A zero-turn mower operates using a combination of specialized systems that allow it to make tight, precise turns. Below is a breakdown of each key system, with a detailed explanation of how every part works.
1. Engine System
1. The engine provides the necessary power to drive the mower and operate its cutting blades.
2. Most zero-turn mowers use gasoline engines, typically ranging from 15 to 30 horsepower.
3. The engine has a carburetor or fuel injection system that mixes air and fuel for combustion.
4. Spark plugs ignite the fuel-air mixture inside the cylinders, generating power.
5. The cooling system, which includes air or liquid cooling, prevents the engine from overheating.
6. A governor regulates engine speed to maintain consistent power output.
7. The air filter prevents dirt and debris from entering the engine.
8. The oil system lubricates moving parts to reduce friction and wear.
9. The exhaust system removes burned gases from the engine.
10. The starter motor and battery power the ignition system to start the mower.
2. Drive System (Hydrostatic Transmission)
1. Zero-turn mowers use hydrostatic transmissions, which provide smooth and precise control.
2. A hydraulic pump is connected to the engine and moves hydraulic fluid under pressure.
3. The hydraulic motor receives fluid from the pump and transfers power to the wheels.
4. The fluid reservoir stores hydraulic oil, which is essential for smooth operation.
5. Control levers adjust fluid flow to each wheel, enabling independent movement.
6. A bypass valve allows the mower to be pushed manually when needed.
7. Hoses and fittings connect the hydraulic components and ensure proper fluid flow.
8. The filter removes contaminants from the hydraulic fluid to prevent damage.
9. The cooling fan prevents the hydraulic system from overheating.
10. The drive axles transfer power from the hydraulic motors to the wheels.
3. Steering System
1. Instead of a traditional steering wheel, zero-turn mowers use two independent lap bars or joysticks.
2. Pushing both bars forward makes the mower move straight ahead.
3. Pulling both bars backward makes the mower reverse.
4. Moving one bar forward and the other back allows for zero-radius turns.
5. The hydrostatic drive system controls the wheel speed based on lap bar input.
6. A dampening system smooths steering movements for better control.
7. The linkage system connects lap bars to the hydraulic pumps.
8. Steering dampers prevent sudden jerky movements.
9. Return springs help bring the lap bars back to a neutral position.
10. Some models have an electronic control system for added steering precision.
4. Cutting Deck System
1. The cutting deck houses the mower blades and determines the cutting width.
2. A deck shell made of steel or aluminum protects internal components.
3. Mower blades rotate at high speeds to cut grass cleanly.
4. A spindle assembly connects the blades to the drive system.
5. The belt system transfers power from the engine to the blades.
6. A tensioner pulley maintains proper belt tension for efficiency.
7. Anti-scalp wheels prevent the deck from cutting too close to uneven terrain.
8. The discharge chute directs grass clippings away from the mower.
9. Some models have a mulching kit that finely chops clippings.
10. Deck height adjustment levers allow users to change the cutting height.
5. Fuel System
1. The fuel tank stores gasoline to power the engine.
2. A fuel cap seals the tank to prevent leaks and evaporation.
3. Fuel lines transport fuel from the tank to the engine.
4. A fuel pump moves fuel to the carburetor or fuel injectors.
5. The fuel filter removes dirt and debris before it reaches the engine.
6. The carburetor mixes fuel with air before combustion.
7. On fuel-injected models, injectors spray fuel directly into the engine.
8. A fuel shutoff valve allows users to cut off fuel supply when needed.
9. Some models have a fuel gauge to monitor fuel levels.
10. The return line sends excess fuel back to the tank in some systems.
6. Electrical System
1. The battery provides power to the starter motor and electrical components.
2. The ignition switch starts and stops the engine.
3. Fuses and relays protect electrical circuits from overload.
4. The starter motor engages the engine’s flywheel to start it.
5. A charging system recharges the battery while the engine runs.
6. The alternator or stator generates electricity to power accessories.
7. Safety switches prevent the engine from starting if conditions aren’t met.
8. Some models include headlights or LED displays for improved visibility.
9. The hour meter tracks engine run time for maintenance purposes.
10. Wiring harnesses organize and route electrical connections.
7. Suspension System
1. The frame supports all components and absorbs vibrations.
2. Shock absorbers reduce the impact of rough terrain.
3. The front caster wheels pivot for smooth turning.
4. Rear drive wheels provide traction and stability.
5. The floating deck system allows the cutting deck to move with terrain changes.
6. Some models have adjustable seat suspension for rider comfort.
7. Rubber isolators reduce vibration from the engine and transmission.
8. Heavy-duty bearings in the wheels enhance durability.
9. The low center of gravity improves stability on slopes.
10. Reinforced steel frame construction ensures long-term durability.
8. Braking System
1. Zero-turn mowers use dynamic braking, where hydraulic motors slow the machine.
2. The parking brake locks the wheels when the mower is stopped.
3. Some models use disk brakes for additional stopping power.
4. Spring-loaded brake levers engage when the lap bars are in neutral.
5. Hydraulic fluid pressure control helps slow the mower gradually.
6. The brake linkage connects the brake system to the control levers.
7. Safety interlocks prevent the mower from moving if the brakes are engaged.
8. The tire tread pattern affects braking performance on different surfaces.
9. Brake pads or drums may be used in heavy-duty models.
10. Electronic braking systems are available on some advanced models.
9. Safety System
1. Seat safety switches shut off the engine if the operator leaves the seat.
2. Blade engagement safety switches prevent accidental blade activation.
3. Roll-over protection structures (ROPS) protect the operator in case of tipping.
4. Safety shields cover moving parts to prevent injury.
5. Emergency shut-off switches allow quick engine shutdown.
6. Automatic braking systems engage when the mower is stopped.
7. Headlights and reflectors improve visibility in low light.
8. Warning decals and labels remind users of potential hazards.
9. Hearing protection recommendations help prevent long-term hearing damage.
10. Kill switches immediately stop the engine if needed.
Each of these systems plays a crucial role in ensuring that a zero-turn mower operates efficiently, safely, and effectively. Let me know if you want me to expand on any specific part!
A zero-turn mower like your John Deere Z525E operates with several key systems working together for precision cutting and maneuverability. Below is a detailed explanation of each major system, breaking down how they function in 10 sentences each.
1. Engine System
1. The engine powers all functions of the mower, including movement and blade rotation.
2. Your Z525E uses a V-twin 24 HP Briggs & Stratton engine, known for durability and power.
3. It operates on a four-stroke cycle, meaning it completes intake, compression, power, and exhaust strokes per cycle.
4. The carburetor or fuel injection system mixes air and fuel for combustion inside the cylinders.
5. A spark plug ignites the fuel mixture, causing an explosion that drives the piston down.
6. The crankshaft converts the pistons’ movement into rotational power, which is sent to the transmission and mower deck.
7. The engine is air-cooled with a fan and fins to prevent overheating during long mowing sessions.
8. A fuel pump moves gasoline from the tank to the carburetor to ensure steady fuel delivery.
9. The throttle control allows you to adjust engine speed, affecting cutting performance and movement speed.
10. Regular maintenance, like changing the oil, air filter, and spark plugs, is essential for efficient engine operation.
2. Transmission and Drive System
1. Zero-turn mowers use a dual hydrostatic transmission, which allows each wheel to move independently.
2. Your Z525E has Hydro-Gear EZT transaxles, which control speed and direction.
3. The hydraulic pump pushes hydraulic fluid through hydraulic motors, converting pressure into movement.
4. These motors directly power the rear wheels, eliminating the need for a traditional drivetrain.
5. Levers on each side control the hydrostatic transmission—pushing forward moves the mower ahead, while pulling back reverses it.
6. If one lever moves forward while the other stays neutral or reverses, the mower turns sharply.
7. This independent wheel control is what gives zero-turn mowers their precise and fast maneuverability.
8. A bypass valve allows the mower to be moved manually when the engine is off by disengaging the hydraulic motors.
9. Keeping the hydraulic fluid clean and at the correct level ensures smooth performance and prevents overheating.
10. Worn-out hydraulic hoses or pumps can lead to weak movement, requiring regular inspection and maintenance.
3. Steering and Control System
1. Zero-turn mowers do not have a steering wheel; instead, they use dual lap bars to control direction.
2. Pushing both bars forward moves the mower straight ahead, while pulling them back puts the mower in reverse.
3. Pushing one lever forward while pulling the other back makes the mower spin in place, allowing for zero-radius turns.
4. The lap bars are connected to control rods, which transfer motion to the hydraulic pumps.
5. These rods adjust fluid flow in the hydrostatic transmission, controlling wheel speed.
6. A neutral position in the lap bars ensures the mower does not move when they are centered.
7. The bars have dampers to smooth out movements and prevent jerky operation.
8. Some models allow lap bars to be adjusted for operator comfort and control sensitivity.
9. The parking brake automatically engages when the bars are in the outward position.
10. If the mower is not responding correctly to steering inputs, it may need an alignment adjustment or hydraulic system check.
4. Cutting Deck System
1. The cutting deck houses the mower blades and determines the width of the cutting path.
2. Your Z525E has a 54-inch Accel Deep™ mower deck, designed for efficient grass discharge.
3. The deck is powered by a belt-driven system, which connects to the engine’s PTO (Power Take-Off) clutch.
4. The PTO engages the blades, allowing them to spin when activated.
5. Under the deck, three high-lift blades create suction that lifts grass for an even cut.
6. The deck height adjustment system lets you change the cutting height from 1 to 4 inches in quarter-inch increments.
7. The anti-scalp wheels on the deck help prevent damage to uneven lawns by keeping the deck from digging into the ground.
8. A discharge chute directs grass clippings out the side, or you can use a mulching kit to recycle clippings back into the lawn.
9. The deck is made of reinforced 10-gauge steel, making it durable against impacts and wear.
10. Keeping the blades sharp, belts tight, and deck clean ensures optimal performance and prevents clogs.
5. Electrical System
1. The electrical system powers essential components like the starter, PTO clutch, and safety switches.
2. A 12-volt battery provides electricity to start the engine and run electrical accessories.
3. The starter motor cranks the engine when the ignition key is turned.
4. The alternator recharges the battery while the engine is running.
5. Safety switches in the seat, parking brake, and lap bars prevent the mower from operating under unsafe conditions.
6. The PTO switch sends power to an electromagnetic clutch that engages the cutting blades.
7. If a safety switch fails, the mower may not start or may shut off unexpectedly.
8. Fuses protect the electrical circuits from overloads and should be checked if components stop working.
9. The key switch controls the ignition system, and some models have additional security features.
10. Keeping battery terminals clean and checking wiring connections prevents electrical issues.
6. Fuel System
1. The fuel system supplies gasoline to the engine for combustion.
2. Your Z525E has a 3.5-gallon fuel tank, allowing for extended mowing sessions.
3. A fuel pump moves fuel from the tank to the carburetor.
4. The fuel filter removes dirt and debris to keep the engine running smoothly.
5. The carburetor or fuel injectors mix fuel with air before it enters the engine.
6. A choke valve helps start the engine in cold conditions by enriching the fuel mixture.
7. The fuel cap has a vent to prevent pressure buildup inside the tank.
8. Ethanol-blended fuels can cause carburetor issues, so using fresh, ethanol-free gas is recommended.
9. A clogged fuel line can prevent the engine from running, requiring maintenance.
10. Regularly draining old fuel and replacing the fuel filter helps prevent engine problems.
Each of these systems plays a critical role in making your Z525E zero-turn mower function efficiently. Proper maintenance—such as checking fluids, sharpening blades, and cleaning components—will keep your mower running smoothly for years. Let me know if you need details on specific repairs or troubleshooting!
John Deere Zero Turn Z525E
1GXZ525FEHH061319
The original price for a Z525e in the year it was released was $3,899 in 2020 .
The Resale value for a machine with similar hours is around $2400--$3000
The mower was built in Greeneville, Tennessee, USA in the year 2016-2020
You can purchase parts at :
The green parts store
John deere
Customer claims that mower won't start or crank engine .
Mechanic:
* Dead battery
* Fuel pump not functioning
* V-Belt needs to be replaced
* All filters Need to be Replaced
* Remove corrosion off all metals
* Oil change and filter replacement
* low compression
* No spark
* Carburetor needs a cleaning
Engine Specification
Make Briggs & Stratton
Model number 40ELS
Bore 75.4mm (2.97in.)
Stroke 73.40mm (2.890in.)
Displacement 656 cm3 (40.03 cu in.)
