John Deere Z540R

24-hp (17.9-kW) engine

Overhead valve engine

Key engine features include:

• 24 hp (17.9 kW) provides plenty of power.
• Large 44.3 cu in. (726-cc) displacement provides plenty of torque.
• V-twin air-cooled design is efficient.
  • Excellent power and performance
  • Smooth, quiet power
  • Easy starts
• Engine model FS730V
• Many quality features are included.
  • Cast-iron cylinder liners provide a long-wearing surface for longer engine life.
  • Overhead valves allow the engine to breathe easily for excellent power and fuel economy.
  • Full-pressure lubrication is more effective.
  • Replaceable oil filter keeps the oil cleaner for longer engine life.
  • Dual-stage air cleaner thoroughly cleans engine intake air.
  • Electronic ignition contributes to fast starts.
  • Solenoid-shift starter for easy starts, even in cold weather.
• Rear engine guard protects the engine and provides additional vehicle strength and integrity.
• A flywheel alternator provides plenty of capacity to quickly recharge the battery and power electrical equipment, such as lights or a sprayer.
  • 20-amp capacity
  • Regulated to keep the battery at a full charge, without risk of overcharging

Air filter cover

Cover removed to show air filter

First-stage foam filter stops large dirt particles before they make contact with the filter.

The air filter is easily removed for cleaning or replacement.

Engine cooling-air screen

Engine oil fill, filter, and drain

Air screen cover provides protection for the rotating air screen. Rotating screen filters out debris and reduces the size of material that gets through so it will pass harmlessly past the engine fins.

Full-pressure lubrication system provides plenty of oil to the engines moving parts to ensure reliable operation and long life:

• Replaceable oil filter keeps the oil cleaner for a longer engine life.
  • Extends the time between oil changes
• Full-pressure lubrication is more effective.
• No-tools oil drain is convenient to use.

John Deere recommends the use of fuel stabilizer in gasoline. See Fuel-Protect for gasoline engines (8 oz [237 mL]) for more information.

Operator station (Z535M shown)

Color-coded controls are easy to identify

The operator station is designed for operator comfort and convenience in operating all controls:

• Excellent visibility forward and to the trim side of the deck makes operation easy and comfortable for the operator.
• Controls are color coded for easy identification.
• Twin-lever motion-control levers adjust, using cut-height pin/socket, for convenience and operator comfort.
• Shock absorbers dampen control movements to give smooth operation.

Comfortable seat

Comfortable seat (Z525E)

Comfortable seat (Z535M, Z540M)

Comfortable seat (Z535R, Z540R)

Comfortable seats have two suspension springs and no-tools fore-aft seat adjustment that can be used by the operator while seated:

• Z525E – Medium-back, 15-in. (38-cm) seat with adjustable armrests and 3-in. (7.6-cm) fore-aft adjustment
• Z535M – High-back, 18-in. (45.7-cm) seat with adjustable armrests and 3-in. (7.6-cm) fore-aft adjustment
• Z540M – High-back, 18-in. (45.7-cm) seat with adjustable armrests and 3-in. (7.6-cm) fore-aft adjustment
• Z535R – High-back, 21-in. (53.3-cm) seat with adjustable armrests and 4.5-in. (11.4-cm) fore-aft adjustment
• Z540R – High-back, 21-in. (53.3-cm) seat with adjustable armrests and 4.5-in. (11.4-cm) fore-aft adjustment

Seat suspension

Seat suspension springs

Two steel springs under the seat absorb shocks when traveling over rougher areas to provide a smoother ride.

Cup holder and storage compartment

Cup holder (Z525E shown)

Open storage compartment

Flip-up foot platform

Flip-up foot platform

The commercial-style steel footrest flips up to provide easy access for servicing the mower deck:

• Easy to clean grass off the top of the mower
• Provides convenient access to the mower drive

Service interval decal (Z300 Series shown)

Service interval decal (Z500 Series shown)

A convenient service interval decal provides basic maintenance information. It provides a quick-reference for keeping recommended service up to date.

Mower deck access

Footrest easily removed for access to mower (Z335E shown)

Footrest removal bolt and hand grip (Z335E shown)

The footrest area is hinged and easily raised for service to mower deck:

• It is necessary to remove just one bolt that can be conveniently removed with the lift-height pin.
• Easy to clean grass off the top of the mower
• Provides convenient access to the mower drive

Loosening bolt to remove platform for access to mower deck

Footrest opens for access to mower deck

Engine service

Z335E engine

Z335E engine oil and fuel filters shown

Z535M and Z535R engine

Z540M and Z540R engine

Easy-to-access oil filter, fill/check oil tube, and oil drain

The engines are easy to service, including changing the oil and the oil filter and servicing the air filter.

Accel Deep Mower Deck

Tie-down locations

Accel Deepâ„¢ Mower Decks have several features that make them easy to service:

• Flat-top design minimizes places for debris to collect.
• Spring-loaded, flip-up belt guards make removing debris easy.
• Provision is provided for a standard, 3/8-in. (9.5-mm) ratchet wrench to be used for releasing belt tension when removing the drive belt.

