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FOREWORD thank you for choosing the KIOTI ZXR/ZXC series brand of zero turn mowers. Our products are designed to provide maximum performance and dependability. the following manual contains important information regarding safety, operation, maintenance and adjustment. before operating the machine, all users should read and understand the manual in its entirety.
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TABLE OF CONTENTS SAFETY PRECAUTIONS ........ SERvICE ............SPECIFICATIONS ..........FUNCTION DESCRIPTION AND OPERATING TIPS ..SECTION OPERATION ............ MAINTENANCE ..........STORAGE AND DISPOSAL ......TROUBLEShOOTING ........PART ILLUSTRATIONS ........INDEX...............
TABLE OF CONTENTS SAFETY PRECAUTIONS ........1-1 MOwer serIAl nUMber ..........2-2 enGIne serIAl nUMber ..........2-2 PRECAUTION BEFORE OPERATION ..... 1-2 trAnsAXle nUMber ........... 2-2 SAFE OPERATION PRACTICES ......1-3 SERvICE ..............2-3 Owners respOnsIbIlIty .......... 1-3 sUpplyInG serVICe pArts ........2-3 OperAtIInG ..............
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TABLE OF CONTENTS EXTERIOR vIEW ............. 4-2 MOwer DeCK MOUntInG ........... 5-2 MOwer DeCK DIsMOUntInG ........5-4 DESCRIPTION OF OPERATING SYSTEM ....4-3 OPERATING ThE ENGINE ........5-4 DIsplAy pAnel ............. 4-3 stArtInG tHe enGIne ..........5-4 steerInG leVers ............. 4-10 JUMp stArtInG ............
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TABLE OF CONTENTS CleAnInG MOwer DeCK .......... 5-23 ADJUstInG trAnsAXle DrIVe belt tensIOn ..6-14 wAsHInG MOwer ............5-23 MOUntInG AXle belt ..........6-14 CHeCKInG pArKInG brAKe ........6-16 MAINTENANCE ...........6-1 ADJUstInG tHrOttle COntrOl AnD CHOCK .... 6-17 RECOMMENDED MAINTENANCE SChEDULES ... 6-3 CHeCKInG AnD CHArGInG bAttery ......
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TABLE OF CONTENTS CHeCKInG blADe ............6-26 MOwer trOUblesHOOtInG ........8-7 InspeCtIOn AnD sHArpenInG blADe ....6-27 PART ILLUSTRATIONS ........9-1 replACInG blADe ............. 6-27 hOW TO READ PART ILLUSTRATIONS ....9-3 replACInG MOwer belt ......... 6-28 ADJUstInG belt tensIOn ........6-29 01A.
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TABLE OF CONTENTS 30b. trAns AXle GrOUp .......... 9-44 60C. MOwer DeCK GrOUp ........9-88 33A. ptO ClUtCH GrOUp ......... 9-46 60C. MOwer DeCK GrOUp ........9-90 33b. ptO ClUtCH GrOUp ......... 9-48 80A. MAIn HArness GrOUp ........9-98 35A. FrOnt wHeel GrOUp ........9-50 80b.
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TABLE OF CONTENTS 92b. reAr bUMper GrOUp ........9-138 93. rOps GrOUp ............9-140 95A. DeCAl GrOUp 1 ..........9-142 95A. DeCAl GrOUp 1 ..........9-144 95b. DeCAl GrOUp 1 ..........9-146 95b. DeCAl GrOUp 1 ..........9-148 95A. DeCAl GrOUp 2 ..........9-150 95b.
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SAFETY AND vEhICLE DAMAGE WARNING this manual includes information titled as WARNING, CAUTION, IMPORTANT and NOTE. these titles indicate the following: This indicates that a condition may result in harm, serious injury or death to you or other persons if the warning is not heeded.
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SYMBOLS MARK Various universal symbols have been used on the instruments and controls of your KIOTI mower. below is a list of the symbols mark and their meanings. engine Oil Indicator Headlight battery Charging Condition High speed parking brake low speeed...
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TERMS FOR DIRECTIONS the front, rear, left and right directions referred in this manual are the directions seen from an operator in the driver's seat. right turn left turn (Clockwise) (Counter Clockwise) right rear Front left...
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SAFETY PRECAUTIONS PRECAUTION BEFORE OPERATION ......1-2 SAFE OPERATION PRACTICES ......... 1-3 Owners respOnsibility ............1-3 OperAtiinG .................1-4 DriVinG On slOpe ..............1-6 pArKinG ..................1-9 MAintenAnCe ................1-9 stOrinG ..................1-11 trAnspOrtinG ................. 1-11 UsinG tHe rOps ...............1-12 UsinG A spArK ArrestOr ............1-13 SAFETY dECAl mAINTENANCE ......
ZXr / ZXC series MOwer ZXr / ZXC series MOwer ZXr / ZXC series MOwer PRECAUTION BEFORE OPERATION to ensure safe mower operation, be 3. r e m o v e a l l h a z a r d s s u c h a s sure to read this manual completely stones, wires, wood, large sticks Safety helmet...
sAFety preCAUtiOns sAFety preCAUtiOns SAFE OPERATION PRACTICES OwNERS RESPONSIBIlITY comply with the sAe J137 and/or ensure they are in good working Ansi/AsAe s279 when driven on condition. if issues are found, do public roadways. not operate until they are fixed or resolved.
ZXr / ZXC series MOwer ZXr / ZXC series MOwer ZXr / ZXC series MOwer OPERATIING to be trained, and the owner is operator is properly trained on the responsible for training the users safety information and the operation of this machine. the owner is liable 3.
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sAFety preCAUtiOns sAFety preCAUtiOns 3. the driver must always sit on the 6. be careful not to touch the hot parts especially when ground is wet. seat before starting the engine. with your body or foreign objects. 11. when working in groups, always 4.
ZXr / ZXC series MOwer ZXr / ZXC series MOwer ZXr / ZXC series MOwer dRIVING ON SlOPE 18. Do not cut area in reverse motion wARNING unless it is unavoidable. • dO NOT use hands to dislodge 19. During operation, if steering a clogged discharge chute.
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sAFety preCAUtiOns sAFety preCAUtiOns 1. b e c a r e f u l w h e n s t o p p i n g o r 7. take special care when changing [Slope Angle] turning mowers on a slope, as the direction on a slope.
