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1/20/12

ZSR54 & ZSR60 Accu-Z Razor

®

Zero Turn Mowers 357-388SM

Table of Contents

Table of Contents

Tires  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . 59
Hydrostatic Drive System  . . . . . . . . . . . . . . . . . . 60
Hydraulic Oil Level Check . . . . . . . . . . . . . . . . . . 60
Transaxle Oil and Filter Change  . . . . . . . . . . . . . 60
Transaxle Purging Procedures  . . . . . . . . . . . . . . 61
Fuel System  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Evaporative Emission Control System . . . . . . . . . 63
Fuel Filter  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Draining The Fuel Tank . . . . . . . . . . . . . . . . . . . . 63
Belt Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 64

Deck Drive Belt Removal & Installation . . . . . . 64
Ground Drive Belt Removal & Installation . . . . 64

Mower Blade Maintenance . . . . . . . . . . . . . . . . . 66
General Engine Maintenance . . . . . . . . . . . . . . . 68
Engine Oil and Oil Filter . . . . . . . . . . . . . . . . . . . . 68

Check Engine Oil . . . . . . . . . . . . . . . . . . . . . . 68
Change Engine Oil . . . . . . . . . . . . . . . . . . . . . 68

Engine Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Internal Type Air Filters . . . . . . . . . . . . . . . . . . 69
Canister Type Air Filters . . . . . . . . . . . . . . . . . 69

Air Filter Handling  . . . . . . . . . . . . . . . . . . . . . . . . 70
End of Season & Long Term Storage  . . . . . . . . . 71
New Season Preparation . . . . . . . . . . . . . . . . . . . 71
Lubrication Points  . . . . . . . . . . . . . . . . . . . . . . . . 72

Section 10: Troubleshooting . . . . . . . . . 74

Section 11: Appendix . . . . . . . . . . . . . . . 76

Engine Specifications  . . . . . . . . . . . . . . . . . . . . . 76
Hydrostatic Transaxle Specifications . . . . . . . . . . 76
General Specifications . . . . . . . . . . . . . . . . . . . . . 76
ZSR54 & ZSR60 Zero Turn Mowers  . . . . . . . . . . 78
Additional Torque Values  . . . . . . . . . . . . . . . . . . 79

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Содержание Accu-Z Razor ZSR54

Страница 1: ...Table of Contents Copyright 2012 Printed ZSR54 ZSR60 Accu Z Razor Zero Turn Mowers 357 388SM Service Manual 27800 7 30 12...

Страница 2: ...per Guard Removal 16 Engine Bumper Guard Installation 16 Section 3 Mower Deck 17 Deck Removal 17 Deck installation 18 Pulley and Blade Hub Removal 19 Pulley and Blade Hub Installation 19 Spindle Hub R...

Страница 3: ...Removal Installation 64 Ground Drive Belt Removal Installation 64 Mower Blade Maintenance 66 General Engine Maintenance 68 Engine Oil and Oil Filter 68 Check Engine Oil 68 Change Engine Oil 68 Engine...

Страница 4: ...up and off of the drive control stub 3 Repeat steps 1 through 2 for other side Steering Arm Installation Refer to Figure 1 2 1 Slide steering arm to desired height and install pivot bolt and nut 2 In...

Страница 5: ...of the control damper and remove from frame stud Refer to Figure 1 5 6 Loosen and remove nut on the drive control rod assembly and remove from steering lever 7 Loosen and remove the steering lever re...

Страница 6: ...ud into the control arm The control rod retaining nut may be loosely installed to aid in assembly Refer to Figure 1 9 7 Push the control lever out into the brake position and insert though frame 8 Ali...

Страница 7: ...oosen and remove the park brake handle retaining flanged lock nut Refer to Figure 1 11 5 Remove the carter pin and retaining washer from the upper end of the brake link spring assemblies 6 Disconnect...