Cylinders V-Twin
Cycle Four
Valve Clearance 0.10 - 0.15mm (0.004 - 0.006in)
Spark Plug Gap 0.76 mm (0.030 in)
Spark Plug Torque 20 N*m (180 Ib-in)
DriveTrain
Transaxle motors Tuff Torq TZT7 D
Number of Speeds Hydrostatic, Variable Speed
Travel Speeds at Full Engine RPM
Forward 0-13.7 km/h (0-8.5 mph)
Reverse 0-6.4 km/h (0-4.0 mph)
Electrical Specifications
Battery Type 12 volt
Cold Cranking Capacity 300 Amps
Fuel System
Fuel Types Regular Grade 87 Octane unleaded Fuel
Ethanol Blended fuel (up to 10%)
Fuel filter Inline fuel PN:AM116304
Fuel Pump PN: UC34375
Fuel Delivery Carburetor PN: MIA11790
Tires
Front 13x5.00-6 (Ribbed)
Inflation front 69 kPa (10 psi)
Rear 22x9.5-10 (Turf)
Inflation Rear 69 kPa (10 psi)
Capacities
Crankcase with oil filter 1.9 L (2.0 qt)
Fuel tank Any models 17L (4.5 gal)
Transaxle oil reservoir filter PN: MIU800365
Transmission oil filter element PN: MIU800957
Dimensions
Height 980 mm
Width (48A Deck) 1590 mm
Length 1955 mm
Weight (48A Deck) 283 kg (624 Ib)
Mower Decks
Cutting Width 1.22 m (48 in)
Blade-Rotary 3
Blade Bolt Torque 68 N*m (50 Ib-ft)
Cutting Height 25-102 mm (1 - 4 in)
Speed of Rotation of Cutting Device 3594 r/min at 3350 r/min
Recommended Lubricants
Engine oil Turf-Gard or Plus-4
Grease Grease- Gard Premium Plus or
John Deere Multi-Purpose HD Lithium Complex Grease
Fast Idle Engine Speed
Z525E without mower Deck 3350+/- 100 r/min
Speed of Rotation of Cutting Device
Z525E with 48A 122 cm mower deck 3594 r/min at
3350 r/min
Sound Measurements
Without mower deck 86.9/1 dB(A) at 3350 r/min
Engine speed
With mower deck .91/1 dB(A) at 3350 r/min Engine speed
Vibration Measurements
WIthout the mower deck the total value of the handarms system doesn’t exceed 2.5m.s^2
With mower deck 3.1 m/s^2
The first step we took was to remove all the corrosion from the zero-turn mower to restore its functionality. During this process, we utilized a metal brush to scrub away the rust, along with WD-40 to help loosen the corrosion, and rust remover gel for a more thorough cleanup.
We performed a thorough battery and alternator test using a multimeter, connecting the leads to the battery terminals to check the voltage, which should be around 12.6 volts for a healthy battery. After starting the vehicle, we monitored the multimeter for an increase in voltage, indicating that the alternator was properly charging the battery, typically producing a reading between 13.2 and 14.3 volts while the engine was running.
We utilized a spark gap tester during our test to ensure that our armatures were effectively supplying power to the spark plugs. This verification was crucial for confirming the functionality of the ignition system.
During the service, we conducted a thorough filter inspection and replaced all filters due to their deteriorated condition. To replace the oil filter, we utilized an oil filter wrench. We carefully examined the dual-layer air filter to assess its condition and employed our hands for a more precise evaluation. For the fuel filter replacement, we utilized a pair of pliers to detach the hose clamps effectively.
Old New
To conduct the armature gap adjustment, we utilized a piece of cardstock that adequately covered both sides of the armature. Upon measurement, the cardstock was determined to be 0.10 mm thick, which falls within the specified armature gap range of 0.08 to 0.12 or (0.20-0.30mm). Afterwards, we used a 5/16 socket and a torque wrench to securely tighten the bolts
to the required specifications specifications.
specifications.
specifications.
When we first performed a compression test on the Zero Turn mower, we found that the compression was low. To address this issue, we adjusted the valves to achieve the correct valve lash. We used a T-40 screwdriver and a 13mm wrench to adjust the gap between the rocker arm and the push rod, ensuring it was set to 0.05 using a feeler gauge . After making these adjustments, we conducted another compression test and were pleased to see that the compression exceeded 100, which is an excellent reading for this mower. Once we confirmed the compression was adequate, we torqued the rocket arm lock nut to 60 in.ibs. And the valve covers 100 in.ibs. to complete the process.
We executed an RPM measurement test utilizing a tachometer, an instrument that measures the rotational speed of a shaft or disk, and reflective tape to guarantee precise readings. Our objective for this test was to achieve a fast idle of approximately 3350 RPM, allowing for a tolerance of plus or minus 100 to accommodate any possible variations.
To effectively perform this service, we utilized a tachometer, which is a vital tool for measuring the engine's RPM to ensure it operates within the specifications outlined in the mower’s manual. We used a Phillips screwdriver to make precise adjustments to the idle screw.
This adjustment is essential for maintaining smooth engine performance and ensuring optimal operation at idle. By taking the time to fine-tune the idle setting, we successfully achieved the required RPM specifications of 3350
During the maintenance of the zero-turn mower, we used a grease gun to service all grease points, paying special attention to the mower deck. We also lubricated the front lift arm and the front caster spindles. A thorough check of the dipstick showed that the oil level was low, so we added the necessary oil. To further evaluate the oil levels, we used a flashlight to inspect the inside of the transmission canister and confirmed that both sides were also low, requiring a refill with the right oil.
*DCY*
Z525E, Z535M and Z540R ZTrak™ (Serial No. 110001 -XXXXXX)
*OMUC18704*
OPERATOR'S MANUAL
Z525E, Z535M and Z540R ZTrak™ OMUC18704 ISSUE H8 (MULTI-LINGUAL)
John Deere Power Products
Export Edition
Printed in U.S.A.
*omuc18704*
Z525E, Z535M and Z540R ZTrak™ (Serial No. 110001 -XXXXXX)
*OMUC18704*
OPERATOR'S MANUAL
Z525E, Z535M and Z540R ZTrak™
OMUC18704 ISSUE H8 (ENGLISH)
John Deere Power Products Export Edition Printed in U.S.A.
Introduction
Thank You for Purchasing a John Deere Product We appreciate having you as a customer and wish you many years of safe and satisfied use of your machine.
MX00654,000020B-19-10MAY17
Emissions Performance and Tampering
Operation and Maintenance
The engine, including the emissions control system, shall be operated, used, and maintained in accordance with the instructions provided in this manual to maintain the emissions performance of the engine within the requirements applicable to the engine's category/certification.
Tampering
No deliberate tampering with or misuse of the engine emissions control system shall take place; in particular with regard to deactivating or not maintaining an exhaust gas recirculation (EGR) or a DEF dosing system. Tampering with an engine’s emissions control system will void the European Union (EU) type approval and applicable emissions related warranties. DX,EMISSIONS,PERFORM-19-12JAN18
Using Your Operator’s Manual
This manual is an important part of your machine and should remain with the machine when you sell it.
Reading your operator’s manual will help you and others avoid personal injury or damage to the machine. Information given in this manual will provide the operator with the safest and most effective use of the machine. Knowing how to operate this machine safely and correctly will allow you to train others who may operate this machine.
If you have an attachment, use the safety and operating information in the attachment operator’s manual, along with the machine operator’s manual, to operate the attachment safely and correctly.
This manual and safety signs on your machine may also be available in other languages (see your authorized dealer to order).
Sections in your operator’s manual are placed in a specific order to help you understand all the safety messages and learn the controls so you can operate this machine safely. You can also use this manual to answer any specific operating or servicing questions. A convenient index located at the end of this book will help you find needed information quickly.
The machine shown in this manual may differ slightly from your machine, but will be similar enough to help you understand our instructions.
RIGHT-HAND and LEFT-HAND sides are determined by facing in the direction that the machine will travel when going forward. When you see a broken line (------), the item referred to is hidden from view.
Before delivering this machine, your dealer performed a predelivery inspection to ensure best performance.
MX00654,000020C-19-05JUN17
Machine Use
This machine is designed solely for use in customary lawn mowing operations. Use in any other way is considered as contrary to the intended use.
The manufacturer accepts no liability for damage or injury resulting from this misuse, and these risks must be borne solely by the user. Compliance with and strict adherence to the conditions of operation, service, and repair as specified by the manufacturer also constitute essential elements for the intended use.
This machine should be operated, serviced, and repaired only by persons familiar with all its particular characteristics and acquainted with the relevant safety rules (accident prevention). The accident prevention regulations, all other generally recognized regulations on safety and occupational medicine, and the road traffic regulations must be observed at all times.
2
Setting fuel delivery beyond published factory specifications or otherwise overpowering will result in loss of warranty protection for this machine.
Any arbitrary modifications carried out on this machine will relieve the manufacturer of all liability for any resulting damage or injury.
OUO1023,0000025-19-05JUN17
Special Messages
Your manual contains special messages to bring attention to potential safety concerns and machine damage, as well as helpful operating and servicing information. Please read all the information carefully to avoid injury and machine damage.
CAUTION: Avoid injury! This symbol and text highlight potential hazards or death to the operator or bystanders that may occur if the hazards or procedures are ignored.
IMPORTANT: Avoid damage! This text is used to tell the operator of actions or conditions that might result in damage to the machine.
NOTE: General information is given throughout the manual that may help the operator in the operation or service of the machine.
MX00654,000020D-19-05JUN17
Parts
We recommend John Deere quality parts and lubricants, available at your John Deere dealer.
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.
Order Service Parts Online
Visit http://JDParts.deere.com for your Internet connection to parts ordering and information.
TC00531,00000E9-19-06MAR15
Service Literature
If you would like to purchase a copy of the Parts Catalog or Technical Manual for this machine, visit The John Deere Technical Information Store at:
https://techpubs.deere.com/?cid=VURL_TechInfoStore or call:
● U.S. & Canada: 1-800-522-7448.
● All Other Regions: Your John Deere dealer.
TH84124,0000199-19-15AUG17
Contents
Contents
Product Identification
Introduction.................................................... 2 Product Identification......................................... 3 Safety Labels without Text ................................... 4 Safety.......................................................... 6 Machine Cleanout ...........................................12 Assembly.....................................................13 Operating Controls..........................................15 Operating.....................................................16 Service Intervals.............................................26 Service Lubrication..........................................26 Service Engine...............................................27 Service Transmission.......................................36 Service Mower...............................................38 Service Electrical ............................................43 Service Miscellaneous......................................45 Troubleshooting..............................................48 Storage.......................................................50 Specifications................................................51 John Deere Quality Statement .............................54 Service Record...............................................55 Declaration of Conformity...................................56 Slope Gauge.................................................60 Index..........................................................61
Original Instructions. All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice.
COPYRIGHT © 2018
DEERE & COMPANY Moline, Illinois
All rights reserved. Previous Editions Copyright © 2015, 2016, 2017
3
Record Identification Numbers
Zero Turn Mowers
PIN (110001-)
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.
__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
Transaxle Serial Numbers:
S/N tag on forward side of each transaxle housing.
LEFT SIDE:
__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ RIGHT SIDE:
__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ SU68010,00000DE-19-13JUN18
Safety Labels without Text
Safety Labels without Text
Safety Label Location
PY38742—UN—05JUN17
A—Avoid Injury From Loaded Spring M146577
B—Avoid Injury From Equipment Fires GX24503
C—Avoid Injury From Getting Caught in Belts GX23397
D—Avoid Injury From Rotating Blades GX23398
E—Read Operator’s Manual, Avoid Injury From Thrown Objects, Keep Children Away From Mower, Avoid Injury From Tipping M172428
Understanding the Machine Safety Labels without Text
TCT005498—UN—11SEP12
4
F—Avoid Injury From Thrown Objects, Avoid Injury From Rotating Blades M138631
G—Avoid Injury From Thrown Objects, Avoid Injury From Rotating Blades M173018
MX52301,0000FED-19-06JUN17
At several important places on this machine, safety signs are affixed which signify potential danger. The hazard is identified by a pictorial in a warning triangle. An adjacent pictorial provides information on how to
avoid personal injury. These safety signs, their placement on the machine, and a brief explanatory text are shown in this Safety section.
There can be additional safety information contained on parts and
Safety Labels without Text
components sourced from suppliers that is not reproduced in this operator’s manual.
MX00654,0000389-19-21JUN18
Avoid Injury From Loaded Spring
MXAL42777—UN—09APR13 ● Keep fingers and hands away from pinch point.
● Read operator’s manual.
MX00654,000038C-19-29AUG16
Avoid Injury From Equipment Fires
● Do not operate mower without discharge chute/deflector or entire grass catcher in place.
MX00654,0000392-19-15JUN16
Read Operator’s Manual
MXAL42776—UN—09APR13
● This operator’s manual contains important information necessary for safe machine operation.
● Carefully read operator’s manual before operating machine or attachment. Observe all safety rules to avoid accidents.
MX00654,000038B-19-15JUN16
Avoid Injury From Thrown Objects
● Avoid equipment fires.
MXT018019—UN—04MAY16
● Accumulation of grass, leaves and debris on or near hot or moving parts can cause a fire.
● Inspect and clean the entire machine before, during and after use. ● Shut off engine and allow machine to cool before cleaning. ● Carefully read Operator’s Manual Machine Clean out section for details.
MX00654,0000390-19-19JUN16
Avoid Injury From Getting Caught in Belts MXT018017—UN—03MAY16 ● Stay clear of moving belts.
● Do not operate machine without shields in place.
MX00654,0000391-19-15JUN16
Avoid Injury From Rotating Blades
MXT018016—UN—03MAY16 ● Do not put hands or feet under or into mower when engine is running.
5
MXAL42780—UN—09APR13 ● Keep a safe distance from the machine as long as the engine is running.
MX00654,000038F-19-24JUL13
Keep Children Away from Mower
MXAL42778—UN—09APR13 ● Mower can cause dismemberment or death.