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ZXr / ZXC series MOwer ZXr / ZXC series MOwer ZXr / ZXC series MOwer 12. Use caution when operating 16. in the event of hitting an obstacle wARNING machine on inclines when a during cutting, stop the machine • Always reduce speed when grass catcher is installed.
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sAFety preCAUtiOns sAFety preCAUtiOns PARKING mAINTENANCE 1. place all control levers in the 3. before servicing any engine or n e u t r a l l o c k p o s i t i o n , s e t t h e mechanical mower parts, allow the parking brake, stop the engine.
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11. Help KIOTI protect the environment. blades, where gloves or cover when changing fluids, make 20.
sAFety preCAUtiOns sAFety preCAUtiOns STORING TRANSPORTING 23. Use care when checking the 1. After daily operation, clean unit cutting blades. Do not touch and store indoors as much as the blades directly, wear safety possible. gloves or use a blade buddy to 2.
5. never repair a damaged rOps, vehicle roll-over. replace it with OeM KIOTI parts. lower the rOps bar only when Contact your local KIOTI dealer absolutely necessary. Do not wear before replacing.
USING A SPARK ARRESTOR attachments added to the rOps A spark arrester is a mechanical wARNING must be approved by KIOTI. device constructed of nonflammable when the ROPS is folded in the materials specifically for the purpose 7. it is recommended to inspect the...
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KIOTI selling dealer. U s e o n l y t h e a p p r o v e d p a r t recommended by the engine manufacturer.
ZXr / ZXC series MOwer ZXr / ZXC series MOwer ZXr / ZXC series MOwer dECAlS 1. part no.: Z2131-95201 3. part no.: Z2131-95231 2. part no.: Z2131-95211 4. part no.: Z2131-95201...
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sAFety preCAUtiOns sAFety preCAUtiOns 5. part no.: MM605-12422 6. part no.: MM605-12434 7. part no.: Z2131-95321 DANGER When the ROPS is folded in the down position, there is nothing to protect the operator during a vehicle roll-over. Lower the ROPS bar only when absolutely necessary.
ZXr / ZXC series MOwer ZXr / ZXC series MOwer dECAl mAINTENANCE safety decals are attached to the ImPORTANT mower for safe operation. Make sure • If a decal is damaged or lost, to follow the instruction on the decals c o n t a c t y o u r l o c a l K I O T I as well as the following instruction: dealer immediately to install a...
about service vehicle identification number ......2-2 MOWER SERIAL NUMBER ............2-2 ENgINE SERIAL NUMBER ............2-2 TRANSAXLE NUMBER ..............2-2 service ..............2-3 SUPPLYINg SERVICE PARTS ............2-3 SERVICINg ENgINE AND DRIVE TRAIN COMPONENTS ...2-4 gENUINE PARTS ................2-4...
ZXR / ZXC SERIES MOWER vehicle identification number transaXle number engine serial number moWer serial number 1 1 1 ZXCO201A ZXCO202B ZXCO203A (1) Model and Production Serial Number Plate (1) Briggs & Stratton Professional Series (1) Transaxle Serial Number (2) Briggs & Stratton Commercial Series (3) Kohler ZT Series (4) Kohler CV Series The production serial number is The engine model and serial number...
ABOUT SERVICE service suPPlYing service Parts Your local Kioti dealer has the In case of mechanical trouble, refer Service parts for this machine are right service solutions for all of your to “Troubleshooting” in chapter 8 of available through your local servicing Kioti products and can provide this manual.
Please use manual. Any of these components only genuine Kioti parts for safety needing service, especially during and longevity. the limited warranty period, should only be performed by your authorized Kioti dealer.
ZXR / ZXC SERIES MOWER SpecificationS ZXR.ReSiDentaL.MoDeLS econoMY.MoDeL StanDaRD.MoDeL iteM ZXR48 ZXR54 ZXR60 ZXR48.Se ZXR54.Se ZXR60.Se Maker Briggs & Stratton Kohler Model Professional Series Confidant Series (ZT720/730/740) Gross power Displacement ← ← Max speed 3,600 ← Choke Auto Manual Auto Battery 12V 20Ah ←...
ZXR / ZXC SERIES MOWER toRQUe.tiGHteninG.cHaRt Sae.faSteneR.toRQUe.cHaRt Sae.faSteneR.toRQUe.cHaRt note : Use these torques, unless special torques are specified. Values are for UNC and UNF thread fasteners, plated or unplated as received from supplier. Fasteners can be dry or lubricated with normal engine oil. Values do not apply if graphite, moly-disulphide or other extreme pressure lubricant is used.
SPECIFICATIONS toRQUe.tiGHteninG.cHaRt MetRic.faSteneR.toRQUe.cHaRt MetRic.faSteneR.(iSo).toRQUe.cHaRt note : Use these torques, unless special torques are specified. Values are for UNC and UNF thread fasteners, plated or unplated as received from supplier. Fasteners can be dry or lubricated with normal engine oil. Values do not apply if graphite, moly-disulphide or other extreme pressure lubricant is used. iSo.class.no.
FUNCTION DESCRIPTION AND OPERATING TIPS description oF operating system dispLay paneL start-up code The display panel controls the operation of the mower. TACH VOLT TACH VOLT START STOP ZXCO417A (1) Start-Up Code For safety and security, a start-up code must be entered before the mower can be operated.
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5. If the new code is entered correctly • T h e s t a r t - u p c o d e c a n b e forgotten. Only the Kioti dealer can both times, "SAVED CODE" will changed from the default code reset a forgotten start-up code.
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FUNCTION DESCRIPTION AND OPERATING TIPS warning LigHts started again. ▶Battery voltage The battery voltage light indicates the system voltage is below 12 VDC TACH VOLT or above 15 VDC. Have the battery charging system checked. ▶operator presence The operator in seat light indicates START STOP t h e s e a t s w i t c h i s i n t h e o p e n...
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ZXR / ZXC SERIES MOWER dispLay modes parking brake is disengaged. To reset the service timer, press and release the hour meter button ▶pto switch until the service timer screen is on The PTO switch light indicates the the display. Press and hold the hour PTO switch is in the "ON"...