Страница 8: ...frame and allow the spring to push into place Refer to Figure 1 14 4 Assemble the brake link spring assemblies by inserting a brake link into each end of the spring 5 Align and install the brake link...

Страница 9: ...uge bar out of the frame channel The height pawl will not need to be removed for removal of the height gauge bar 6 Disconnect and remove the deck lift assist spring from the deck lift pivot Refer to F...

Страница 10: ...assembly to install the rear lift spring trunnion in the rear deck lift arm Secure rear lift spring trunnion to the rear deck lift arm with E clip 6 Tighten the lift spring compression nut and instal...

Страница 11: ...ties securing the throttle and choke cables to the frame Refer to Figure 1 23 5 Loosen engine clamps on both the throttle and choke cables Mark each cable for reference 6 Disconnect the throttle and c...

Страница 12: ...ss Wiring Schematics on page 25 of the manual for more information on correct connections 4 Secure control panel to the fuel tank with cross head bolts Tighten bolts until snug against the control pan...

Страница 13: ...n 4 Disconnect the operator presence switch from the wiring harness at the switch Refer to Figure 2 2 5 Loosen and remove the seat pan retainer nuts on the left and right side of the seat pan assembly...

Страница 14: ...t bushings in frame from the inside out 4 Align and install seat pan assembly on unit with hex socket bolts raise and secure with flange nuts Refer to Figure 2 6 5 Insert washer and spring retaining b...

Страница 15: ...mower and prevent movement while repairs are made 2 Loosen and remove floor panel retaining bolts Refer to Figure 2 8 3 Pull forward on the front section of the floor panel to disengage the slotted re...

Страница 16: ...ne muffler Engine Bumper Guard Installation Refer to Figure 2 11 1 Assemble the engine bumper guard and tighten all fasteners to standard torque See Torque Values Chart on page 79 2 Align engine bumpe...

Страница 17: ...nter clockwise to disengage the latch Remove belt from the clutch Refer to Figure 3 2 5 Remove the seat pan assembly from the mower for ease of access See Seat and Latch Removal on page 13 6 Loosen th...

Страница 18: ...were removed during deck removal align and reinstall the deck interface arms to the frame with pivot bolts and flanged lock nuts Do not tighten until the deck interface gimbals have been secured to t...

Страница 19: ...retaining nuts on top of the deck for the spindle assembly to be removed Pull the spindle assembly out though the bottom of the mower deck Pulley and Blade Hub Installation Refer to Figure 3 9 1 Inser...

Страница 20: ...he spindle shaft with the lower bearing and blade hub attached in vice with the blade hub facing upright Pad shaft in vice with shop rag to prevent scaring or damage to the spindle shaft 8 Loosen and...

Страница 21: ...mallet tap the blade hub to fully seat the lower bearing into the spindle hub 17 Loosen vice turn the spindle hub assembly over and re secure in vice with the blade hub down and against the vise clam...

Страница 22: ...t connect the battery tray to unit frame 7 Remove the battery tray from the unit frame Battery Assembly Installation Refer to Figure 4 3 1 Align and install the battery tray in the unit frame 2 Secure...

Страница 23: ...er to Figure 4 5 5 Remove control panel and disconnect it from wiring harness See Control Panel Removal on page 11 6 Disconnect the wiring harness from all brake seat and neutral interlock switches Se...

Страница 24: ...e routed as close to the frame and tie down points as possible Refer to Figure 4 8 4 Connect the wiring harness to the brake seat and neutral interlock switches See Main Harness Wiring Schematics on p...

Страница 25: ...25 Section 4 Electrical System 7 30 12 ZSR54 ZSR60 Accu Z Razor Zero Turn Mowers 357 388SM Table of Contents 27774 Main Harness Wiring Schematics...

Страница 26: ...4 Electrical System ZSR54 ZSR60 Accu Z Razor Zero Turn Mowers 357 388SM 7 30 12 Table of Contents Engine Wiring Schematics Briggs Stratton Engine Wiring Schematics Kawasaki Engine Wiring Schematics 2...