● Stay a safe distance from the machine.
● Make sure that children stay clear of mower at all times when the engine is running.
MX00654,000038D-19-22JUL13
Safety
Avoid Serious Injury or Death From Tipping
- Replace all fuel tank and container caps securely.
MXAL42779—UN—09APR13 ● 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.
● Refer to the Operating on Slopes section for more information. MX00654,000038E-19-15JUN16
Safety
Training
● Read the instructions carefully. Be familiar with the controls and the proper use of the equipment.
● Never allow children or people unfamiliar with these instructions to use the lawnmower. Local regulations can restrict the age of the operator.
● Never mow while people, especially children, or pets are nearby. ● Keep in mind that the operator or user is responsible for accidents or hazards occurring to other people or their property.
● Do not carry passengers.
● All drivers should seek and obtain professional and practical instruction. Such instruction should emphasize:
- The need for care and concentration when working with ride-on machines.
- Control of a ride-on machine sliding on a slope will not be regained by the application of the brake.
● The main reasons for loss of control are:
- insufficient wheel grip;
- being driven too fast;
- inadequate braking;
- the type of machine is unsuitable for its task;
- lack of awareness of the effect of ground conditions, especially slopes;
- incorrect hitching and load distribution.
OUO1023,0000030-19-05JUL17
Preparation
● While mowing, always wear substantial footwear and long trousers. Do not operate the equipment when barefoot or wearing open sandals.
● Thoroughly inspect the area where the equipment is to be used, and remove all objects which can be thrown by the machine. ● WARNING-Fuel is highly flammable.
- Store fuel in containers specifically designed for this purpose. - Refuel outdoors only and do not smoke while refueling. - Add fuel before starting the engine. Never remove the cap of the
fuel tank or add fuel while the engine is running or when the engine is hot.
- If fuel is spilled, do not attempt to start the engine but move the machine away from the area of spillage and avoid creating any source of ignition until fuel vapors have dissipated.
6
● Replace faulty silencers.
● Before using, always visually inspect to see that the blades, blade bolts, and cutter assembly are not worn or damaged. Replace worn or damaged blades and bolts in sets to preserve balance.
● On multi-bladed machines, take care as rotating one blade can cause other blades to rotate.
OUO1023,0000031-19-05JUL17
Operation
● Do not operate the engine in a confined space where dangerous carbon monoxide fumes can collect.
● Mow only in daylight or in good artificial light.
● Before attempting to start the engine, disengage all blade attachment clutches and shift into neutral.
● Do not use on slopes of degrees more than recommended by the manufacturer.
● Remember there is no such thing as a safe slope. Travel on grass slopes requires particular care. To guard against overturning: - do not stop or start suddenly when going up or downhill; - engage clutch slowly, always keep machine in gear, especially when traveling downhill;
- machine speeds should be kept low on slopes and during tight turns;
- stay alert for humps and hollows and other hidden hazards; - never mow across the face of a slope, unless the machine is designed for this purpose.
● Use care when pulling loads or using heavy equipment: - use only approved drawbar hitch points;
- limit loads to those you can safely control;
- do not turn sharply;
- use care when reversing;
- use counterweights or wheel weights when suggested in the operator’s manual.
● Watch out for traffic when crossing or near roadways. ● Stop the blades from rotating before crossing surfaces other than grass.
● Never direct discharge of material toward bystanders nor allow anyone near the machine while in operation.
● Never operate the machine with defective guards or without safety protective devices in place.
● Do not change the engine governor settings or overspeed the engine. Operating the engine at excessive speed can increase the hazard of personal injury.
● Before leaving the operator’s position:
- disengage the drive to any attachments and lower them; - change into neutral and lock the parking brake;
- stop the engine and remove the key.
● Disengage drive to attachments, stop the engine, disconnect the spark plug wires and remove the ignition key:
- before clearing blockages or unclogging chute;
- before checking, cleaning, or working on the machine; - after striking a foreign object—inspect the machine for damage and make repairs before restarting and operating the equipment; - if the machine starts to vibrate abnormally (check immediately). ● Disengage drive to attachments when transporting or not in use. ● Stop the engine and disengage drive to attachment: - before refueling;
- before removing the grass catcher;
- before making height adjustment unless adjustment can be made from the operator’s position.
● Reduce the throttle setting during run-out and, if the engine is
Safety
provided with a shut-off valve, turn the fuel off at the conclusion of mowing.
● Read, understand, and follow all instructions in the manual and on the machine before starting.
● Equipment owners are responsible for ensuring that operators are responsible, trained, familiar with the instructions and are mentally and physically capable of performing the tasks associated with operating this equipment safely.
● Age, both young and old, can be a factor in operator related injuries. Operators should evaluate their ability to operate the equipment safely enough to protect themselves and others from serious injury.
● Inspect machine before you operate. Repair or replace damaged, badly worn, or missing parts. Make any necessary adjustments before you operate.
● Be sure all drives are in neutral and parking brake is locked before starting engine. Only start engine from the operator’s position. ● Do not operate mower without discharge chute or entire grass catcher in place. Never operate with the discharge deflector raised, removed, or altered, unless using a grass catcher.
● Check brake action before you operate. Adjust or service brakes as necessary.
● Stop machine if anyone enters the area.
● Do not leave machine unattended when it is running. ● Use care when approaching blind corners, shrubs, trees, or other objects that may obscure vision.
● Use only accessories and attachments approved by the manufacturer of the machine. Keep safety labels visible when installing accessories and attachments.
● Do not operate machine if you are under the influence of drugs or alcohol.
● Do not wear radio or music headphones. Safe service and operation requires your full attention.
MX00654,0000438-19-19JUL18
Maintenance and Storage
● Keep all nuts, bolts, and screws tight to be sure the equipment is in safe working condition.
● Never store the equipment with fuel in the tank inside a building where fumes can reach an open flame or spark.
● Allow the engine to cool before storing in any enclosure. ● To reduce the fire hazard, keep the engine, silencer, battery compartment and fuel storage area free of grass, leaves, or excessive grease.
● Check the grass catcher frequently for wear or deterioration. ● Replace worn or damaged parts for safety.
● If the fuel tank has to be drained, this should be done outdoors. ● On multi-bladed machines, take care as rotating one blade can cause other blades to rotate.
● When machine is to be parked, stored or left unattended, lower the cutting means unless a positive mechanical lock in used. ● Use jack stands or lock service latches to support components when required. Securely support any machine elements that must be raised for service work.
● Before servicing machine or attachment, carefully release pressure from any components with stored energy, such as hydraulic components or springs.
● 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.
● Disconnect battery before making any repairs. Disconnect the negative terminal first and the positive last. Reconnect positive first and negative last.
● Use care when checking blades. Wrap the blades or wear gloves, and use caution when servicing them. Only replace blades. Never straighten or weld them.
● Keep hands, feet, clothing, jewelry, and long hair away from moving parts. If possible, do not make adjustments with the engine running.
7
● Charge batteries in an open, well ventilated area, away from spark and flames. Unplug charger before connecting or disconnecting from battery. Wear protective clothing and use insulated tools.
OUMX068,00004CD-19-05JUL17
Checking Mowing Area
MXAL41932—UN—22MAY13
● Clear mowing area of objects that might be thrown. Keep people and pets out of mowing area.
● 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.
● 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.
● Survey all mowing sites to determine which slopes are safe for machine operation and which slopes should be maintained through other maintenance techniques.
MP47322,00F4617-19-05JUL17
Parking Safely
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.
4. Lock the park brake.
5. Stop the engine.
6. Remove the key.
7. Wait for engine and all moving parts to stop before you leave the operator’s seat.
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.
OUO1023,0000035-19-21FEB13
Rotating Blades are Dangerous
MXAL41928—UN—18FEB13
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. ● Keep hands, feet, and clothing away from mower deck when engine is running.
● 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.
● Before backing up, stop mower blades or attachments and look down and behind the machine carefully, especially for children. ● Do not mow in reverse.
● Shut off blades when you are not mowing.
Safety
ft) long on the slope and measure the angle of the slope with an
● Park machine safely before leaving the operator’s station for any reason, including emptying the grasscatchers or unplugging the chute.
● 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.
MP47322,00F4619-19-05JUL17
Protect Children
MXT005340—UN—06JUN13
● 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.
● Children are attracted to lawn mowing machines and mowing activities. They do not 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.
● 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.
● 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.
● Never allow children or an untrained person to operate the machine. Instruct all operators not to give children a ride on the machine or in an attachment.
● 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.
● Use extreme care when approaching blind corners, shrubs, trees, or other objects that may block your view of a child.
MP47322,00F461A-19-05JUL17
Operating on Slopes
NOTE: Remove Slope Gauge Template page from the back of this operator’s manual. Follow the instructions included with the template.
● Slopes are a major factor related to loss-of-control and tip-over accidents, which can result in severe injury or death. Operation on all slopes requires extra caution.
Identify Slopes for Safe Operation
● Follow safe procedures for operation on slopes. Measure slopes of all mowing 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.
Measuring Slopes
● Suggested Method 1: Lay a straight piece of sturdy lumber 1.2 m (4 8
angle indicator or protractor level.
● Suggested Method 2: Refer to the slope gauge provided at the end of this manual.
Operate Safely on Slopes
● Exceeding the recommended maximum slope angle increases the risk of rollover accidents that can result in serious injury or death. ● 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.
● 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.
● Watch for holes, ruts, bumps, rocks, or other hidden objects. Uneven terrain could overturn the ride-on mower. Tall grass can hide obstacles.
● 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. ● 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.
Safety
Operating Near Hazards
MXAL42786—UN—09APR13 Example side view of slope and hazards, showing areas (A), (B), and (C).
● 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.
● Hazards (A) include but are not limited to:
- Drop-offs, ditches, embankments, or bodies of water.
- 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.
● Use a walk-behind mower or string trimmer in and around areas (A) and (B).
MP47322,00F461B-19-05JUL17
Keep Riders Off
MXAL42882—UN—26MAR13
● 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.
MXT005363—UN—10JUL13 9
MP47322,00F461C-19-15MAR13
Towing Loads Safely
● Stopping distance increases with speed and weight of towed load. Travel slowly and allow extra time and distance to stop.
● 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.
Safety
● Never tamper with safety devices. Check their proper operation regularly.
● 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
● 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.
MP47322,00F461D-19-05JUL17
Wear Appropriate Clothing
TCT015572—UN—24MAY18 ● Always wear eye protection when operating the machine. ● Wear close fitting clothing and safety equipment appropriate for the job.
● While operating this machine, always wear substantial footwear and long trousers. Do not operate the equipment when barefoot or wearing open sandals.
● Wear a suitable protective device, such as earplugs. Loud noise can cause impairment or loss of hearing.
MP47322,00F461E-19-09JUL18
Driving Safely on Public Roads
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.
● 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.
OUO2005,000021C-19-05FEB13
Practice Safe Maintenance
MXAL41933—UN—18FEB13
● Only qualified, trained adults should service this machine. Understand service procedure before doing work.
● Never operate machine in a closed area where dangerous carbon monoxide fumes can collect.
● Keep all nuts and bolts tight, especially blade attachment bolts, to be sure the equipment is in safe working condition.
10
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.
● 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.
● 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.
● 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.
● Keep hands, feet, clothing, jewelry, and long hair away from any moving parts to prevent them from getting caught.
● 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.
● 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.
● 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.
● Do not strike the flywheel with a hammer or hard object because the flywheel may later shatter during operation.
● 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.
MP47322,00F4620-19-05JUL17
Avoid High Pressure Fluids
TCAL25960—UN—24MAY12
● 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.
● 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
Safety
Handling Fuel Safely
Department in Moline, Illinois, U.S.A. Information may be obtained in the United States and Canada only by calling 1-800-822-8262.
OUO2005,0000220-19-05FEB13
Prevent Fires
● Please review these recommendations with all operators. See your John Deere dealer with questions.
● Always follow all safety procedures posted on the machine and in this operator’s 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.
● 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.
● Completely remove any combustible materials from equipment before storing by emptying any grass catcher bags, containers, and cargo boxes.
● Debris can accumulate anywhere on the machine, especially on horizontal surfaces. Remove grass and debris completely from engine compartment, muffler area, and from the mower deck or cutting units both before and after operating machine. Additional cleaning may be necessary when mowing or mulching in dry conditions.
● 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.
● 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.
● 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.
● 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.
● 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.
OUO2005,0000221-19-05JUL17
11
MXAL41938—UN—18FEB13
To avoid personal injury or property damage, use extreme care in handling fuel. Fuel is extremely flammable and fuel vapors are explosive:
● 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. ● Never remove the fuel tank cap or add fuel with the engine running. Allow engine to cool before refueling.
● 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.
● Prevent fire and explosion caused by static electric discharge. Static electric discharge can ignite fuel vapors in an ungrounded fuel container.
● 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.
● 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.
● 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.
OUO2005,0000223-19-12OCT16
Tire Safety
TCAL25965—UN—24MAY12
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.
● Always maintain the correct tire pressure. Do not inflate the tires
Machine Cleanout
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.
OUO2005,0000222-19-10MAY17
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.
● Wheel hardware must be tightened to specified torque using the proper procedure anytime it is loosened.