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FUNCTION DESCRIPTION AND OPERATING TIPS pto switcH HeadLigHt Button start/stop Button GREEN Engine will start Engine will not start TACH TACH TACH VOLT VOLT VOLT START START START STOP STOP STOP ZXCO521A ZXCO422A TG1O405A (1) PTO Switch (1) Headlight Button (1) Start/Stop Button (A) ON (B) OFF...
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ZXR / ZXC SERIES MOWER aLarms 1. T h e s t a r t - u p c o d e m u s t b e When the start engine light is green, correctly entered. press and hold both sides of the "START/STOP"...
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FUNCTION DESCRIPTION AND OPERATING TIPS service aLerts Your console is programmed to alert the operator of upcoming service as follows: First time, nonreoccurring break in oil change at 20 hours followed by normal reoccurring intervals of 100 hrs. A gentle reminder will start flashing the "CHG OIL"...
ZXR / ZXC SERIES MOWER steering Levers tHrottLe Lever caution • do not move steering levers from forward to reverse or reverse to forward position r a p i d l y. s u d d e n d i r e c t i o n changes could cause loss of control or damage to the machine or property.
FUNCTION DESCRIPTION AND OPERATING TIPS cHoKe Lever parKing BraKe caution • to prevent unwanted mower movement, when exiting the m a c h i n e , a l w a y s s t o p t h e engine with the start button, then apply the parking brake.
ZXR / ZXC SERIES MOWER seat BeLt seat Use the armrest adjusting screw under the armrest to adjust to the desired angle. warning • only adjust the seat when the machine is stopped. • when the seat is adjusted to the desired position, push gently on the seat deck and b a c k r e s t t o e n s u r e i t h a s...
FUNCTION DESCRIPTION AND OPERATING TIPS rops decK LiFt pedaL as a tree or lower building over- hang. When using the machine with the ROPS in the lowered position, the seat belt should NOT be worn. To Raise or Lower the ROPS: Pull the Fix Pins from each side of the support bar, then raise or lower, then install the fix pins into the available...
ZXR / ZXC SERIES MOWER decK HeigHt adJust diaL FueL gauge Once the desired deck height is selected, to lower the mower deck: 1. Press and hold the Deck Lift Pedal . 2. Pull and hold the Deck release lever. 3.
FUNCTION DESCRIPTION AND OPERATING TIPS cup HoLder dc power outLet running low on fuel, air may enter the fuel supply, so be sure to replenish it before it runs out. Residential models come equipped with a left side fuel tank. Commercial models are equipped with dual, left and right side fuel tanks.
/ t i r e a s s e m b l y t o a (C) Over Inflated qualified titan tire service center or your local Kioti Tire pressure is filled to the required servicing dealer.
FUNCTION DESCRIPTION AND OPERATING TIPS wHeeL Front wHeeL rear wHeeL fork bracket, make sure the fork is oriented for forward movement, then insert the wheel bolt from the outside. Tighten to the torque specs listed below. important • insert the front wheel bolt from the outside of the bracket.
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ZXR / ZXC SERIES MOWER tigHtening torQue oF wHeeL BoL t (nut) 120 N・m (88.5 ft.- lb) (12.2 kgf・m)
ZXR / ZXC SERIES MOWER DECK MOUNTING / DISMOUNTING MOWER DECK MOUNTING ZXCO534A ZXCO501A ZXCO502A (1) Mower Deck (2) lift link (1) Mower Deck (1) lift link (2) Mounting Hardware 1. before mounting the mower deck, 2. Change the direction of the front 3.
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OPERATION Deck assembly left/right height adjustment: less than 0.12 inches (3mm) Deck assembly front/back height adjustment: less than 0.24 inches (6mm) (front needs to be lower than back) Tighten the deck mounting bolts as following. ZXCO535A ZXCO503A TIGHTENING TORQUE (1) lifting Position (1) PTO belt...
ZXR / ZXC SERIES MOWER OPERATING THE ENGINE MOWER DECK DISMOUNTING STARTING THE ENGINE When removing the mower deck, follow the steps described in mounting section in reverse order. ZXCO504A ZXCO505A (1) Steering levers (2) Arm Rest (1) Parking brake lever (3) Seat Adjustment lever (A) Engaged (b) Disengaged...
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OPERATION TACH VOLT START STOP ZXCO506A ZXCO417A ZXCO507A (1) PTO Switch (1) Throttle lever (2) Choke (1) Start-Up Code (A) ON (b) Off (A) fast (b) Slow 3. Check that the PTO switch is on 5. Set the throttle lever to the "Slow 6.
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ZXR / ZXC SERIES MOWER 7. Warm up the engine at medium WARNING CAUTION speed and start-up according to • • Before starting the engine, D O N O T U S E S TA R T I N G below depending on the outside be sure to sit on the seat and flUIDS.
OPERATION JUMP STARTING 2. Check the length of the jumper with the discharged battery. c a b l e a n d p o s i t i o n a n o t h e r 8. Disconnect the black cable from mower near the mower with the the negative battery terminals of discharged battery.
ZXR / ZXC SERIES MOWER MOWER OPERATION STOPPING THE ENGINE TIPS fOR BREAKING-IN Driving a new mower at a high speed IMPORTANT or under heavy load can affect its • Do not stop the engine when GREEN durability. Engine will start the machine is on a slope Engine will not start TACH...
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OPERATION OPERATION WARNING • On a slope, when the engine stops, immediately apply the parking brake so that the unit does not move. • Avoid driving with people other than the driver and be sure to sit down on the seat and drive.
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ZXR / ZXC SERIES MOWER TACH VOLT START STOP ZXCO422A ZXCO512A ZXCO511A (1) Throttle lever (2) Choke lever (1) Deck lift Pedal (2) Deck Height Adjust Dial (A) Increase (b) Decrease (A) Raise and lock (b) lower 3. Start the engine according to the 5.
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OPERATION DRIVING CONTROlS ▶MOVING REVERSE Pull both the left and right steering levers at the same time towards you slowly to propel the mower in reverse. ▶TURNING To turn in either left or right direction when the mower is moving, to turn ZXCO513A ZXCO429A right-move just the left steering...