Страница 27: ...nd insure that both tanks are fully empty and well ventilated For best ventilation allow the tanks to set overnight if possible to allow excess fuel to evaporate 6 Cut and remove all the plastic zip t...

Страница 28: ...turn towards the tank being used when installed 4 Secure the fuel valve to the pedestal base with the jam nut retaining washer and tighten until snug against the pedestal base Rotate the fuel valve ha...

Страница 29: ...let See Fuel Valve and Hose Removal on page 27 Refer to Figure 5 8 5 Loosen and remove the lower inside fuel tank bolt located just above the fuel tank outlet 6 Loosen and remove the two upper fuel ta...

Страница 30: ...nt tank bolt Refer to Figure 5 11 3 Align the fuel tank with upper pedestal and loosely install the two upper pedestal bolts 4 Align and install the fuel tank support arm bolts and tighten snugly agai...

Страница 31: ...er spindle hub cap bolt and remove the hub cap Refer to Figure 6 2 4 Raise front of the mower main frame until the caster wheel pivot shaft is clear of the bearing housing to remove the caster wheel f...

Страница 32: ...to the bottom bearing housing With a bearing set tool seat the bearing against the lower race Refer to Figure 6 5 4 Align the caster wheel pivot shaft with the lower bearing and lower the front of the...

Страница 33: ...he floor panel to access the floor panel attachment bracket over the front end pivot mount See Floor Panel Removal on page 15 5 Loosen and remove the front axle pivot bolt from the floor panel attachm...

Страница 34: ...to the front end pivot mount with the strut pivot bolts Refer to Figure 6 11 4 Align and slide the front pivot axle onto the front end pivot mount 5 Align and install the floor panel attachment brack...

Страница 35: ...Remove the rear drive wheel lug nuts and remove the wheel from the axle hub Rear Drive Wheel Installation Refer to Figure 6 14 1 Align and install the rear drive wheel on the axle hub 2 Secure the re...

Страница 36: ...ust Remove muffler from the engine mount studs 4 Remove the muffler gaskets from the muffler Muffler Installation Refer to Figure 7 3 1 Align and install new muffler gaskets on the muffler mounting st...

Страница 37: ...isconnect the throttle and choke cables from the engine 8 Disconnect the wiring harness from the engine Engine ground start solenoid ground magneto fuel shut off solenoid regulator start solenoid powe...

Страница 38: ...t and tighten until the spring lock washer is fully compressed against the washers approximately 15 18 ft lbs 5 Route and connect the wiring harness to the engine Engine ground start solenoid ground m...

Страница 39: ...er to Figure 7 11 5 To prevent accidental start unplug the coil wires on both spark plugs prior to removing the belt 6 Remove the floor panel to access the over center latch See Floor Panel Removal on...

Страница 40: ...front Install the clutch stop rotation bracket to prevent turning of the clutch Refer to Figure 7 14 4 Install the clutch retaining bolt with both the flat washer and lock washer thought the clutch hu...

Страница 41: ...nsaxle assemblies 4 Remove the deck drive clutch and belt See Clutch Removal on page 39 Refer to Figure 7 17 5 Loosen pump drive tensioner arm from the unit frame to provide enough slack to remove the...

Страница 42: ...the pump control bracket 10 Drain transaxle oil into an appropriate waist oil container and disconnect the expansion tank from the top of the transaxle Refer to Figure 7 20 11 With a floor jack or ot...

Страница 43: ...transaxle and secure with washer and cotter pin Refer to Figure 7 22 3 With a floor jack or other lift devise support the transaxle and align into frame 4 Install the rear and front transaxle support...

Страница 44: ...th spring hose clamp Fill transaxle with SAE 20W 50 engine oil 10 Install belt on drive pulleys ensuring correct belt routing and tension spring See Ground Drive Belt Removal Installation on page 64 R...