MP47322,00F4625-19-15MAR13
Handling Waste Product and Chemicals
Waste products, such as, used oil, fuel, coolant, brake fluid, and batteries, can harm the environment and people:
● 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.
● See your local Recycling Center or authorized dealer to learn how to put your machine out of service at the end of the machine’s service life.
MX00654,00003A8-19-24JUN13
Machine Cleanout
General Cleaning Guidelines
Machine must be inspected periodically throughout the day. Buildup of debris must be removed to ensure proper machine function and to reduce the risk of fire. Frequency of these inspections and cleanings will vary depending on a number of factors including operating conditions, machine configuration, operating speeds, and weather conditions. Inspections and cleanings may be required multiple times throughout the day particularly in dry, hot, and windy conditions.
IMPORTANT: Regular and thorough cleaning of machine combined with other routine maintenance procedures listed in the Operator’s Manual greatly reduce the risk of fire, downtime and improve machine performance.
Besides proper maintenance the condition of the material being handled is the most significant factor contributing to fires. Dry, light and fluffy materials that can create a dust cloud are the most likely to catch fire. Debris can
accumulate in various areas especially on horizontal surfaces. Conditions such as wind speed and direction can change where the material accumulates. Be aware of these changing conditions and adjust your cleaning schedule and practices to ensure proper machine function and to reduce the risk of fire.
Always follow all safety procedures posted on the machine and in the Operator’s Manual. Before carrying out any inspection or cleaning, always shut OFF engine, set parking brake and remove key.
The entire machine should be inspected, with extra attention given to the areas noted below.
OUMX068,0001043-19-10MAY17
12
Cleanout Areas
NOTE: Also see machine Service Label.
Primary areas that must be inspected and cleaned on the machine include:
GXT003036—UN—15JUL16 1.Muffler components (A):
- Exhaust Manifold
- Muffler Pipes
- Muffler
- Muffler Shield
2.Engine cooling fins (B) and oil cooler (if equipped.) 3.Engine screen guard (C) (See Cleaning Engine Screen Guard in the SERVICE ENGINE section.)
GXT002175—UN—05JUN15 4.Top of mower deck, under shields (D), including spindle and belt area (E).
Assembly
APY08036—UN—18MAY18
GXT002176—UN—05JUN15
5.On or near transaxles (F) and belt drives and fins.
APY08035—UN—16MAY18 6.Under the seat and near fuse block (G), including the battery (H) and wiring harness.
MX52301,0000FCD-19-17MAY18
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.
● Always route battery cables away from battery posts. ● Do not jump start or charge a frozen battery. Warm battery to specification.
Specification
Battery—Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16°C (60°F) 13
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.
3. Connect positive (+) battery cable (A) to battery positive terminal (B).
4. Connect negative (–) battery cable to battery negative terminal (C).
5. Apply general purpose grease or silicone spray to terminal to help prevent corrosion.
6. Slide red cover over positive battery cable.
SU68010,000009E-19-17MAY18
Install Seat (if applicable)
NOTE: Seats on some models are shipped with back of seat in a horizontal position for shipping only. Do not operate machine with seat in this horizontal position.
GXT002404—UN—15JUL15 1. Remove rear bolt (A) and discard plastic washer from each side of seat bracket (B).
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.
4. Begin by hand tightening the four bolts. Then, tighten four bolts to specification.
Specification
Assembly
Seat Hardware—Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N·m (18 lb-ft) RM87422,000076F-19-07JUN17
Install Seat
Z540R Models
NOTE: 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.
APY08037—UN—16MAY18 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 notch (E) in the seat pan.
4. Push the L-pin through the tether loop and push the L-pin handle down into the snap-lock groove in the seat pan.
SU68010,000009F-19-17MAY18
Adjusting Motion Control Levers
1. Park machine safely. (See Parking Safely in the SAFETY section.) 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.
14
APY08038—UN—18MAY18 3. Remove two bolts and nuts and raise each control lever to the highest position first. If uncomfortable, adjust accordingly for the operator.
● For highest lever position, use holes (A).
● For lowest lever position, use holes (B).
4. You can also adjust each motion control lever slightly forward or rearward (C) within slotted holes.
SU68010,000008E-19-17MAY18
Check Tire Pressure
Check tire pressure. (See Checking Tire Pressure in the SERVICE MISCELLANEOUS section.)
MP47322,00F4629-19-15MAR13
Adjust Mower Deck Level
Adjust mower deck level. (See Adjusting Mower Deck Level in the OPERATING section.)
MP47322,00F462A-19-31MAY13
Check Engine Oil Level
Check engine oil level. (See Checking Engine Oil Level in the SERVICE ENGINE section.)
MP47322,00F462B-19-15MAR13
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.)
MP47322,00F462C-19-15MAR13
Check Transmission Oil Level
Check Transmission Oil Level (see Checking Transaxle Oil Level in the SERVICE TRANSMISSION section)
MX00654,0000322-19-02JUN13
Operating Controls Operator Station Controls
Operating Controls
PY38745—UN—05JUL17
A—Park Brake Lever
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 Tool
G—Ignition Key Switch
15
H—Mower Engagement Switch
I—Choke Control Lever
J—Throttle Control Lever
K—Hourmeter
L—Fuel Tank Cap
M—Fuel-Sight Window
RM87422,000075D-19-07JUL17
Operating
Daily Operating Checklist ⃞ Test safety systems.
Operating
Adjusting Seat
⃞ Check fuel level. (See SERVICE MISCELLANEOUS section, Using Proper Fuel and Stabilizer)
⃞ 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.
⃞ Remove debris from engine fixed and rotating screens. ⃞ Check transaxle oil level - sight on reservoir.
⃞ Clean air intake screen.
⃞ Check area below machine for leaks.
⃞ Clean mower deck with water using washout port after each use. MX00654,0000328-19-16JUL13
Avoid Damage to Plastic and Painted Surfaces ● 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. MP47322,00F4630-19-13JUN13
Mounting and Dismounting Machine
APY08040—UN—23MAY18 1. Slide lever (A) sideways to the left.
2. Slide seat forward or rearward to desired position. 3. Release lever.
SU68010,00000A0-19-17MAY18
Adjusting Armrests
1. Raise each armrest (A).
APY08042—UN—16MAY18
GXT002179—UN—05JUN15 ● Do not step on the mower deck when mounting and dismounting the machine.
● Mount the machine from front (A).
● Park machine safely before dismounting (see Parking Safely in the SAFETY section).
● Keep the foot plate clean.
TH84124,00001E2-19-24JUN15
16
2. Turn adjustment knob (B) clockwise to lower armrest and counterclockwise to raise armrest..
SU68010,00000AB-19-18MAY18
Adjusting Motion Control Levers
1. Park machine safely. (See Parking Safely in the SAFETY section.)
Operating
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.
GXT002182—UN—05JUN15 3. Remove two bolts and nuts and raise each control lever to the highest position first. If uncomfortable, adjust accordingly for the operator.
● For highest lever position, use holes (A).
● For lowest lever position, use holes (B).
4. You can also adjust each motion control lever slightly forward or rearward (C) within slotted holes.
MX52301,000103B-19-13SEP16
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.).
17
GXT002184—UN—05JUN15
1. Raise mower deck:
● Z500 Series with 48A Mower Decks: Pull upward on mower deck lift lever (A) and push lever outward to lock in raised position.
● Z500 Series with 48HC Mower Decks: Push down on lift pedal (B), and pull upward on mower deck lift lever (A) and push lever outward to lock in raised position.
2. Insert the deck height pin tool (C) in the proper hole for the desired height of cut.
3. Lower mower deck:
● Z500 Series with 48A Mower Decks: Lift slightly on mower deck lift lever, pull lever slightly toward center, and lower lift lever (A) onto deck height pin tool (C).
● Z500 Series with 48HC Mower Decks: Place foot on lift pedal (B) and release lift pedal rearward while lowering mower deck lift lever (A) onto deck height pin tool (C).
SU68010,000010D-19-17JUL18
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.
3. Position caster wheels to the forward driving position.
4. Set mower to preferred cutting height, and lower deck into the mowing position.
5. Measure mower level (side-to-side).
Operating
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.
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.).
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.
6. Measure mower level (front-to-rear).
18
GXT002188—UN—08JUN15
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.
GXT002517—UN—17JUL15 48 in. deck shown.
c. 48A 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.
GXT002518—UN—17JUL15 d. 48HC 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.
Operating
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.
MX52301,0000FD0-19-15JUL16
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.
• Always wear gloves when handling mower blades or working near blades.
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:
48A and 48HC Mower Decks
GXT001459—UN—02JUN15
Position 1 (A)
25 - 38 mm (1 - 1-1/2 in.) Height of Cut
Position 2 (B)
38 - 50 mm (1-1/2 - 2 in.) Height of Cut
Position 3 (C)
50 - 76 mm (2 - 3 in.) Height of Cut
Position 4 (D)
76 - 101 mm (3 - 4 in.) Height of Cut
● 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.
Specification
Mower Wheel Nut—Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 N·m (25 lb-ft) TH84124,0000231-19-24JUN15
19
Testing Safety Systems
MXAL42804—UN—09APR13
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.
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.
Use the following checkout procedures to check for normal operation of machine.
If there is a malfunction during one of these procedures, do not operate machine. See your authorized dealer for service.
Perform these tests in a clear open area. Keep bystanders away. MP47322,00F4637-19-26MAY15
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.
MP47322,00F4638-19-19MAR13
Testing Park Brake
1. Park machine safely. (See Parking Safely in the SAFETY section.) 2. Lock the park brake.
3. Engage bypass valve control.
4. Try to push machine manually.
Result: Park brake must prevent machine from moving. If machine moves, see your authorized dealer for service.
NOTE: When testing is complete, disengage bypass valve control prior to returning machine to service.
TH84124,0000115-19-19MAY14
Testing Mower Engagement (PTO) Switch 1. Park machine safely. (See Parking Safely in the SAFETY section.) 2. Sit on seat.
3. Lock the park brake.
4. Engage the mower. 5. Try to start engine.
Operating
Checking Fuel Level
Result: Engine must not crank. If engine cranks, there is a problem with your safety interlock circuit.
MP47322,00F463A-19-27MAR13
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.
b. Start engine.
c. Unlock park brake.
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.
4. Third test:
a. Lock park brake.
b. Disengage mower.
c. Start engine.
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.
MP47322,00F463B-19-19MAR13
Testing Motion Control Lever Switch
1. Park machine safely. (See Parking Safely in the SAFETY Section.) 2. Sit on seat.
3. First test:
a. With the park brake locked, start engine.
b. Move right motion control lever inward.
Result: Engine should stop. If engine does not stop, there is a problem with your safety interlock circuit.
4. Second test:
a. Start engine.
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.
5. Repeat first and second test using left motion control lever. MP47322,00F463C-19-19MAR13
20
PY44505—UN—06JUL17 The fuel level sight window (A) shows the amount of fuel in the fuel tank. The fuel level sight window is located between the seat and the mower deck foot plate and is visible to an operator from the seat. The fuel level decal (B) is orientated to be correct for an operator sitting in the seat.
RM87422,00007BA-19-06JUL17
Using Park Brake
CAUTION: Avoid injury! 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.
Setting Park Brake
1. Raise park brake lever to lock park brake.
Releasing Park Brake
1. Lower park brake lever to unlock park brake.
TH84124,000024A-19-25JUL16
Using Key Switch
MXAL42805—UN—09APR13 A - STOP (off) position - With key in the STOP position, all switched power is off, and engine should not run.
B - Run (on) position - Turn key from STOP to this position, and all switched power circuits will be on.
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.
MP47322,00F463E-19-15MAR13
Using Mower Engagement Switch ● To Engage Mower - Pull mower engagement knob up.
Operating
● Motion control levers must be in the start/shutdown position to safely enter and exit the operator seat.
● To Disengage Mower - Push mower engagement knob down. MP47322,00F463F-19-15MAR13
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.
● Turn the key to STOP position when not using the machine. ● Hour meter cannot be reset.
MP47322,00F4640-19-05JUN15
Using the Motion Control Levers
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.
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.
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.
The functions of the motion control levers are:
● Dual function neutral position.
● Steering.
● Acceleration.
● Braking.
Start/shutdown Position
APY08043—UN—23MAY18 ● 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.
21
Neutral Position
APY08044—UN—23MAY18 ● 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
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. 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
Operating
Left Turn
APY08045—UN—23MAY18
1.Gradually move both motion control levers evenly forward (A) from
APY08047—UN—23MAY18
neutral. To speed up, move the levers farther forward. To slow down smoothly, slowly move the levers toward neutral.
Reverse Travel
APY08046—UN—23MAY18 1.Look down and behind, then gradually move both motion control levers evenly rearward (B) from neutral. To speed up, move the levers farther rearward. To slow down smoothly, slowly move the levers toward neutral.
22
1. To turn slightly to the left, push right control lever (C) further forward than the left control lever (D).
APY08048—UN—23MAY18 2. To turn sharply to the left, push right control lever (C) forward and pull left control lever (D) rearward at the same time.
Right Turn
Operating
● 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.
IMPORTANT: Starter may be damaged if starter is operated for more than 20 seconds at a time:
● Wait two minutes before trying again if engine does not start.
6. Turn key switch to the start position.
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.
