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