Страница 45: ...45 Section 7 Power Train 7 30 12 ZSR54 ZSR60 Accu Z Razor Zero Turn Mowers 357 388SM Table of Contents This Page Left Blank Intentionally...

Страница 46: ...around oil openings fuel openings and air inlets Minute dust particles are abrasive to close tolerance engine and hydraulic components Some repairs require the assistance of a trained service mechanic...

Страница 47: ...e blade switch and turn ignition switch off 2 Position control levers in neutral position as shown 3 Remove fan mounting hardware and fans 4 if jam nuts 3 are not easily accessible 4 Loosen jam nuts 3...

Страница 48: ...right or left when pushing the levers equally forward IMPORTANT Make sure lower control levers have been adjusted before adjusting upper control levers See page 47 for lower control lever adjustments...

Страница 49: ...ring 11 by tightening up eyebolt 10 Replace deck belt when it becomes excessively worn or damaged Instructions for replacing the deck drive belt are provided on page 64 With deck height set at 3 check...

Страница 50: ...ange nuts 18 20 four or more turns away from spring assist trunnion 19 8 Loosen adjuster jam nuts 15 24 and adjuster yoke whiz nuts 27 28 9 Loosen adjuster screws 14 23 until adjuster yokes 16 25 can...

Страница 51: ...to decrease springs tension and to increase deck weight against the stop handle 5 After adjusting nut 35 has been properly adjusted tighten jam nut 36 against the adjusting nut 6 Replace floor platfo...

Страница 52: ...p notches 3 4 below if mounted in the 2nd notches 1 1 4 below if mounted in the 3rd notches 1 3 4 below if mounted in the bottom notches For protection of deck and blades it is best if the rollers are...

Страница 53: ...53 Section 8 Adjustments 7 30 12 ZSR54 ZSR60 Accu Z Razor Zero Turn Mowers 357 388SM Table of Contents This Page Left Blank Intentionally...

Страница 54: ...fety DANGER Repairs or maintenance specifically requiring engine power should be performed by trained personnel only Control levers should be out If control levers are to be operated the tires should...

Страница 55: ...hours indicated in column or annually whichever comes first Maintenance Schedule Service at Intervals Indicated Every 25 Hrs Every 50 Hrs Every 100 Hrs Every 200 Hrs Every 500 Hrs Refer to Page Clean...

Страница 56: ...11 Discharge Chute Refer to Figure 5 2 12 Blade Bolt 13 Blade Washer 14 Cutting Blades 15 Deck Underside Refer to Figure 5 3 16 Engine Oil Fill Dipstick Kawasaki RH side Briggs Stratton LH side 17 En...

Страница 57: ...Shown Figure 5 3 Bottom view of Mower Deck Not Shown Figure 5 4 27764 26 29 28 32 24 23 16 22 31 17 18 Left Side Right Side 30 27 31 30 16 17 Briggs Stratton Kawasaki 20 21 22 25 32 Pulley Guard See...

Страница 58: ...acement Thereafter they should be checked every 50 hours of operation Blade bolts See item 12 in Figure 5 2 on page 56 Electric Clutch bolt See item 44 in Figure 5 4 on page 57 Wheel lug nuts See item...

Страница 59: ...cking the battery Flush area with clean water and call a physician immediately Acid will also damage clothing WARNING Do not overfill battery Electrolytes may overflow and damage paint wiring and stru...

Страница 60: ...h system will require separate oil and oil filter changes It is best to change oil soon after using the mower while dirt particles are still suspended in the oil See page 76 for transaxle oil specific...

Страница 61: ...ecifications The following procedures are best performed with mower drive wheels off the ground and then repeated under normal operating conditions If this is not possible the procedure should be perf...

Страница 62: ...ccur if not followed Observe safe fuel handling precautions Fuel is flammable and vapors are very explosive An explosion or fire can burn destroy and kill property animals and people Do not fill tank...

Страница 63: ...ing on which engine your mower is equipped with See engine owner s manuals for exact location of fuel filter and instructions on removal and installation Refer to Figure 5 13 Replace fuel filter annua...