8. Allow the engine to warm up for 20 seconds.
9. Release park brake.
10. Set both motion control levers to the neutral position.
APY08049—UN—23MAY18
1. To turn slightly to the right, push left control lever (D) further forward than the right control lever (C).
APY08050—UN—23MAY18 2. To turn sharply to the right, push left control lever (D) forward and pull right control lever (C) rearward at the same time.
SU68010,00000A1-19-17MAY18
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. 4. Set both motion control levers to the start/shutdown position. 5. Move throttle lever to set engine speed:
23
MX00654,000032F-19-04JUN13
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.
NOTE: The travel speed and turn rate will vary with the amount that the control levers are moved.
7. Push motion control levers forward slowly. Mow at a safe travel speed.
MP47322,00F4643-19-15MAR13
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.
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.
CAUTION: Children or bystanders may attempt to move or operate an unattended machine.
Operating
Always lock the park brake and remove the key before leaving the machine unattended.
8. Remove key.
MP47322,00F4644-19-15MAR13
Moving Machine by Hand
CAUTION: Avoid injury! When the bypass valve is open, the machine will have unrestricted motion.
• Do not open the bypass valve when the machine is stopped on an incline to prevent it from going downhill out of control.
IMPORTANT: Transmission damage may occur if the machine is towed or moved incorrectly:
• Move machine by hand only.
• Do not use another vehicle to move machine.
• Do not tow machine.
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.
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).
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.
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.
1. Park machine safely. Wait for all moving parts to stop before getting off to inspect machine.
2. Open hopper cover. Check chute outlet.
3. Remove chute from mower deck or blower assembly. Check chute inlet.
4. Check under mower deck for debris.
MP47322,00F4646-19-26MAY15
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).
1. Rotate levers (A) inward until lever hits a stop. 2. Release park brake.
GXT002403—UN—30JUL15
GXT002324—UN—06JUL15
3. Push machine to desired location and lock park brake. 4. Rotate bypass levers (A) outward to the disengaged position. TH84124,00001EA-19-16JUL15
Unplugging Mower, Bagger, or Material Collection System
CAUTION: Avoid injury! Do not attempt to unplug
attachment with machine running.
● 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.
24
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.
Operating
12. Remove quick-coupler from garden hose and store for future use. TH84124,000024E-19-06JUL15
Transporting Machine on Trailer
NOTE: Trailer capacity must exceed combined machine weight and attachment weight. (See Specifications section in operator’s
manual).
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.
• To load, back slowly and in a straight line. Keep wheels
GXT002405—UN—16JUL15
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.
• Use a trailer with sides.
1. Park trailer on level surface.
2. Raise mower deck before driving machine onto trailer. MXAL42817—UN—09APR13 3. Back machine onto heavy-duty trailer with full-width ramp.
4. Lower mower deck completely.
5. Lock park brake.
GXT002198—UN—08JUN15 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.
7. Turn off machine and remove key.
25
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.
TH84124,00001EB-19-16JUL15
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:
● 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.
● 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.
TH84124,000020A-19-24JUN15
Mowing Tips
● Mow grass with throttle lever in the full fast / mow position. ● Mow grass when it is dry.
● Keep mower deck and discharge chute clean.
● Mow with sharp blades.
● Properly level mower deck for a smooth cut.
● Mow grass frequently.
● 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.
- Travel slow when mowing tall or thick grass.
- Avoid damaging grass by slipping or skidding machine drive wheels. Practice smooth control lever movements.
- When performing sharp turns, do not allow inside machine drive wheel to stop and twist on grass.
MP47322,00F4649-19-15MAR13
Blade Choices
Several types of blades are available for ZTrak Z500 series mowers:
● 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.
● Mulching blades. These blades are designed for optimal performance when used with a mulch cover or mulch plug installed.
SU68010,000010E-19-17JUL18
Service Intervals
Servicing Your Machine IMPORTANT: Avoid damage!
Service Intervals
Every 200 Hours
● Check / adjust engine valve clearance. See your John Deere dealer for this service.
RM87422,00007B5-19-14JUL17
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.
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.
Avoid spraying water with any great force near or into the following places:
● Air intake
● Electrical connections (including battery compartment) ● Wheel bearings
● Radiator (if equipped)
● Warning labels
● Other labels
● Ignition switch
● Instrument panel (gauges and switches)
● Breather/tube vents
● Mower spindles
● Mower idler bearings
● Transmission cooling fans
Please use the following timetables to perform routine maintenance on your machine.
Park the vehicle safely. (See Park Safely in the SAFETY Section.) OUMX068,00006EF-19-22NOV16
Service Intervals
Break-In after 8 Hours
● Check mower deck level.
Every 50 Hours or Annually (Whichever Comes First)
● Change engine oil. (Service more frequently under dusty conditions.)
● Replace engine oil filter. (Service more frequently under dusty conditions).
● Lubricate mower deck spindles.
● Lubricate mower deck idler arm
● Check mower deck level. Level if necessary.
Every 100 Hours or Annually (Whichever Comes First) ● Replace spark plugs.
● Replace air filter element(s). (Service more frequently under dusty conditions.)
● Replace fuel filter.
● Check mower belt. Replace if necessary.
● Sharpen / replace mower blades.
● Clean underside of deck.
● Check tire pressure.
● Clean engine cooling fins.
26
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
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.
OUMX068,0000642-19-27AUG14
Lubricating Mower Deck Spindles
1. Remove mower deck foot plate. (See SERVICE MOWER Section for Removing and Installing Mower Deck Foot Plate.)
GXT003043—UN—19JUL16 2. Remove two screws (A) and the right deck shields (B).
3. Remove three screws (C) and the left deck shield (D).
Service Engine
MXAL47075—UN—16APR13
● The two front caster wheel supports (A) utilize bearings, which do
not require lubrication. There are no grease fittings in the wheel
supports.
GXT003044—UN—19JUL16
4. Lubricate three mower deck spindle grease fittings (E) with two
pumps of grease each at specified interval.
5. Remove cover (F) and lubricate mower deck idler arm (G).
6. Install left and right deck shields with original hardware.
7. Install mower deck foot plate.
MX52301,0000FE1-19-07JUL17
Lubricating Front Lift Arm
MXAL42825—UN—09APR13
● The caster wheel yoke spindle (B) should be lightly greased prior to
assembly if the wheel unit is serviced, to prevent the spindle from
seizing in the bushings.
MX00654,000003F-19-31JUL13
Service Engine
Carbon Dioxide Emissions (CO₂)
To identify the carbon dioxide (CO₂) output, locate the engine
emissions label. Find the appropriate family on the emissions label and
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.
TH84124,00001ED-19-11JUN15
Lubricating Front Caster Spindles
CAUTION: To avoid injury, Do not lubricate machine while the engine is running.
27
refer to the engine manufacturer’s website listed below. http://www.briggsandstratton.com
https://power.kohler.com/en/engines
https://www.kawasaki-engines.eu/en/support/
This CO₂ measurement results from testing over a fixed test cycle under laboratory conditions a(n) (parent) engine representative of the engine type (engine family) and shall not imply or express any guarantee of the performance of a particular engine.
MK71445,000007A-19-24AUG18
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.
Service Engine
Move the machine to an outside area before running the engine.
MP47322,00F4652-19-13JAN15
Gasoline Engine Oil
SAE 40
● ACEA Oil Sequence C1
DX,ENOIL2-19-20JUL15
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:
• 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.
NOTE: Check oil twice a day if you run engine over 4 hours in a day. Make sure engine is cold when checking engine oil level.
SAE 15W-40
SAE 10W-40
SAE 5W-30
SAE 10W-30
1. Park machine safely. (See Parking Safely in the SAFETY section.)
SAE 30
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.
Oil Viscosities for Air Temperature Ranges
TS1734—UN—04SEP13
Use oil viscosity based on the expected air temperature range during the period between oil changes.
Using single viscosity grade oils such as SAE 30 or SAE 40 can reduce oil consumption in air cooled engines.
John Deere Turf-Gard™ is preferred.
The following oils are also recommended:
● John Deere Plus-4™
● John Deere Plus-50™ II
Other oils may be used if they meet one or more of the following: ● ILSAC GF-5
● API Service Category SN
● API Service Category SM
● API Service Category SL
● API Service Category SJ
● ACEA Oil Sequence A5
● ACEA Oil Sequence A3
● ACEA Oil Sequence A1
● ACEA Oil Sequence C4
● ACEA Oil Sequence C3
● ACEA Oil Sequence C2
Turf-Gard is a trademark of Deere & Company
Plus-4 is a trademark of Deere & Company
Plus-50 is a trademark of Deere & Company
28
GXT002409—UN—15JUL15 Model Z525E
APY08053—UN—16MAY18 Model Z535M
Service Engine
Model Z540R
3. To check oil level on dipstick:
Model Z525E and Z535M
a. Remove dipstick (A). Wipe with clean cloth. b. Install and tighten dipstick.
c. Remove dipstick.
GXT002415—UN—15JUL15
Z525E
GXT002410—UN—15JUL15
d. Check oil level on dipstick. Oil must be between ADD and FULL marks.
Model 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.
SU68010,00000A2-19-23MAY18
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.)
APY08054—UN—16MAY18 Z535M
IMPORTANT: Dirt and contamination can enter engine when checking oil level. Clean area around dipstick before loosening or removing.
Z540R
4. Prepare to drain oil:
GXT002416—UN—15JUL15
3. Clean area around dipstick to prevent debris from falling into crankcase.
29
● Z525E and Z535M— Disconnect oil drain hose (A) from the side of the engine and lower hose.
● Z540R — Put drain pan under drain valve (A).
5. Drain oil:
Service Engine
● Models Z525E and Z535M - Loosen dipstick (C). Remove the
oil drain cap (B). Carefully lower the quick oil drain into an
approved container and allow oil to drain completely.
● Model 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 cap completely. Drain
oil into an approved container until the oil has drained
completely.
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. For models Z525E and Z535M, attach drain hose assembly (A) to side
of engine.
10. Add oil no higher than FULL mark on dipstick. Begin with per
specification, do not overfill.
Specification
Z525E and Z535M Engine Oil—Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 L (2.0 qt) Z540R Engine Oil—Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 L (2.2 qt)
11. Tighten dipstick.
12. Start and run engine at idle to check for leaks. Stop engine. Fix any leaks before operating.
13. Check oil level. Add oil if necessary.
SU68010,00000A3-19-17MAY18
30
Cleaning Engine Screen Guard Z525E
Service Engine
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.
GXT002411—UN—15JUL15 1. Locate rotating screen guard (A) at top of engine, and the two retaining tabs (B), embossed with a finger symbol.
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.
Z535M
Removal of engine screen guard is not necessary.
Z540R
GXT002417—UN—15JUL15 31
MXT005379—UN—31JUL13 1. Locate rotating screen guard (A) at top of engine, and remove the three rivets (B) by prying them up using a screwdriver under the head until it pops up. Lift off screen guard.
2. Clean guard, flywheel cover and the rotating flywheel screen of debris.
3. Install guard after cleaning. Rivets can be reinstalled by pushing them into the fastened position.
RM87422,0000772-19-05JUL17
Cleaning Engine Shroud
CAUTION: 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: 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.
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.
Z525E
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).
Service Engine
Z535M
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.
GXT002522—UN—17SEP15
3. Locate rotating screen guard (A) at top of engine, and the two
retaining tabs (B), embossed with a finger symbol. Remove screw
(C) at front of screen guard (if equipped).
4. Push in on the two retaining tabs and lift off guard (A).
5. Clean guard and flywheel cover of debris.
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 bolts (E) and engine shroud (F).
7. Remove four bolts and rotating screen (G) located under intake screen.
MXAL47082—UN—16APR13 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 the slots in the shroud align with the ridge in the 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.
10. Install shroud with hardware.
32
APY08056—UN—16MAY18
4. Loosen clean out port screws (A) until the cover can be removed. 5. Remove port covers (B).
APY08057—UN—16MAY18 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.
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).
Service Engine
GXT002418—UN—15JUL15
3. Loosen two knobs and remove air cleaner cover (A) and air filter.
8. Clean debris from:
● Fan areas (G)
● Cylinder head cooling fins (H)
● Area between engine and frame
MXT005356—UN—31JUL13
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).
IMPORTANT: Engine shroud must be assembled so that the slots in the shroud align with the ridge in the 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.
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.
SU68010,00000A4-19-17MAY18
Checking and Cleaning Air Cleaner Element 1. Park machine safely. (See Parking Safely in the SAFETY section.) 2. Let engine cool.
Z525E
33
GXT002412—UN—15JUL15
Service Engine
APY08058—UN—13JUN18
Z535M
APY08059—UN—16MAY18
Z540R
GXT002419—UN—15JUL15
Z540R
MXT005354—UN—08JUN13
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.
MXAL47088—UN—16APR13 Z525E
34
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.
• Replace element only if it is very dirty, damaged or the seal is cracked.
6. Inspect the foam precleaner (D) 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 precleaner. 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 precleaner is completely dry.
d. Replace the precleaner if damaged or missing.