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Adjustment of the tracking in levers. Perform the following starting regards to the steering levers sequence. should only be performed by a qualified KIOTI dealer. Do not CAUTION attempt to adjust in the field. • When the engine is stopped, t h e s t e e r i n g l e v e r c a n n o t control the machine.
OPERATION WARNING • O b s e r v e t h e t e r r a i n t o b e traveled on to identify hazards before proceeding. Remove 1 1 1 1 1 1 all obstructions and clear the 1 1 1 1 1 1 area.
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ZXR / ZXC SERIES MOWER 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 ZXCO530A ZXCO531A ZXCO533A (1) Steering levers (1) Steering levers (1) Steering levers (A) General left Turn (A) General Right Turn (A) Sharp left Turn ▶GENERAl lEfT TURN ▶GENERAl RIGHT TURN...
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OPERATION RESTARTING ON A SlOPE W h e n y o u n e e d t o r e s t a r t a f t e r 6. Stay two cut widths (width of the s t o p p i n g a t a s l o p e , f o l l o w t h e mower deck) away from ditches, procedure below.
ZXR / ZXC SERIES MOWER STOPPING 3. Move the throttle lever to the WARNING medium speed position and set the • DO NOT operate this mower PTO switch to "Off" and lower the on steep slopes. To check if deck to ground. the slope is too steep, attempt 4.
OPERATION MOVING MOWER WHEN THE PARKING ENGINE IS STOPPED 4. Press the START / STOP button to stop the engine. CAUTION • M a k e s u r e t h e m o w e r i s completely stopped and that the parking brake is securely engaged, and then get off the...
ZXR / ZXC SERIES MOWER TOWING TRANSPORTING 1. NEVER allow anyone in or on equipment being towed. 2. Only Tow with a machine that has a hitch designed for towing. Do not attach towing equipment except at the designated hitch point. 3.
OPERATION HOW TO USE THE MOWER PROfICIENTly MOWER PERfORMANCE TIPS 5. When getting off, please use a 1. When cutting grass with the mower 6. When cutting tall or wet grass loading ramp that is longer and deck for the first time, select a (higher than 8”), for best results, the area should be cut twice.
OPERATION BATTERy & fUSE ACCESS IMPORTANT DANGER • • N e v e r p u t h a n d s i n t o t h e Do not work on the machine discharge chute while the with the brake applied. e n g i n e i s r u n n i n g f o r a n y •...
ZXR / ZXC SERIES MOWER HOW TO lIfT THE MOWER CAUTION CAUTION • • When raising the seat, make Do not work under the machine sure it is positioned all the when it is not firmly secured way forward at a 90 degree with a support stand or wheel angle as shown in the photo chocks.
OPERATION ClEANING MOWER DECK WASHING MOWER 1. lift the mower and clean it with a water hose or air. CAUTION • Before starting the engine, b e s u r e t o s i t o n t h e s e a t and check that each steering 1 1 1 lever is in the "neutral lock"...
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ZXR / ZXC SERIES MOWER 1. Electrical Parts: Disconnection or damage may occur to the wire harnesses or cables, which can potentially cause a fire. 2. Hydraulic hoses: Do not apply d i r e c t w a t e r p r e s s u r e t o t h e hydraulic lines, doing so may cause hoses to break or come loose, causing oil to leak at a high...
maintenanCe RECOMMENDED MAINTENANCE SCHEDULES to prevent accidents, breakdowns and keep your work in good condition, regular inspections and maintenance are required. MAINTENANCE SERVICE INTERVAL MAINTENANCE PROCEDURE 1. After the first 50 hours Change the engine oil. Check the wheel hub slotted nut torque specifications. ...
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Zxr / ZxC SerieS mower MAINTENANCE SERVICE INTERVAL MAINTENANCE PROCEDURE Change the engine oil. lubricate the deck lift pivots. 6. every 100 hours Remove the engine shrouds and clean the cooling fins. Check the spark plugs. replace the primary air cleaner element - check secondary air cleaner element;...
LUBRICANTS to prevent serious damage to the equipment, use only genuine KIOTI fluids, oils and greases or equivalents. ITEM CAPACITY LUBRICANTS residential: 7.5 u.S. gal. fuel automobile unleaded or unleaded gasoline 87 octane or higher Commercial: 12.5 u.S. gal.
Zxr / ZxC SerieS mower DAILY CHECK CHECKING ENGINE OIL LEVEL GENERAL INfORMATION it is a good practice to know the CAUTION condition of your tractor before you • E nga ge t h e p a r k in g b r a k e start it.
maintenanCe CHECKING AND ADDING fUEL 1 1 1 ZxCo602a ZxCo643a (1) oil gauge (1) filler neck (2) fuel gauge (a) upper limit (B) lower limit (a) fuel level 4. pull out the oil dipstick, clean it, 1. Check the amount of fuel by fuel and then insert it into its original gauge.
Zxr / ZxC SerieS mower CHECKING AND CLEANING AIR INTAKE SCREEN DANGER CAUTION To avoid injury from burns, • To avoid personal injury: a l l o w t h e m o w e r t o c o o l •...
maintenanCe CHECKING TRANSAxLE fLUID LEVEL IMPORTANT • If the oil level drops too low, do not start the engine. ZxCo605a (1) oil filler neck (a) lower limit 1. park the mower on a level ground and lower the implement. 2. make sure the parking brake is set, set all shift levers into the neutral position.
Zxr / ZxC SerieS mower LUBRICATION Apply quality multi-purpose grease to the following locations specified in the following figure when necessary. Also, record the operating hour on every application. ZxCo606a ZxCo607a ZxCo608a (1) front Cast Support pipe (lh/rh) (1) deck front link pipe (lh/rh) (1) Shaft Support Bracket (lh/rh-front)
maintenanCe EVERY 50 HOURS AIR fILTER MAINTENANCE CHECK SPARK ARRESTER (If EQUIPPED) if you do not have a spark arrester must not exceed 2 kgf/cm² (29 equipped, do not refuel or start the psi). maintain reasonable distance engine. between the nozzle and the filter. 1.
Zxr / ZxC SerieS mower EVERY 100 HOURS CHANGING ENGINE OIL CAUTION A A B B • Hot exhaust components can ignite gasoline vapors even a f t e r t h e e n g i n e h a s s h u t down.
