Plastic And Painted Surfaces, Avoid Damage To . . . . . . . . . . . . . .19
E
Electrical Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Engine Shroud, Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Engine, Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Engine, Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
R
Record service dates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Replacement parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
S
F
Safety labels, no-text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety labels, text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety Systems, Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Safety, Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Seat, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Seat, Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Service Information, Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Service Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Slopes, operating on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Spark Arrestor, Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Spark Arrestor, Using. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Spark Plug, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Storage, Preparing Machine for . . . . . . . . . . . . . . . . . . . . . . . . . .52
Storage, Removing Machine from. . . . . . . . . . . . . . . . . . . . . . . . .53
Storing Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Style Cover, Removing and Installing . . . . . . . . . . . . . . . . . . . . . .50
Switch, Testing Motion Control Lever . . . . . . . . . . . . . . . . . . . . . .23
Switch, Testing Mower Engagement (PTO) . . . . . . . . . . . . . . . . . .22
Switch, Testing Park Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Switch, Testing Seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Switch, Using Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Switch, Using the Mower Engagement . . . . . . . . . . . . . . . . . . . . .23
Filter, Changing Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Filter, Changing Transaxle Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Filter, Replacing Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Foot Plate, Removing and Installing Mower Deck . . . . . . . . . . . . .41
Fuel and Stabilizer, Using Proper . . . . . . . . . . . . . . . . . . . . . . . . .47
Fuel Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Fuel Tank, Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Fuse, Replacing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
G
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Guard, Cleaning Engine Screen . . . . . . . . . . . . . . . . . . . . . . . . . .32
H
Hour Meter, Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
I
Identification Numbers, Record. . . . . . . . . . . . . . . . . . . . . . . . . . . 3
L
Labels, Locating Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Labels, safety no-text. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Labels, safety text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Levers, Using the Motion Control . . . . . . . . . . . . . . . . . . . . . . . . .23
Lift Arm, Lubricating Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Lifting Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
T
Template, slope gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Tire Pressure, Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Tracking, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Transaxle, Cleaning Cooling Fans. . . . . . . . . . . . . . . . . . . . . . . . .40
Transaxle Drive Belt, Checking and Replacing. . . . . . . . . . . . . . . .40
Transporting Machine on Trailer . . . . . . . . . . . . . . . . . . . . . . . . . .27
Transporting Material Collection System . . . . . . . . . . . . . . . . . . . .28
Troubleshooting chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
M
Machine, Mounting and Dismounting. . . . . . . . . . . . . . . . . . . . . . .19
Machine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Material Collection System, Unplugging. . . . . . . . . . . . . . . . . . . . .26
Metal Surfaces, Repairing and Cleaning . . . . . . . . . . . . . . . . . . . .50
Motion Control Levers, Adjusting. . . . . . . . . . . . . . . . . . . . . . . . . .19
Moving Machine by Hand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Mower, Adjusting Cutting Height . . . . . . . . . . . . . . . . . . . . . . . . . .20
Mower, Adjusting Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Mower Deck, Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Mower Deck Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Mower Deck Spindles, Lubricating . . . . . . . . . . . . . . . . . . . . . . . .29
Mower Drive Belt, Replacing (Z500 Series 48A, 48HC,
W
Warranty, product. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Warranty Registration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Wheel Assembly, Removing and Installing. . . . . . . . . . . . . . . . . . .49
Wheels, Adjusting Mower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Wheels, Removing and Installing Front Caster. . . . . . . . . . . . . . . 49
54A, 54HC, 60HC, and 62C) . . . . . . . . . . . . . . . . . . . . . . . . . .44
Mower, Engaging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Mower, Installing Deck (48A, 48HC, 54A, 54HC, 60HC
and 62C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Mower, Removing Deck (48A, 48HC, 54A, 54HC,
60HC and 62C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Mower Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Mowing Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
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