7. Inspect paper filter element. Replace the filter element if damaged or dirty.
8. Clean air cleaner base carefully. Prevent any dirt from falling into carburetor or air intake tube.
Service Engine
9. Install foam precleaner (D) mesh side up on paper filter element. Position air filter in air filter base:
● Z525E install cartridge. Make sure cartridge and seal are properly seated and sealing the carburetor air intake area. ● All other models, install also on air intake tube (E). Align air filter clamp on intake tube groove and tighten clamp by turning thumbscrew clockwise until secure.
10. Install air cleaner cover and tighten knobs. Do not overtighten. SU68010,00000A5-19-17MAY18
Checking Spark Plug
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.
1. Park machine safely (See Parking Safely in the SAFETY section). 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. 6. Replace spark plug(s) as necessary.
8. Install spark plugs and tighten to specification.
Specification
Spark Plug—Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N·m (180 lb-in.)
9. Connect spark plug wire(s).
TH84124,0000267-19-17SEP15
Adjusting Carburetor
NOTE: Carburetor is calibrated by the engine manufacturer and is not adjustable.
If engine is operated at altitudes above 1006 m (3,300 ft), some carburetors may require a special high altitude main jet. See your authorized dealer.
If engine is hard to start or runs rough, check the
TROUBLESHOOTING section of this manual.
Possible engine surging will occur at high throttle with transmission in “N” neutral and mower engagement lever disengaged. This is a normal condition due to the emission control system.
After performing the checks in the troubleshooting section and your engine is still not performing correctly, contact your authorized dealer.
MP47322,00F465A-19-15MAR13
Replacing Fuel Filter
CAUTION: Fuel vapors are explosive and flammable: • Do not smoke while handling fuel.
• Keep fuel away from flames or sparks.
• Shut off engine before servicing.
• Cool engine before servicing.
• 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.
Model Z525E shown.
GXT002414—UN—15JUL15
MXAL47092—UN—16APR13
7. Check plug gap (C) with a wire feeler gauge. To change gap, move the outer electrode. Gap must be set to specification.
Specification
Spark Plug—Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.75 mm (0.030 in.) 35
5. Slide hose clamps on both sides of fuel filter (A) away from fuel filter ends using pliers.
6. Disconnect hoses from filter.
Service Transmission
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.
TH84124,0000239-19-17SEP15
Service Transmission
Transmission Oil
Use only John Deere Hy-Gard™ .
DO NOT use type “F” automatic transmission fluid.
SU68010,0000149-19-08AUG18
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.
GXT002204—UN—09JUN15 3. Locate the left-hand and right-hand reservoirs at the rear of the machine. Each transmission has its own reservoir.
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.
9. Install cap (C).
10. Start engine.
Hy-Gard is a trademark of Deere & Company
36
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.
TH84124,00001FB-19-16JUL15
Changing Transaxle Oil and Filter
The transaxles on these models require no maintenance. If you suspect transmission problems, contact your authorized dealer.
MP47322,00F465F-19-15MAR13
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.) 2. Raise seat.
GXT002408—UN—30JUL15 Right side of machine shown with machine parts removed for a more clear image.
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.
TH84124,0000266-19-17SEP15
Adjusting Tracking
If the machine does not track in a straight line while going in full forward position, the tracking requires adjustment.
1. Park machine safely. (See Parking Safely in the SAFETY section.)
Service Transmission
2. Clean transaxle fan fins (A) and around exterior of each fan with a
rag, brush or compressed air.
TH84124,00001FE-19-24JUN15
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.
NOTE: The transmission drive belts are self-adjusted using a spring
tensioner and do not require a tension adjustment.
Checking Transaxle/Transmission Drive Belt
1. Park machine safely. (See Parking Safely in the SAFETY section.)
GXT002205—UN—09JUN15
2. Adjust tracking with the 13 mm socket on the free end of the deck
height adjustment deck height pin tool (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.
TH84124,00001FD-19-05JUL17
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.
1. Park machine safely. (See Parking Safely in the SAFETY section.)
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.
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.
Components viewed from top front.
GXT002514—UN—30JUL15
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).
37
6. Remove belt from drive sheave on engine. 7. Disconnect spring (E) from rockshaft 8. Remove belt from underneath the machine.
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.
11. Insert electric clutch wiring harness connector (I) to main wiring harness.
12. Install mower deck.
13. Install style cover.
TH84124,00001FF-19-30JUL15
Service Mower
Mower Deck Identification
Mower decks in the following instructions are identified by a code designation. The codes are as follows:
Code
Description
48A
48 Inch Accel Deep™ Mower Deck
48HC
48 Inch High Capacity Edge™ Mower Deck
Accel Deep is a trademark of Deere & Company
Edge is a trademark of Deere & Company
TH84124,0000263-19-16SEP15
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.) 38
GXT002215—UN—10JUN15
2. Remove bolt (A).
3. Rotate foot plate up using finger pull (B).
4. Remove foot plate.
Installing Foot Plate
1. Place tabs (C) of foot plate into slots in frame.
2. Lower foot plate.
3. Install bolt (A) to secure foot plate.
TH84124,0000210-19-24JUN15
Removing Mower Deck (48A and 48HC) 1. Park machine safely. (See Parking Safely in the SAFETY section.) 2. Allow engine and muffler to cool completely.
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.
3. Raise mower deck to the transport lock position. GXT002216—UN—10JUN15 4. Remove deck height pin tool, push handle to its lowest position (A) and install pin just above lever (B) to lock deck in lowered position.
5. Remove mower deck foot plate.
6. Remove mower deck front draft linkage: 48A Mower Deck Only:
Service Mower
7. Remove three screws (K) and left deck shield (L).
8. Remove two screws (M) and right deck shield (N).
GXT002297—UN—22JUN15
GXT002300—UN—22JUN15
● Remove locking clips (C) from front draft rod (D).
● Remove draft rod from draft brackets (E) and mower deck brackets (F).
48HC Mower Deck Only:
GXT002298—UN—22JUN15 ● Remove locking clip (G) from front draft link (H).
● Remove draft link from mower deck bracket (I) and draft bracket (J).
● Repeat steps on opposite side of deck.
GXT002299—UN—22JUN15 48A mower deck shown. 48HC mower deck is similar
39
9. Remove four screws (O) and center deck shield (P).
CAUTION: Avoid injury! Component is spring-assisted and under tension. Injury can occur if spring-assisted component is released suddenly.
PY44506—UN—06JUL17 10. From the left side of machine, insert a 3/8 inch ratchet into square hole (Q) in tension arm. Pull clockwise and hold to release tension on belt. Remove belt (R) from spindle.
11. Remove mower drive belt from engine sheave.
GXT002523—UN—22SEP15 12. Remove spring clip (S) and pin (T) from each side of rear mower bracket.
13. 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. 14. Rotate front caster wheels to maximize clearance.
15. Slide mower out from under the machine.
Service Mower
● 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.)
TH84124,0000242-19-06JUL17
Installing Mower Deck (48A and 48HC)
1. Park machine safely. (See Parking Safely in the SAFETY section.) 2. Allow engine and muffler to cool completely.
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.
3. Raise mower lift lever fully upward into transport lock position. 4. Slide mower deck under machine.
GXT002259—UN—10JUN15 5. Lower mower lift lever, and install pin (A) and spring clip (B) onto each side of rear mower bracket.
GXT002305—UN—22JUN15 ● Install front draft rod (G) onto mower deck bracket (H) and onto draft bracket (I).
● Install locking clip on draft rod stud end with locking clip (J). ● Repeat steps on opposite side of deck.
GXT002524—UN—22SEP15 7. Install belt (K) onto engine sheave (L).
CAUTION: Avoid injury! Component is spring-assisted and under tension. Injury can occur if spring-assisted component is released suddenly.
6. Install mower deck front draft linkage: 48A Mower Only:
GXT002304—UN—22JUN15
PY44507—UN—06JUL17
● Install front draft rod (C) onto mower deck bracket (D) and onto draft bracket (E).
● Secure each stud end with locking clip (F).
48HC Mower Only:
40
8. Insert 3/8 inch ratchet onto square hole (O) in tension arm and rotate clockwise to release spring tension on idler sheave. Install mower belt (P) onto left spindle sheave. Make sure that belt is properly seated on all sheaves. Release tension arm.
Service Mower
GXT002309—UN—22JUN15
9. Install center deck shield (Q) with four screws (R).
GXT002216—UN—10JUN15
10. Install right deck shield (S) with two screws (T). 11. Install left deck shield (U) with two screws (V). 12. Install mower deck foot plate.
4. Remove deck height pin tool, push handle to its lowest position (A)
and install pin just above lever (B) to lock deck in lowered position.
5. Remove mower deck floor plate.
GXT002310—UN—22JUN15
TH84124,0000243-19-06JUL17
Replacing Mower Drive Belt (Z500 Series with 48A and 48HC Mowers)
Remove Mower Belt
1. Park machine safely. (See Parking Safely in SAFETY section.) 2. Allow engine and muffler to cool completely.
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.
3. Raise mower deck to the transport lock position.
41
GXT002311—UN—23JUN15
48A mower deck shown. 48HC mower deck is similar
6. Remove three screws (C) and left deck shield (D). 7. Remove two screws (E) and right deck shield (F).
GXT002312—UN—23JUN15 8. Remove four screws (G) and center deck shield (H).
CAUTION: Avoid injury! Component is spring-assisted and under tension. Injury can occur if spring-assisted component is released suddenly.
Service Mower
PY44508—UN—06JUL17
9. From the left side of machine, insert a 3/8 inch ratchet into square hole (I) in tension arm. Pull clockwise and hold to release tension on belt. Remove belt from spindle (J).
10. Remove mower drive belt from engine sheave.
PY44509—UN—06JUL17 11. Loosen nut (K) on tension sheave, and remove belt (L) from all sheaves.
12. Inspect belt for wear or damage; replace as necessary. 13. Clean top surface of mower deck and sheaves.
Install Mower Belt
GXT002526—UN—22SEP15 1. Route belt above transaxle brace (A) and install onto engine sheave (B).
42
PY44510—UN—06JUL17
48A mower deck shown. 48HC mower deck is similar.
2. Install belt on five deck sheaves (C) as shown.
3. Tighten idler sheave nut (D) to specification.
Specification
Sheave Nut—Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 N·m (35 lb-ft)
CAUTION: Avoid injury! Component is spring-assisted and under tension. Injury can occur if spring-assisted component is released suddenly.
4. From the left side of machine, insert a 3/8 inch ratchet into square hole (E) in tension arm. Rotate arm counterclockwise and install belt on left spindle sheave (F).
GXT002318—UN—23JUN15 5. Install center deck shield (G) with original hardware (H).
GXT002319—UN—23JUN15 48A mower deck shown. 48HC mower deck is similar
6. Install right deck shield (I) with original hardware (J). 7. Install left deck shield (K) with original hardware (L).
8. Install foot plate and secure with original hardware.
Service Electrical
TH84124,0000244-19-07JUL17
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.
48A deck shown. 48HC deck is similar.
GXT002321—UN—18SEP15
MXAL42867—UN—09APR13
Mower deck with side discharge used for illustration
3. Measure distance (A) between blade tip and flat ground surface.
4. Rotate blade 180° and measure distance between other blade tip and flat ground surface.
5. Install new blade if the difference between the two measurements is more than 3 mm (1/8 in).
6. Repeat for all blades.
MP47322,00F466C-19-25JUL18
Servicing Mower Blades
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.
Removing Mower Blades
1. Park machine safely. (See Parking Safely in the SAFETY section.)
2. Raise mower deck to gain access to mower blades. If necessary, remove mower deck.
3. Block mower blade with a piece of wood to prevent it from spinning. 43
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.
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) TH84124,0000245-19-22SEP15
Service Electrical
Service the Battery Safely
MXAL42869—UN—09APR13
CAUTION: Avoid injury! The battery produces a flammable and explosive gas.
To prevent the battery from exploding:
● Do not smoke or have open flame near battery. ● Wear eye protection and gloves.
● Do not allow direct metal contact across battery posts.
Service Electrical
● Remove negative cable first when disconnecting. ● Install negative cable last when connecting.
● Always route battery cables away from battery posts. MX52301,000102B-19-12SEP16
Removing and Installing the Battery
Removing
1. Park machine safely. (See Parking Safely in the SAFETY section.) 2. Rotate operator seat forward.
3. Remove battery compartment cover.
Using Booster Battery
CAUTION: Avoid injury! The battery produces a flammable and explosive gas.
To prevent the battery from exploding:
● Do not smoke or have open flame near battery. ● Wear eye protection and gloves.
● Do not jump-start or charge a frozen battery. Warm battery to specification.
Specification
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.
4. Disconnect negative (-) battery cable (A).
APY08060—UN—16MAY18
MXAL42872—UN—09APR13 A—Booster Battery
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.
SU68010,00000A6-19-17MAY18
Cleaning Battery and Terminals
1. Park machine safely. (See Parking Safely in the SAFETY section.) 2. Disconnect and remove battery.
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.
4. Rinse the battery with plain water and dry.
5. Clean terminals and battery cable ends with wire brush until bright. 6. Install battery.
7. Attach cables to battery terminals, beginning with the positive cable, using washers and nuts.
8. Apply general-purpose grease or silicone spray to terminals to help prevent corrosion.
SU68010,000010C-19-17JUL18
44
B—Disabled Vehicle Battery
C—Positive (+) Post
D—Positive (+) Post
E—Negative (-) Post
F—Negative (-) Booster Cable End
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).