3. Check the fuel filter and replace it of children. plug wrench. immediately if it is blocked by dust or dirt. to replace the fuel filter, 3. Check spark plug for cracks, wear contact your KIOTI dealer. and damage, and replace spark plug if necessary.
Zxr / ZxC SerieS mower ADjUSTING TRANSAxLE MOUNTING AxLE BELT DRIVE BELT TENSION CAUTION • S t o p t h e e n g i n e w h e n checking the following items. • Inspect the fuel pipe regularly. The fuel pipes are subject to wear and aging.
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maintenanCe ZxCo648a ZxCo649a ZxCo650a (1) Spanner 17 mm (2) Spacer (1) Spanner 14 mm (2) Bracket (3) pulley no. 5 (3) Bolt 2. using a Spanner (17 mm), hold 3. using spanner (14 mm) hold the 4. make sure the axle belt path is the nut on the upside of no.
4. if the machine does not move, it is brake properly, contact your KIOTI correctly adjusted. dealer for further brake adjustments. 1. l o o s e n t h e f i x e d n u t o n t h e...
1. the battery cable should always performed by your Authorized KIOTI be clean and firmly connected. dealer to ensure proper and efficient when installing a new or used running of the engine.
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2. B o o s t c h a r g i n g i s o n l y f o r three months in hot seasons and by your local KIOTI Dealer. e m e r g e n c i e s . i t w i l l p a r t i a l l y once every six months in cold •...
IMPORTANT filter firmly by hand. • Use only specified engine oil 2. Fill the engine oil to the specified and KIOTI genuine filter to level and turn filter clockwise ZxCo618a insure smooth operation and until rubber seal contacts the (1) transaxle (2) transaxle oil filter durability of the engine.
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Zxr / ZxC SerieS mower 2. Remove hex flange bolts and filter 10. d i s c o n n e c t t h e a i r b r e a t h e r ▶AIR BLEEDING PROCEDURE guard and remove debris around port from the left and right side due to the efficiency of the air in...
maintenanCe CHECKING TRANSAxLE fLUID HOSE operating conditions. if this task is CAUTION difficult, it should be done in a free • Always stop the engine before space with no objects or people. checking the oil hoses. 1. release the brakes. •...
CLEANING ENGINE SHROUD REPLACING fUEL fILTER ADjUSTING PTO ELECTRIC CLUTCH replace it every 400 hours, or if the fuel filter is clogged, immediately. when replacing, contact KIOTI dealer where you purchased it. ZxCo621a ZxCo620a (1) engine Shroud (2) mounting Bolt (1) pto electric Clutch 1.
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maintenanCe REMOVING SHIM 4. Check that the clutch connector has 12v when the pto switch is connected. 5. measure the gap between the rotor and armature and proceed to the next step if the gap is greater than 0.04 in. •...
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Zxr / ZxC SerieS mower • use a 0.010 inch feeler gauge to check for gap widths between the rotor and amateur surfaces o n e i t h e r s i d e o f t h e b r a k e pole as shown.
maintenanCe EVERY 1 YEAR REPLACING AIR CLEANER ELEMENT CHECKING SPARK PLUG 2. loosen the air cleaner clip and remove the cover. 3. Clean the inside of the air cleaner housing thoroughly. 4. replace the air cleaner element a n d i n s p e c t t h e h o u s i n g f o r damage.
Zxr / ZxC SerieS mower SERVICE AS REQUIRED REPLACING fUSES CHECKING BLADE 3. the main fuse protects the follow- ing functions. NO PROTECTION CIRCUIT CAPACITY regulate Control panel power outlet ZxCo622a ZxCo644a (1) relay (2) fuse Box (1) new Blade (2) worn Blade (3) Cracked Blade 1.
maintenanCe INSPECTION AND SHARPEN- REPLACING BLADE ING BLADE 1. make sure that the engine is off, BLADE TIGHTENING TORQUE the parking brake is set, and the 103 ~ 118 n・m b l a d e s h a v e s t o p p e d m o v i n g (76 ~ 87 ft - lb) completely.
Zxr / ZxC SerieS mower REPLACING MOWER BELT secure the blade to the vise firmly. use a large mill file to sharpen until it is sharpened according to the original angle. 5. to c h e c k t h e b a l a n c e o f t h e blade, pass a small rod through the center hole.
maintenanCe ADjUSTING BELT TENSION ADjUSTING TRAVEL neutral or tracking adjustments will DECK SIZE ADjUSTING LENGTH need to be made if: 48” 7.1"±0.2" (180mm±5mm) 1. the steering control levers are in 54” 7.5"±0.2" (190mm±5mm) the neutral position and the ma- chine creeps forward or backward. 60”...
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Zxr / ZxC SerieS mower ▶ NEUTRAL ADjUSTMENT 7. Check that the drive wheels re- mained in neutral and readjust if 1. Be sure the dump valve levers are necessary. in the run position and the steering control levers are in the neutral lock position.
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maintenanCe control rod to stroke the lh pump CAUTION less, slowing down the lh wheel. • T h e e n g i n e a n d d r i v e u n i t 2. if at full speed the mower pulls can get hot during operation left, it is an indication that the right causing burn injuries.
Zxr / ZxC SerieS mower ADjUSTING ANTI-SCALP ROLLER ADjUSTING DECK LEVEL 5. attach the auxiliary wheels rollers with attaching hardware. IMPORTANT • Check the auxiliary wheels adjustments whenever the mower deck cutting height changes. • It is recommended that all the anti-scalp rollers be kept ZxCo628a ZxCo634a...
maintenanCe ADjUSTING DECK RAKE CAUTION • Park the machine on a level surface, engage the parking brake and turn off the PTO switch. • S t o p t h e e n g i n e w h e n checking and adjusting the mower deck height.
STORAGE AND DISPOSAL MOWER STORAGE ............7-2 Daily storage................7-2 long-term storage ..............7-2 Using mower aFter long term storage ......7-3 USAGE AND DISPOSAL ..........7-4...
ZXr / ZXC series mower MOWER STORAGE DAILy STORAGE LONG-TERM STORAGE 1. Keep the mower clean when it is t o p r e v e n t d e t e r i o r a t i o n , o f IMPORTANT stored.
storage anD DisPosal USING MOWER AFTER LONG TERM STORAGE 12. Chock the frame in order to re- 1. Check the tire air pressure and mower. Check if there is leakage. move the weight from the tires. inflate the tires if they are low. 9.