Страница 64: ...new deck drive belt 3 per the illustration shown in Figure 5 15 10 Re tension idler 6 by turning bolt 9 clockwise until over center release locks in place Check belt tension per the Deck Drive Belt Ad...

Страница 65: ...Pin 9 Over center release Use 3 4 socket wrench 10 Tension eye bolt 11 Tension idler spring 12 Idler arm 27819 Ground Drive Belt Layout Figure 5 16 1 Deck drive pulley 2 Deck drive belt 3 Ground drive...

Страница 66: ...balanced blade may come loose and fly out from under the deck Also an unbalanced blade will shorten the spindle bearing s life CAUTION ALWAYS wear eye protection and gloves when sharpening a blade 1 C...

Страница 67: ...rpened and balanced Blade Balancing Figure 5 21 19074 Resharpening Cutting Edge Pattern NAIL OR SHAFT HORIZONTAL 19046 Blade Installation WARNING When mounting blades rotate them after installation to...

Страница 68: ...erting the dipstick correctly when checking oil Incorrect oil levels can cause engine problems 4 If oil level on the dipstick is near or below the lower limit mark then add recommended oil until it re...

Страница 69: ...orn stays open or is missing See also Burp Valve Information on page 70 5 Install new inner element into the new outer element as shown in Figure 5 25 6 Install new outer filter element by inserting t...

Страница 70: ...nister and properly seated on both ends to prevent dirt from entering the engine Damaged Air Filtering System A damaged air filtering system occurs from mishandling of the filter element and operating...

Страница 71: ...oil into each spark plug hole Install plugs but do not reconnect plug leads h Crank engine with starter at least a dozen revolutions to distribute oil over cylinder walls and valve mechanism i Clean...

Страница 72: ...ey cover 1 Zerk Type of Lubrication Multi purpose Grease Quantity As required 50 hrs Multi purpose spray lube Multi purpose grease lube Multi purpose oil lube Intervals in hours at which lubrication i...

Страница 73: ...pivot mount 2 Zerks Type of Lubrication Multi purpose Grease Quantity As required Every 100 hrs or monthly whichever comes first 27826 100 M Hours 27825 100 M Hours Deck Lift Points Locate on both si...

Страница 74: ...See Engine Operator s Manual Grass cutting is ragged or uneven Dull bent or broken cutting blades Sharpen or replace cutting blades Deck full of wet sticky grass Clean underside of deck Cutting Blade...

Страница 75: ...47 Hydro drive faulty See your dealer Hydraulic system operates hot Hydro drive faulty See your dealer Not operating engine at rated speed Increase engine speed to 3600 rpm Steering levers do not ret...

Страница 76: ...1 N A Spark Plug No BPR4ES NGK Oil Capacity with Filter Change 2 US quarts 1 9L Oil Type SAE 10W 30 Oil Filter Part No 831 073C 831 053C Fuel Filter Part No 831 031C 831 035C Air Filter Part No 831 0...

Страница 77: ...during normal engine operation Seat Options Deluxe cushion seat with arm rests Mainframe Construction Welded steel Front Caster Wheels Free turning with greasable roller bearings Front Caster Fork Co...

Страница 78: ...78 Section 11 Appendix ZSR54 ZSR60 Accu Z Razor Zero Turn Mowers 357 388SM 7 30 12 Table of Contents 27830 ZSR54 ZSR60 Zero Turn Mowers...

Страница 79: ...0 875 645 1230 910 M24 X 2 525 390 830 610 1150 845 1 12 370 275 955 705 1350 995 M30 X 3 5 960 705 1510 1120 2100 1550 1 1 8 7 480 355 1080 795 1750 1290 M30 X 2 1060 785 1680 1240 2320 1710 1 1 8 12...

Страница 80: ...Corporate Office P O Box 5060 Salina Kansas 67402 5060 USA www landpride com...

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