3. Connect negative (–) booster cable to booster battery negative (–) post (E).
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.
MP47322,00F4672-19-05JUN15
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.
Service Miscellaneous
5. Remove the fuse and check metal strip in fuse window. Discard fuse (s) if strip is broken.
6. Push new, correct amp, fuse into correct socket.
7. Lower operator’s seat.
MP47322,00F4673-19-15MAR13
Service Miscellaneous
Using Proper Fuel and Stabilizer
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.
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.
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.
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.
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.
MP47322,00F4674-19-26MAY15
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 a 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.
45
● To keep condensation out of the fuel tank, fill the fuel tank at the end of operation each day.
● If using a funnel, make sure it is plastic and has no screen or filter.
To prevent condensation and freezing during cold weather, fill fuel tank at the end of operation each day.
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 it clicks.
MP47322,00F4675-19-05JUL17
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. ● Lower machine onto jack stands or other stable supports and block wheels before servicing.
NOTE: Remove any material collection system attachments prior to lifting machine.
GXT002211—UN—09JUN15 2. Safely lift rear of machine frame points (A). Place jack stands or other stable supports onto transaxle locations (B).
Service Miscellaneous
IMPORTANT: Avoid damage! Place jack stands under frame, not
under transmission or engine, when raising or supporting
machine.
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.
GXT002212—UN—09JUN15
3. Safely lift front of machine at machine frame point (C). Place jack
stands or other stable supports onto machine frame locations (D).
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.
TH84124,0000209-19-24JUN15
Checking Tire Pressure
CAUTION: Avoid injury! Explosive separation of tire and rim parts is possible when they are serviced incorrectly:
● 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.
● 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.
● 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.
1. Check tires for damage.
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.
MP47322,00F4677-19-05JUL17
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.
46
MXAL42875—UN—09APR13
3. Remove the wheel nuts (A).
4. Remove the wheel assembly.
CAUTION: Avoid injury! Explosive separation of tire and rim parts is possible when they are serviced incorrectly:
● Do not attempt to mount a tire without the proper equipment and experience to perform the job.
5. Take wheel assembly to an authorized service dealer for repairs.
Installing
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.
4. Tighten wheel nuts to specification.
Specification
Wheel Nuts—Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 102 N·m (75 lb.-ft.) MP47322,00F4678-19-26MAY15
Removing and Installing Front Caster Wheels Disassembly:
1. Park machine safely. See “Park Machine 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.
NOTE: Remove all attachments prior to lifting machine. 2. Jack up front of machine and place on safety stands.
Service Miscellaneous
MXAL47140—UN—16APR13
8. Remove shield (F) and bearing (G). Inspect shields, wheel, and
MXAL47137—UN—16APR13
3. Support caster assembly and remove flange bolt (A) and cap (B). 4. Remove caster from machine.
MXAL47138—UN—16APR13 5. Inspect bearings (C) at top and bottom of frame. Replace worn or damaged bearings.
NOTE: Inner race extends above outer race.
bearings for wear or damage. Replace worn or damaged parts. GXT002156—UN—02JUN15 9. Inspect bearing wear areas (H), and bolt holes (I) for wear or damage. Replace if necessary.
Assembly
● Apply grease to caster shaft and bolt.
● Assemble in the reverse order of disassembly.
● 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) MX52301,0001044-19-13SEP16
Removing and Installing Style Cover
1. Park machine safely. (See Parking Safely in the SAFETY section.)
6. Remove nut (D) and pull bolt out of caster. 7. Remove wheel assembly (E).
MXAL47139—UN—16APR13 47
Troubleshooting
Troubleshooting
Using Troubleshooting Chart
If you are experiencing a problem that is not listed in this chart, see your Technical Manual or authorized dealer for service.
MP47322,00F467B-19-07SEP17
Engine
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).
4. Disconnect seat switch wiring harness connector (C). Lift switch harness from channel in cover, and place in battery compartment.
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. TH84124,0000255-19-30JUL15
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):
1. Clean area to be repaired thoroughly.
IMPORTANT: Avoid damage! Do not use rubbing compound on painted surfaces.
2. Use automotive polishing compound to remove surface scratches. 3. Apply wax to entire surface.
Repairing Deep Scratches (bare metal or primer showing): 1. Clean area to be repaired with rubbing alcohol or mineral spirits.
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.
3. Smooth out surface using an automotive polishing compound. Do not use power buffer.
4. Apply wax to surface.
MP47322,00F467A-19-26MAY15
48
IF
CHECK
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 Fuel blended with alcohol or ether may contribute to
performance problems by
causing gum and varnish
deposits, especially if fuel is stored for several weeks or more. Obtain fresh fuel.
Engine Will Not Start - No Crank Park brake not locked.
Motion control levers not in Start/ Shutdown position.
Mower is engaged.
Defective brake, mower
engagement, or key switch. Electrical problem - See
Electrical Troubleshooting
Section
Engine Cranks But Will Not Start Spark plug wire is loose or
disconnected.
Improper fuel.
Plugged fuel filter.
Electrical problem - See
Electrical Troubleshooting
Section
Engine Is Hard To Start
Carburetor is not adjusted
properly or dirty.
Choke not fully closing.
Plugged fuel filter.
Faulty spark plug.
Stale or improper fuel.
Loose or corroded electrical connections.
Engine oil viscosity.
Engine Runs Unevenly
Cooling fins plugged.
Loose electrical connections. Choke or throttle cable sticking. Choke not fully open.
Fuel line or fuel filter plugged. Stale or dirty fuel.
Improper fuel.
Air cleaner element plugged.
Engine Misses Under Load
Faulty spark plug.
Stale or dirty fuel.
Plugged fuel filter.
Engine Vapor Locks
Fuel tank vent plugged.
Dirt in fuel filter.
Cooling fins plugged.
Loose hose connection at fuel filter or fuel pump.
Troubleshooting
IF
CHECK
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.
Engine Will Not Idle
Spark plug not gapped correctly. Faulty spark plug.
Operator raising off the seat.
Engine Knocks
Stale or low octane fuel.
Engine overloaded.
Low engine speed.
Oil level low.
Engine Stops Or Misses When Operating On Hillsides
Fuel tank less than half full of fuel.
Operator raising off of the seat.
Engine Backfires
Faulty spark plug.
Operator raising off of the seat.
Engine Loses Power
Engine overheating.
Too much oil in engine.
Dirty air cleaner.
Faulty spark plug.
Travel speed is too fast for conditions.
Improper fuel.
Excessive Fuel Consumption
Choke is not fully open.
Black Exhaust Smoke
Air filter is dirty or oil soaked.
MX00654,0000351-19-03JUN13
Electrical
IF
CHECK
Starter Does Not Work Or Will Not Turn Engine
Park brake not locked.
Mower is engaged.
Battery terminals are corroded. Battery not charged.
Motion control levers not in Start/ Shutdown position.
Blown fuse.
Defective key switch
Battery Will Not Charge
Dead cell in the battery.
Blown charging fuse.
Battery cables and terminals are dirty.
Low engine speed or excessive idling.
Lights Do Not Work
Light plug disconnected.
Loose or burned out bulb.
Blown headlight fuse.
MP47322,00F467D-19-15MAR13
Machine
IF
CHECK
Machine Vibrates Too Much Or Rattles Excessively
Attachment drive belts worn or damaged.
Mower blades not balanced. Traction drive belt damaged or worn.
Dirt on drive sheaves.
Machine Will Not Move With Engine Running
Transmission hydraulic oil level low.
Transmission belt broke.
49
IF
CHECK
Bypass valve levers are
engaged.
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.
Front of machine squeaks while driving
Lubricate mower front draft rod at front and rear pivot points.
MP47322,00F467E-19-15MAR13
Mower
IF
CHECK
Discharge Chute Plugged
Travel speed too fast.
Grass too long.
Grass too wet.
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.
Patches Of Grass Uncut
Travel speed too fast.
Engine rpm not at mow position. Mower deck needs cleaning.
Belt Slipping
Debris in sheaves.
Worn belt.
Belt tension is incorrect.
Too Much Vibration
Debris on mower deck or in sheaves.
Damaged drive belt.
Damaged sheaves or sheaves out of alignment.
Blades out of balance.
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.
Blades Scalping Grass
Cutting too low.
Mower wheels not adjusted correctly.
Turning speed too fast.
Ridges in terrain.
Rough or uneven terrain.
Low tire pressure.
Mower Loads Down Tractor
Engine rpm too low.
Travel speed too fast.
Debris wrapped around mower spindles.
Adjust cutting height to remove only 1/3 of grass at a time.
Uneven Cut
Mower deck not leveled properly. Travel speed too fast.
Blades dull.
Mower wheels not adjusted correctly.
Tire pressure unequal.
Adjust cutting height to remove only 1/3 of grass at a time.
Excessive Clippings are Expelled from Front of Mower Deck
Conditions may be too dry or terrain too uneven to provide good seal between front of deck and grass. Visit http://JDParts.
Storage
IF
CHECK
deere.com or contact dealer to purchase dry condition kit.
MP47322,00F467F-19-11JUL13
Storage
Storing Safety
CAUTION: Avoid injury! Fuel vapors are explosive and flammable.
Engine exhaust fumes contain carbon monoxide and cause serious illness or death:
● Run the engine only long enough to move the machine to or from storage.
● 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.
● Do not store vehicle with fuel in the tank inside a building where fumes reach an open flame or spark.
● Allow the engine to cool before storing the machine in any enclosure.
MP47322,00F4680-19-06MAY15
Preparing Machine for Storage
1. Repair any worn or damaged parts. Replace parts if necessary. Tighten loose hardware.
2. To prevent rust, repair scratched or chipped metal surfaces. 3. Remove grass and debris from machine.
4. Clean under the rotary deck and remove grass and debris from inside chute and bagger, if applicable.
5. Wash the machine and apply wax to metal and plastic surfaces. 6. To dry belts and pulleys, run machine for five minutes.
7. To prevent rust, apply light coat of engine oil on pivot and wear points.
8. Lubricate grease points and check tire pressure.
MP47322,00F4681-19-13JUL16
Preparing Fuel and Engine For Storage
Fuel:
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.
If you are not using “Stabilized Fuel”:
1. Park machine safely in a well-ventilated area. (See Parking Safely in the Safety section.)
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.
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.
50
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.
Engine:
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.
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.
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.
OUMX068,000077B-19-05JUL17
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.
4. Install battery.
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.
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. MP47322,00F4683-19-05JUL17
Specifications Engine
Z525E
Specifications
Z535M
Forward . . . . . . . . . . . . . . . . . . . . . . . . . 0-13.7 km/h (0-8.5 mph) Reverse . . . . . . . . . . . . . . . . . . . . . . . . . .0-6.4 km/h (0-4.0 mph)
Z540R
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Briggs & Stratton Model Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 ELS Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.4 mm (2.97 in.) Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.40 mm (2.890 in.) Displacement. . . . . . . . . . . . . . . . . . . . . . . 656 cm3 (40.03 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.)
Z535M
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.)
Z540R
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Kawasaki Model Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FS730V 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.)
RM87422,0000775-19-05JUL17
Drivetrain
Transaxle Motors (Z525E and Z535M) . . . . . . . . Tuff Torq TZT7 D Transaxle Motors (Z540R) . . . . . . . . . . . . . . . . .Tuff Torq TZT7 M Number of Speeds. . . . . . . . . . . . . . . Hydrostatic, Variable Speed
TH84124,000023C-19-05JUL17
Travel Speeds at Full Engine RPM
Z525E
Forward . . . . . . . . . . . . . . . . . . . . . . . . . 0-13.7 km/h (0-8.5 mph) Reverse . . . . . . . . . . . . . . . . . . . . . . . . . .0-6.4 km/h (0-4.0 mph)
51
Forward . . . . . . . . . . . . . . . . . . . . . . . . . 0-14.5 km/h (0-9.0 mph) Reverse . . . . . . . . . . . . . . . . . . . . . . . . . 0-7.25 km/h (0-4.5 mph)
RM87422,0000776-19-05JUL17
Electrical System
Battery Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Volt Cold Cranking Capacity . . . . . . . . . . . . . . . . . . . . . . . . 300 Amps
TH84124,0000201-19-11JUN15
Fuel System
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
TH84124,000011B-19-19MAY14
Tires
Front (Z525E) . . . . . . . . . . . . . . . . . . . . . . . . 13x5.00-6 (Ribbed) Front (Z535M) . . . . . . . . . . . . . . . . . . . . . . . . 13x5.00-6 (Ribbed) Front (Z540R) . . . . . . . . . . . . . . . . . . . . . . . . 13x6.50-6 (Ribbed) Inflation - Front . . . . . . . . . . . . . . . . . . . . . . . . . . 69 kPa (10 psi)
Rear (Z525E) . . . . . . . . . . . . . . . . . . . . . . . . . . . 22x9.5-10 (Turf) Rear (Z535M) . . . . . . . . . . . . . . . . . . . . . . . . . . . 22x9.5-10 (Turf) Rear (Z540R) . . . . . . . . . . . . . . . . . . . . . . . . . . 23x10.5-12 (Turf) Inflation - Rear. . . . . . . . . . . . . . . . . . . . . . . . . . . 69 kPa (10 psi)
RM87422,0000777-19-06JUL17
Capacities
Crankcase with oil filter
Z525E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 L (2.0 qt) Z535M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 L (2.0 qt) Z540R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 L (2.2 qt)
Fuel Tank
All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 L (4.5 gal) RM87422,0000778-19-06JUL17
Dimensions Z525E
Specifications
(Specifications and design subject to change without notice.)