2. never leave or discard the expired mower or implement, but contact your local KIOTI Dealer to dispose it according to the regulations. 3. avoid working under high load as it can cause excessive exhaust g a s , w h i c h i s h a r m f u l t o t h e environment.
• Fuel is depleted • Refuel difficult • Clogged or damaged fuel hose • Clean or replace fuel line or see your KIOTI dealer or fuel filter • Poor fuel quality • Change fuel and fuel filters • water and dust in the fuel system •...
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• Electrical connections are • Clean and check electrical connections corroded or loose • Relay or switch defective • See your KIOTI dealer • Battery is weak • Cleaning the battery cable or charging if necessary 3. Insufficient engine • Engine overload •...
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• Excessive engine oil • Reduce engine oil level to specified value is white or blue • Piston ring worn or stuck • See your KIOTI dealer 6. when the exhaust gas • Engine overload • Reduce load color is black or gray •...
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TROUBLESHOOTING CaUSE COUNTERmEaSURES 8. when the engine does • Spark plug defect • adjust spark plug gap, or replace not idle • Carburetor problems • See your KIOTI.dealer ※ If you have any question, contact your KIOTI Dealer.
• Bad alternator • Inspect and repair alternator 4. when the terminal • Insufficient terminal tightening • Clean and re-tighten terminals becomes hot due to severe corrosion of the terminal ※ If you have any question, contact your KIOTI Dealer.
• Clogged filter • Replace filter 3. when the mower • Neutral adjustment of HST shift • See your KIOTI dealer moves when the link is not possible steering lever is set to “neutral lock” • adjustment linkage pivot stuck •...
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ZXR / ZXC SERIES mOwER CaUSE COUNTERmEaSURES 6. when the mower belt • weak tension spring • Replace tension spring slips • accumulated grass in pulley • Clean the pulley cleanly • worn out mower belt • Replace mower belt 7.
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• working speed too fast • Slow downwork speed • Grass is accumulated or • Clean mower tangled on mower spindle • Front of the mower is too low • adjust mower deck ※ If you have any question, contact your KIOTI Dealer.
PART ILLUSTRATIONS HOW TO READ PART ILLUSTRATIONS ...9- 33A. PTO CLUTCH GROUP ...... 9-46 33B. PTO CLUTCH GROUP ...... 9-48 01A. 48" MULCHING KIT GROUP (OPTION) ... 9-4 35A. FRONT WHEEL GROUP ....9-50 01B. 54" MULCHING KIT GROUP (OPTION) ... 9-6 35B.
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60C. MOWER DECK GROUP ....9-88 92A. REAR BUMPER GROUP ....9-136 60C. MOWER DECK GROUP ....9-90 92B. REAR BUMPER GROUP ....9-138 80A. MAIN HARNESS GROUP ....9-98 93. ROPS GROUP ........9-140 80B. MAIN HARNESS GROUP ....9-100 95A.
Whenever in need of parts, you will find the correct parts for repair and replacement throughout this manual. In order to extend and/or maintain a good performance of your machine we strongly recommend you to use KIOTI genuine parts. Please carefully read the manual and follow the instructions or figures which will help your parts ordering and repair job, but please refer to our Workshop manual for repairs as this manual does not contain information on repair procedures.
ZXR / ZXC SERIES MOWER 02. LAMP GROUP (OPTION) ZXCO904B...
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PART ILLUSTRATIONS Q'TY PART NO. PART NAME REMARKS 01025-50614 WITH WASHER BOLT 03024-50508 SCREW WITH WASHER Z2131-86101 LED LAMP ASS`Y(3W) Z2131-86201 LED LAMP BRAKET ※ QTY: A:ZXR48/ZXC48, B:ZXR54/ZXC54, C:ZXR60/ZXC60, D:ZXR48SE/ZXC48SE, E:ZXR54SE/ZXC54SE, F:ZXR60SE/ZXC60SE...
ZXR / ZXC SERIES MOWER 04. ANTI SCARP ROLLER GROUP (OPTION) ZXCO906A...
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PART ILLUSTRATIONS Q'TY PART NO. PART NAME REMARKS 01123-50816 WITH WASHER BOLT 01176-51201 BOLT 02310-50080 LOCK NUT Z2131-00411 ROLLER BRACKET, LH Z2131-00421 ROLLER BRACKET, RH Z2131-62431 MOWER DECK ROLLER ※ QTY: A:ZXR48/ZXC48, B:ZXR54/ZXC54, C:ZXR60/ZXC60, D:ZXR48SE/ZXC48SE, E:ZXR54SE/ZXC54SE, F:ZXR60SE/ZXC60SE...
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ZXR / ZXC SERIES MOWER 05. WORK LAMP KIT GROUP (OPTION) ZXCO907A...
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PART ILLUSTRATIONS Q'TY PART NO. PART NAME REMARKS 01025-50614 WITH WASHER BOLT 02310-50100 LOCK NUT 02763-50080B FLANGE NUT T5310-69802 WORK LAMP ASS'Y Z2131-00511 WORK LAMP BRKT, LH Z2131-00521 WORK LAMP BRKT, RH Z2131-00531 WORK LAMP SWITCH ASS'Y Z2131-00541 U BOLT Z2131-03301 WORK LAMP SWITCH ASS'Y Z2131-03101...
ZXR / ZXC SERIES MOWER 20A. FUEL TANK GROUP ZXCO912B...
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PART ILLUSTRATIONS Q'TY PART NO. PART NAME REMARKS 01135-51020 WITH WASHER BOLT 01176-51025 BOLT 02176-50100 04512-50100 SPRING WASHER Z1131-20102 FUEL TANK ASS`Y, LH Z1131-20162 FRONT MOUNTING, FUEL TANK Z1131-20201 FUEL TANK ASS`Y, RH Z2131-20121 CAP, FUEL TANK Z2131-20131 SLOSH VALVE Z2131-20142 FUEL PICK-UP, LH Z2131-20151...
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ZXR / ZXC SERIES MOWER 20B. FUEL TANK GROUP ZXCO913B...
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PART ILLUSTRATIONS Q'TY PART NO. PART NAME REMARKS 01135-51020 WITH WASHER BOLT 01176-51025 BOLT 02176-50100 03027-50512B SCREW 04013-50050B PLAIN WASHER 04512-50100 SPRING WASHER Z2131-20112 BODY, FUEL TANK RH (COMMERCIAL) Z2131-20121 CAP, FUEL TANK Z2131-20131 SLOSH VALVE Z2131-20142 FUEL PICK-UP, LH Z2131-20151 GAUGE, FUEL Z2131-20162...
ZXR / ZXC SERIES MOWER 21A. FUEL LINE GROUP ZXCO914B...
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PART ILLUSTRATIONS Q'TY PART NO. PART NAME REMARKS 01754-50616B FLANGE BOLT 09318-88085 CLIP 1 09318-88115 CLIP 2 Z1131-21111 FUEL LINE Z1131-21163 VAPOR LINE Z1131-21173 VAPOR LINE Z2131-21513 REAR COVER ※ QTY: A:ZXR48, B:ZXR54, C:ZXR60, D:ZXR48SE, E:ZXR54SE, F:ZXR60SE...
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ZXR / ZXC SERIES MOWER 21B. FUEL LINE GROUP 2 12 ZXCO915C...
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PART ILLUSTRATIONS Q'TY PART NO. PART NAME REMARKS 01754-50616B FLANGE BOLT 02761-50040 FLANGE NUT 03054-50412 SCREW 09318-88085 CLIP 1 09318-88115 CLIP 2 Z2131-21112 FUEL LINE Z2131-21121 FUEL LINE Z2131-21131 FUEL LINE Z2131-21141 FUEL LINE Z2131-21162 VAPOR LINE Z2131-21172 VAPOR LINE Z2131-21191 VAPOR LINE Z2131-21301...
ZXR / ZXC SERIES MOWER 40. STEERING GROUP 22 9 4 23 ZXCO924A...
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PART ILLUSTRATIONS Q'TY PART NO. PART NAME REMARKS 01123-50812 WITH WASHER BOLT 01153-50830 BOLT 01153-50840 BOLT 01153-50860 BOLT 01155-50840 BOLT 01754-50812 FLANGE BOLT 02310-50080 LOCK NUT 03024-50516 SCREW 04013-50080 PLAIN WASHER 04014-50080 PLAIN WASHER 04512-50080 SPRING WASHER 07715-00401 BALL Z2131-41112 WLDMT-CONTROL BAR, LH Z2131-41212 WLDMT-CONTROL BAR, RH...
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ZXR / ZXC SERIES MOWER 40. STEERING GROUP 22 9 4 23 ZXCO924A...
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PART ILLUSTRATIONS Q'TY PART NO. PART NAME REMARKS Z2131-41621 HANDLE GRIP Z2131-41631 HANDLE LEVER(RH) Z2131-41652 BUSHING Z2131-41724 ROD, CONTROL Z2131-41752 SPACER, CONTROL ROD 2 Z2131-41761 DAMPER ASSEMBLY Z2131-41811 RETURN SPRING ※ QTY: A:ZXR48/ZXC48, B:ZXR54/ZXC54, C:ZXR60/ZXC60, D:ZXR48SE/ZXC48SE, E:ZXR54SE//ZXC54SE, F:ZXR60SE,ZXC60SE...
ZXR / ZXC SERIES MOWER 50. MAIN FRAME GROUP ZXCO926A...
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PART ILLUSTRATIONS Q'TY PART NO. PART NAME REMARKS 01125-50820B WITH WASHER BOLT 01153-50830 BOLT 02112-50080 06613-10675 GREASE NIPPLE Z2131-50008 MAIN FRAME ASS`Y Z2151-50008 MAIN FRAME ASS`Y Z2131-50114 SEAT SUPPORT BRACKET ※ QTY: A:ZXR48/ZXC48, B:ZXR54/ZXC54, C:ZXR60/ZXC60, D:ZXR48SE/ZXC48SE, E:ZXR54SE/ZXC54SE, F:ZXR60SE/ZXC60SE...
ZXR / ZXC SERIES MOWER 51. FLOOR GROUP ZXCO927A...
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PART ILLUSTRATIONS Q'TY PART NO. PART NAME REMARKS 01754-50620B FLANGE BOLT 03016-50816 SCREW T2555-55851 CUSHION U3215-83701 SEAT RUBBER MOUNT Z2131-51112 FRONT MAT Z2131-51121 FLOOR MAT Z2131-51131 FOOT PLATE Z2131-51144 FRONT COVER, SEAT Z2131-51151 SUB STEP, LH Z2131-51162 SUB STEP, RH ※...
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ZXR / ZXC SERIES MOWER 60A. MOWER DECK GROUP ZXCO928D...
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PART ILLUSTRATIONS Q'TY PART NO. PART NAME REMARKS 04014-50100 PLAIN WASHER 04014-50120 PLAIN WASHER 04512-50080 SPRING WASHER 04512-50100 SPRING WASHER 04512-50120 SPRING WASHER 04611-00320 SNAP RING 04611-00520 SNAP RING 04613-50120 SNAP RING 05911-00735 06613-10675 GREASE NIPPLE 08141-06002 BALL BEARING 08141-06205 BALL BEARING 09500-22327 OIL SEAL...
ZXR / ZXC SERIES MOWER 60B. MOWER DECK GROUP 32 47 ZXCO929D...
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PART ILLUSTRATIONS Q'TY PART NO. PART NAME REMARKS 04014-50100 PLAIN WASHER 04014-50120 PLAIN WASHER 04015-50080B PLAIN WASHER 04512-50080 SPRING WASHER 04512-50100 SPRING WASHER 04512-50120 SPRING WASHER 04611-00320 SNAP RING 04611-00520 SNAP RING 04613-50120 SNAP RING 05911-00735 06613-10675 GREASE NIPPLE 08141-06002 BALL BEARING 08141-06205 BALL BEARING...
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ZXR / ZXC SERIES MOWER 60C. MOWER DECK GROUP 51 13 14 ZXCO930D...