OUMX068,0000657-19-11MAR14
Fast Idle Engine Speed
Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .980 mm Width (48A Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1590 mm Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1955 mm Weight (48A Deck). . . . . . . . . . . . . . . . . . . . . . . . 283 kg (624 lb)
Z535M
Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1045 mm Width (48A Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1590 mm Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1955 mm Weight (48A Deck). . . . . . . . . . . . . . . . . . . . . . . . 291 kg (642 lb)
Z540R
Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1164 mm Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1156 mm Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1955 mm Weight (48HC Deck) . . . . . . . . . . . . . . . . . . . . . . 336 kg (741 lb)
SU68010,00000DF-19-26JUL18
Mower Decks
48A Mower (Z525E)
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.) Speed of Rotation of Cutting Device . . . . 3594 r/min at 3350 r/min engine speed
48A Mower (Z535M)
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.) Speed of Rotation of Cutting Device . . . . 3524 r/min at 3350 r/min engine speed
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.) Speed of Rotation of Cutting Device . . . . 3655 r/min at 3350 r/min engine speed
RM87422,0000779-19-21JUL17
Recommended Lubricants
Engine Oil . . . . . . . . . . . . . . . . . . . . TURF-GARD® OR PLUS-4® Grease
. . . . . . . . . . . . . . . . . . . . . . . . . GREASE-GARD™ Premium Plus . . . . . . . . . John Deere Multi-Purpose HD Lithium Complex Grease
52
Z525E without mower deck . . . . . . . . . . . . . . . 3350 +/- 100 r/min Z535M without mower deck . . . . . . . . . . . . . . . 3350 +/- 100 r/min Z540R without mower deck . . . . . . . . . . . . . . . 3350 +/- 100 r/min
RM87422,000077A-19-06JUL17
Speed of Rotation of Cutting Device
Z525E with 48A 122 cm mower deck . . . 3594 r/min at 3350 r/min engine speed
Z535M with 48A 122 cm mower deck . . . 3594 r/min at 3350 r/min engine speed
Z540R with 48HC 122 cm mower deck . . 3655 r/min at 3350 r/min engine speed
MG39705,00000EB-19-27JUL18
Sound Measurements
Averaged Sound Level at Work Station According to EN ISO 5395-1
Z525E without mower deck . . 86.9 ± 1 dB(A) at 3350 r/min engine speed
Z525E with 48A 122 cm mower deck .91.6 ± 1 dB(A) at 3350 r/min engine speed
Z525E with 48A 122 cm mower deck and Power Flow™ 92.1 ± 1 dB (A) at 3350 r/min engine speed
Z535M without mower deck . . 89.0 ± 1 dB(A) at 3350 r/min engine speed
Z535M with 48A 122 cm mower deck . 91.8 ± 1 dB(A) at 3350 r/min engine speed
Z535M with 48A 122 cm mower deck and Power Flow™ .93.3 ± 1 dB(A) at 3350 r/min engine speed
Z540R without mower deck . . 87.3 ± 1 dB(A) at 3350 r/min engine speed
Z540R with 48HC 122 cm mower deck 94.5 ± 1 dB(A) at 3350 r/min engine speed
Z540R with 48HC 122 cm mower deck and Power Flow™ .93.8 ± 1 dB(A) at 3350 r/min engine speed
SV90572,0000006-19-27JUL18
Vibration Measurements
Hand-Arm Measured Per EN ISO 5395-1
Z525E without mower deck vibration total value to which the hand arm system is subjected does not exceed 2.5 m/s2
Z525E with 48A 122 cm mower deck . . . . . . . . . . . . . . . 3.1 m/s2 Uncertainty K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 m/s2 Z525E with 48A 122 cm mower deck and Power Flow™ . 2.6 m/s2 Uncertainty K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 m/s2
Z535M without mower deck vibration total value to which the hand arm system is subjected does not exceed 2.5 m/s2 Z535M with 48A 122 cm mower deck . . . . . . . . . . . . . . 2.8 m/s2 Uncertainty K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 m/s2
Specifications
Z535M with 48A 122 cm mower deck and Power Flow vibration total value to which the hand-arm system is subjected does not exceed
2.5 m/s2
Z540R without mower deck vibration total value to which the hand arm system is subjected does not exceed 2.5 m/s2 Z540R with 48HC 122 cm mower deck . . . . . . . . . . . . . 3.0 m/s2 Uncertainty K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 m/s2 Z540R with 48HC 122 cm mower deck and Power Flow™. 3.2 m/s2 Uncertainty K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 m/s2
Whole Body Measured Per EN ISO 5395-1
Z525E without mower deck . . . . . . . . . . . . . . . . . . . . . . 0.7 m/s2 Uncertainty K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 m/s2 Z525E with 48A 122 cm mower deck . . . . . . . . . . . . . . . 0.6 m/s2 Uncertainty K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 m/s2 Z525E with 48A 122 cm mower deck and Power Flow™ . 0.7 m/s2 Uncertainty K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 m/s2
Z535M without mower deck . . . . . . . . . . . . . . . . . . . . . . 1.1 m/s2 Uncertainty K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 m/s2 Z535M with 48A 122 cm mower deck . . . . . . . . . . . . . . 0.9 m/s2 Uncertainty K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 m/s2 Z535M with 48A 122 cm mower deck and Power Flow™ . 0.9 m/s2 Uncertainty K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 m/s2
Z540R without mower deck . . . . . . . . . . . . . . . . . . . . . . 0.7 m/s2 Uncertainty K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 m/s2 Z540R with 48HC 122 cm mower deck . . . . . . . . . . . . . 0.6 m/s2 Uncertainty K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 m/s2 Z540R with 48HC 122 cm mower deck and Power Flow™. 0.6 m/s2 Uncertainty K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 m/s2
NOTE: The value listed above represents the weighted root means square acceleration to which the whole body is subjected on a
representative machine during actual mowing and transport
conditions. The acceleration value depends upon the roughness
of the ground, the speed at which the tractor is operating and the
operator weight and driving habits. Measurements were obtained
through actual field data according to STD Procedure in EN ISO
5395-1.
SU68010,00000A7-19-26JUL18
53
John Deere Quality Statement
John Deere Quality Statement
John Deere Quality
John Deere equipment is more than just a purchase, it’s an investment
in quality. That quality goes beyond our equipment to your John Deere
dealer’s parts and service support. This support is needed to keep you
a satisfied customer.
That’s why John Deere has initiated a process to handle your
questions or problems, should they arise. The following three steps will
help guide you through the process.
Step 1
Refer to your operator’s manual
A. It has many illustrations and detailed information on the safe and
proper operation of your equipment.
B. It gives troubleshooting procedures, and specification information.
C. It gives ordering information for parts catalogs, service and technical
manuals.
D. If your questions are not answered in the operator’s manual, then go
to Step 2.
Step 2
Contact your dealer
A. Your John Deere dealer has the responsibility, authority, and ability
to answer questions, resolve problems, and fulfill your parts and
service needs.
B. First, discuss your questions or problems with your dealer’s trained
parts and service staff.
C. If the parts and service people are unable to resolve your problem,
see the dealership manager or owner.
D. If your questions or problems are not resolved by the dealer, then go
to Step 3.
Step 3
Contact John Deere
A. Your John Deere dealer is the most efficient source in addressing
any concern, but if you are not able to resolve your problem after
checking your operator’s manual and contacting your dealer, contact
John Deere for assistance.
B. For prompt, effective service, please have the following ready
before you call:
● The name of the dealer with whom you’ve been working.
● Your equipment model number.
● Number of hours on machine (if applicable).
● Your serial number which you recorded on the inside front cover of
this manual.
● If the problem is with an attachment, your attachment identification
number.
C. Then call 1-800-537-8233 (United States and Canada) and our
advisor will work with your dealer to investigate your concern. If you
are outside the United States and Canada, visit the following website:
http://www.deere.com/globalhome/ deerecom/global_home.
page?CC=true
Select your country and then click on the Contact Us link.
SP66632,00043A7-19-10MAY17
54
Service Record
Service Record
Record Service Dates
Oil Change
Oil Filter Change (If
Equipped)
Lubricate Machine
Air Cleaner Element
Check/Clean
Fuel Filter Change
OUO1082,00066CA-19-15MAY17
55
Declaration of Conformity
Service Record 56
EC Declaration of Conformity
The person named below declares that Machine Type: Zero Turn Mower Models: Z525E
Declaration of Conformity
Deere & Company
Moline, Illinois U.S.A.
Serial Numbers: See Product Identification Page
fulfills all relevant provisions and essential requirements of the following directives:
DIRECTIVE NUMBER CERTIFICATION METHOD Machinery Directive 2006/42/EC Self Certification Electromagnetic Compatibility Directive 2014/30/EU Self Certification RoHS Directive 2011/65/EU Self Certification Noise Directive 2000/14/EC (Annex VI, Procedure 2) Third-Party Certification NOTIFIED BODY
Measured Sound Power Level AV Technology
Z525E with 48A 122 cm Mower Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 dB(A) Z525E with 48A 122 cm Mower Deck and Power Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 dB(A) Guaranteed Sound Power Level
Z525E with 48A 122 cm Mower Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 dB(A) Z525E with 48A 122 cm Mower Deck and Power Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 dB(A)
Name and address of the person in the community authorized to compile the technical construction file:
Brigitte Birk
John Deere GmbH & Co. KG
Mannheim Regional Center
John Deere Strasse 70
D-68163 Mannheim
Place of Declaration: Horicon, WI USA
Date of Declaration: 11 Jan 19
Manufacturing Unit: John Deere Power Products
DXCE01—UN—28APR09
Unit 2 Easter Court
Europa Boulevard
Warrington
Cheshire
WA5 7ZB, United Kingdom
Manager Product Engineering RLE
Name: Steve Dobrot
Title: Manager Product Engineering
GXT003030—UN—05JUL16
SU68010,00000A8-19-26JUL18
57
EC Declaration of Conformity
The person named below declares that Machine Type: Zero Turn Mower Models: Z535M
Declaration of Conformity
Deere & Company
Moline, Illinois U.S.A.
Serial Numbers: See Product Identification Page
fulfills all relevant provisions and essential requirements of the following directives:
DIRECTIVE NUMBER CERTIFICATION METHOD Machinery Directive 2006/42/EC Self Certification Electromagnetic Compatibility Directive 2014/30/EU Self Certification RoHS Directive 2011/65/EU Self Certification Noise Directive 2000/14/EC (Annex VI, Procedure 2) Third-Party Certification NOTIFIED BODY
Measured Sound Power Level AV Technology
Z535M with 48A 122 cm Mower Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 dB(A) Z535M with 48A 122 cm Mower Deck and Power Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 dB(A) Guaranteed Sound Power Level
Z535M with 48A 122 cm Mower Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 dB(A) Z535M with 48A 122 cm Mower Deck and Power Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 dB(A)
Name and address of the person in the community authorized to compile the technical construction file:
Brigitte Birk
John Deere GmbH & Co. KG
Mannheim Regional Center
John Deere Strasse 70
D-68163 Mannheim
Place of Declaration: Horicon, WI USA
Date of Declaration: 11 Jan 19
Manufacturing Unit: John Deere Power Products
DXCE01—UN—28APR09
Unit 2 Easter Court
Europa Boulevard
Warrington
Cheshire
WA5 7ZB, United Kingdom
Manager Product Engineering RLE
Name: Steve Dobrot
Title: Manager Product Engineering
GXT003030—UN—05JUL16
SU68010,00000E0-19-26JUL18
58
EC Declaration of Conformity
The person named below declares that
Machine Type: Zero Turn Mower Models: Z540R
Declaration of Conformity
Deere & Company
Moline, Illinois U.S.A.
Serial Numbers: See Product Identification Page
fulfills all relevant provisions and essential requirements of the following directives:
DIRECTIVE NUMBER CERTIFICATION METHOD Machinery Directive 2006/42/EC Self Certification Electromagnetic Compatibility Directive 2014/30/EU Self Certification RoHS Directive 2011/65/EU Self Certification Noise Directive 2000/14/EC (Annex VI, Procedure 2) Third-Party Certification NOTIFIED BODY
Measured Sound Power Level AV Technology
Z540R with 48HC 122 cm Mower Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103 dB(A) Z540R with 48HC 122 cm Mower Deck and Power Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 dB(A) Guaranteed Sound Power Level
Z540R with 48HC 122 cm Mower Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105 dB(A) Z540R with 48HC 122 cm Mower Deck and Power Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105 dB(A)
Unit 2 Easter Court
Europa Boulevard
Warrington
Cheshire
WA5 7ZB, United Kingdom
Name and address of the person in the European Community authorized to compile the technical construction file:
Brigitte Birk
John Deere GmbH & Co. KG
Mannheim Regional Center
John Deere Strasse 70
D-68163 Mannheim
Place of Declaration: Horicon, WI. USA
Date of Declaration: 11 Jan 19
Manufacturing Unit: John Deere Power Products