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PART ILLUSTRATIONS Q'TY PART NO. PART NAME REMARKS 04014-50100 PLAIN WASHER 04014-50120 PLAIN WASHER 04015-50080B PLAIN WASHER 04512-50080 SPRING WASHER 04512-50100 SPRING WASHER 04512-50120 SPRING WASHER 04611-00320 SNAP RING 04611-00520 SNAP RING 04613-50120 SNAP RING 05911-00735 06613-10675 GREASE NIPPLE 08141-06002 BALL BEARING 08141-06205 BALL BEARING...
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ZXR / ZXC SERIES MOWER 60C. MOWER DECK GROUP 51 13 14 ZXCO930D...
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PART ILLUSTRATIONS Q'TY PART NO. PART NAME REMARKS Z2131-62142 SPACER Z2131-62171 WASHER, SPRING Z2131-62191 TENSION PULLEY,MOWER DECK Z2131-62201 TENSION PULLEY,MOWER DECK Z2131-62231 COLLAR UPPER PULLEY Z2131-62241 COLLAR PULLEY Z2131-62261 PULLEY ARM, TENSION Z2131-62271 BOLT Z2131-62303 SUPPORT, TENSION PULLEY Z2131-62372 TENSION PULLEY BRKT Z2131-62381 TENSION SPRING Z2131-62412...
ZXR / ZXC SERIES MOWER 82A. CONTROL PANEL GROUP ZXCO936A...
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PART ILLUSTRATIONS Q'TY PART NO. PART NAME REMARKS 01053-50620 BOLT 02054-50040 02310-50050 LOCK NUT 02310-50060 LOCK NUT 02761-50060 FLANGE NUT 03027-50516B SCREW 04013-50050B PLAIN WASHER 04013-50060 PLAIN WASHER U3215-81552 SCREW (BLACK) Z2131-82101 CONTROL PANEL Z2131-82113 PANEL, SWITCH CONTROL Z2131-82212 LEVER, THROTTLE CONTROL Z2131-82223 PLATE 1, THROTTLE LEVER Z2131-82241...
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ZXR / ZXC SERIES MOWER 82A. CONTROL PANEL GROUP ZXCO936A...
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PART ILLUSTRATIONS Q'TY PART NO. PART NAME REMARKS Z2131-82282 SPRING PLATE ※ QTY: A:ZXR48, B:ZXR54, C:ZXR60, D:ZXR48SE, E:ZXR54SE, F:ZXR60SE...
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PART ILLUSTRATIONS Q'TY PART NO. PART NAME REMARKS 01025-50614 WITH WASHER BOLT 03024-50508 SCREW Z2131-86101 LED LAMP ASS'Y (3W) Z2131-86201 LED LAMP BRAKET ※ QTY: A:ZXR48/ZXC48, B:ZXR54/ZXC54, C:ZXR60/ZXC60, D:ZXR48SE/ZXC48SE, E:ZXR54SE/ZXC54SE, F:ZXR60SE/ZXC60SE...
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PART ILLUSTRATIONS Q'TY PART NO. PART NAME REMARKS T4935-92502 POWER OUTLET ASS'Y (12V) ※ QTY: A:ZXR48/ZXC48, B:ZXR54/ZXC54, C:ZXR60/ZXC60, D:ZXR48SE/ZXC48SE, E:ZXR54SE/ZXC54SE, F:ZXR60SE/ZXC60SE...
ZXR / ZXC SERIES MOWER 95A. DECAL GROUP 1 20 14 ZXCO953B...
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PART ILLUSTRATIONS Q'TY PART NO. PART NAME REMARKS T5245-55461 CAP, HANDLE Z2111-95103 FUEL TANK DECAL, LH Z2111-95202 FUEL TANK DECAL, LH Z2111-95113 FUEL TANK DECAL, RH Z2111-95212 FUEL TANK DECAL, RH Z2131-95104 DECAL, FRONT Z2131-95112 DECAL, FRONT COVER Z2131-95121 DECAL, ROPS Z2131-95152 LABEL-PRODUCT Z2131-95162...
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ZXR / ZXC SERIES MOWER NUMERIC 40. STEERING GROUP .............9-60 01A. 48" MULCHING KIT GROUP (OPTION) .....9-4 45. PARKING BREAK GROUP ..........9-62 01B. 54" MULCHING KIT GROUP (OPTION) .....9-6 50. MAIN FRAME GROUP ..........9-64 01C. 60" MULCHING KIT GROUP (OPTION) ......9-8 51.
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INDEX 85B. RELAY GROUP............9-120 ADjUSTING THROTTLE CONTROL AND CHOCK ..6-17 86. LAMP GROUP ............9-122 ADjUSTING TRANSAXLE DRIvE BELT TENSION ..6-14 87. ETC GROUP ..............9-124 ADjUSTING TRAvEL ............6-29 90A. SEAT GROUP ............9-126 AIR FILTER MAINTENANCE ..........6-11 90B. SEAT GROUP ............9-128 ALARMS ................4-8 90C.
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ZXR / ZXC SERIES MOWER EvERY 200 HOURS ............6-19 CLEANING MOWER DECK ..........5-23 EvERY 400 HOURS ............6-22 CUP HOLDER ..............4-15 EvERY 50 HOURS ............6-11 EvERY 500 HOURS ............6-22 EXTERIOR vIEW ..............4-2 DAILY CHECK ..............6-6 DAILY STORAGE ..............7-2 DC POWER OUTLET ............4-15 FRONT WHEEL ..............4-17 DECAL MAINTENANCE ............1-18 FUEL GAUGE ..............4-14...
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INDEX jUMP STARTING ..............5-7 OPERATION .................5-9 OWNERS RESPONSIBILITY ..........1-3 LONG-TERM STORAGE .............7-2 LUBRICANTS ...............6-5 PARKING ................1-9 LUBRICATION ..............6-10 PARKING ................5-17 PARKING BRAKE ..............4-11 PART ILLUSTRATIONS ............9-1 MAINTENANCE ..............1-9 PRECAUTION BEFORE OPERATION ........1-2 MAINTENANCE ..............6-1 PTO SWITCH ...............4-7 METRIC FASTENER TORqUE CHART ......3-9 MOUNTING AXLE BELT ............6-14 MOvING MOWER WHEN THE ENGINE IS STOPPED ..5-17 REAR WHEEL ..............4-17...
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