Tie-down locations are provided for convenience and safety when trailering the machine.

48-in. (122-cm) HC Mower Deck

The 48-in. (122-cm) HC Mower Deck has a deep-deck design to handle higher volumes of grass. It is stamped from heavy-gauge steel and has additional durability features to stand up to challenging mowing conditions.

48-in. (122-cm) HC Mower Deck shown on a Z540R

Left side of 48-in. (122-cm) HC Mower Deck

The 48-in. (122-cm) HC Deck is stamped from heavy, 9-gauge, 0.15-in. (3.8-mm) steel to minimize the number of welds and provide a smooth underside for reduced material buildup:

• Deep-deck design of 5.5 in. (14 cm) delivers excellent airflow, so material can be processed quickly and efficiently.
• Wider and higher discharge opening provides even clipping dispersal for an excellent finished appearance in all conditions.
• Durable plastic deflector spreads grass clippings evenly across the lawn, is hinged, and can be raised to minimize the storage space required.
• 1-in. (2.5-cm) cold-forged spindles are heat-treated for strength and are supported by ball bearings.
• Front edge is raised above the blade plane to allow even cutting of tall grass.
• Blade overlap is 1.6 in. (4 cm), nearly 0.8 in. (2 cm) greater than many conventional decks, for a clean cut.

Mower wash port

Mower wash port with hose connector

A wash port is provided to make cleaning the underside of the mower deck easy: 

• Hose connector is included with the mower deck.

Rear angle of 6.5-bu (230-L) Power Flowâ„¢ Rear Bagger shown on Z525E

Side view of 6.5-bu (230-L) Power Flow Rear Bagger shown on Z525E

An optional rear bagger is available:

• Mower is designed to fill the 6.5-bu (230-L) rear hopper using the Power Flow blower.
• Standard or mulch blades may be used with the Power Flow collection system.

Power Flow blower

The Power Flow blower is mounted on a sturdy swing arm that allows easy installation and cleanout.

Mulching attachment components

An optional mulching attachment is available:

• This design requires no drilling for initial mounting, less installation time, and reduced hardware-count that allows for easy removal of the mulch components.
• The high-performance mulching attachment includes formed steel baffles to control the material and special mulching blades for superior performance.
• The special mulching blades that are included can also be used for side discharging or with a material collection system, though the overall cut quality may be slightly less than with the standard mower blades.

54-in. (137-cm) HC Mower Deck

The 54-in. (137-cm) HC Mower Deck has a deep-deck design.

54-in. (137-cm) HC Mower Deck shown on a Z540R

Reinforced mower edge for durability

The 54-in. (137-cm) HC Deck is stamped from heavy, 9-gauge, 0.150-in. (3.8-mm) steel to minimize the number of welds and provide a smooth underside for reduced material buildup:

• Deep-deck design of 5.5 in. (14 cm) delivers excellent airflow, so material can be processed quickly and efficiently.
• Wider and higher discharge opening provides even clipping dispersal for an excellent finished appearance in all conditions.
• Durable plastic deflector spreads grass clippings evenly across the lawn, is hinged, and can be raised to minimize the storage space required.
• 1-in. (25.4-mm) cold-forged spindles are heat-treated for strength and are supported by ball bearings.
• Standard front roller and two double-captured anti-scalp wheels give a more even mowing job and reduce the chance of scalping.
• Front edge is raised above the blade plane to allow even cutting of tall grass.
• Blade overlap is 1.6 in. (40 mm), nearly 0.8 in. (20 mm) greater than many conventional decks, for a clean cut.
• Mower can side-discharge or mulch.

Mower wash port

Mower wash port with hose connector

A wash port is provided to make cleaning the underside of the mower deck easy:

• Hose connector is included with the mower deck.

Rear angle of 6.5-bu (230-L) Power Flowâ„¢ Rear Bagger shown on Z525E

Side view of 6.5-bu (230-L) Power Flow Rear Bagger shown on Z525E

An optional rear bagger is available:

• Mower is designed to fill the 6.5-bu (230-L) rear hopper using the Power Flow blower.
• Standard or mulch blades may be used with the Power Flow collection system.

Power Flow blower

 The Power Flow blower is mounted on a sturdy swing arm that allows easy installation and cleanout.

Optional high-performance mulching attachment

Mulching attachment components (48 HC shown)

An optional mulching attachment is available:

• This design requires no drilling for initial mounting, less installation time, and reduced hardware-count, that allows for easy removal of the mulch components.
• The high-performance mulching attachment includes formed steel baffles to control the material and special mulching blades for superior performance.
• The special mulching blades that are included can also be used for side discharging or with a material collection system, though the overall cut quality may be slightly less than with the standard mower blades.
• Order: BM23977, 54 HC mulching attachment

Optional MulchControlâ„¢ attachment

MulchControl with baffle closed

MulchControl handle

The MulchControl attachment makes mulching more practical for many mowing situations because it not only does an excellent job of mulching but it also allows the mower to be easily converted for times when it is more desirable to side discharge or collect the lawn material. Advantages of mulching grass clippings include:

• A beautiful looking lawn
• Grass clippings not blown onto the operator, driveways, or flower beds
• Less fertilizer use
• Elimination of the effort needed to dispose of clippings

MulchControl is an innovative, simple design that is easy to use and maintain:

• The MulchControl attachment includes baffles to control the flow of material under the deck.
• The left mower blade area is completely enclosed and optimized for mulching, thus will mulch even when the mower is in the side-discharge mode.
• Baffles around the center and right blades are optimized for mulching when the discharge baffle is closed.
• The MulchControl handle is located on top of the mower deck and used to open and close the discharge baffle.
• The operator is required to get off of the machine in order to engage or disengage mulch mode.
• Changing from mulching to side discharge or vice versa takes only a few seconds.

MulchControl is well-suited to the following mowing situations:

• Usually mulch, but side-discharge when grass gets too long
• Usually side discharge, but would like to be able to close the chute to control clippings
• Always mulch a main lawn, but often side discharge secondary lawns
• Bag clippings, but want to go farther before emptying bags

MulchControl puts the operator in control of the clippings. Now the operator can have all the benefits of mulching with the ability to easily change to side-discharge or bagging when needed.

MulchControl limitations

While in the side-discharge mode, MulchControl will still mulch about one third of the material. Therefore, the side-discharge mode is essentially a partial-mulch mode. This can be an advantage when side discharging or bagging, as it helps to reduce the amount of material being discharged. Other times this could work as a disadvantage:

• When cutting strong southern grasses, such as Zoysia and Bermuda
• When cutting in wet, high-growth conditions, such as those found in the Pacific Northwest United States
• When optimum bagging and lawn clean-up is desired

MulchControl compatibility

MulchControl is a field-installed attachment. Mulching blades are included:

• MulchControl is available for 2015 and later EZtrakâ„¢ Z625 and Z655 (SN 170,001-).

Order:

• BM25215 MulchControl attachment (54 HC)

60-in. (152-cm) HC Mower Deck

The 60-in. (152-cm) HC Mower Deck has a deep-deck design.

60-in. (152-cm) HC Mower Deck shown on a Z540R

Reinforced mower edge for durability

The 60-in. (152-cm) HC Deck is stamped from heavy, 9-gauge, 0.15-in. (3.8-mm) steel to minimize the number of welds and provide a smooth underside for reduced material buildup:

• Deep-deck design delivers excellent airflow, so material can be processed quickly and efficiently.
• Wider and higher discharge opening provides even clipping dispersal for an excellent finished appearance in all conditions.
• Durable plastic deflector spreads grass clippings evenly across the lawn, is hinged, and can be raised to minimize the storage space required.
• 1-in. (25.4-mm) cold-forged spindles are heat-treated for strength and are supported by ball bearings.
• Standard front roller and two double-captured anti-scalp wheels give a more even mowing job and reduce the chance of scalping.
• Front edge is raised above the blade plane to allow even cutting of tall grass.
• Blade overlap is greater than many conventional decks, for a clean cut.
• Mower can side-discharge or mulch.

Mower wash port

Mower wash port with hose connector

A wash port is provided to make cleaning the underside of the mower deck easy:

• Hose connector is included with the mower deck.

Optional high-performance mulching attachment

Mulching attachment components (48 HC shown)

An optional mulching attachment is available:

• This design requires no drilling for initial mounting, less installation time, and reduced hardware-count that allows for easy removal of the mulch components.
• The high-performance mulching attachment that includes formed steel baffles to control the material and special mulching blades for superior performance.
• The special mulching blades that are included can also be used for side discharging, though overall performance may be slightly less than with the standard mower blades.
• Order: BM23978, 60 HC mulching attachment

Optional MulchControlâ„¢ attachment

MulchControl with baffle closed

MulchControl handle

The MulchControl attachment makes mulching more practical for many mowing situations because it not only does an excellent job of mulching but it also allows the mower to be easily converted for times when it is more desirable to side discharge the lawn material. Advantages of mulching grass clippings include:

• A beautiful looking lawn
• Grass clippings not blown onto the operator, driveways, or flower beds
• Less fertilizer use
• Elimination of the effort needed to dispose of clippings

MulchControl is an innovative, simple design that is easy to use and maintain:

• The MulchControl attachment includes baffles to control the flow of material under the deck.
• The left mower blade area is completely enclosed and optimized for mulching, thus will mulch even when the mower is in the side-discharge mode.
• Baffles around the center and right blades are optimized for mulching when the discharge baffle is closed.
• The MulchControl handle is located on top of the mower deck and used to open and close the discharge baffle.
• The operator is required to get off of the machine in order to engage or disengage mulch mode.
• Changing from mulching to side discharge or vice versa takes only a few seconds.

MulchControl is well-suited to the following mowing situations:

• Usually mulch, but side-discharge when grass gets too long
• Usually side discharge, but would like to be able to close the chute to control clippings
• Always mulch a main lawn, but often side discharge secondary lawns

MulchControl puts the operator in control of the clippings. Now the operator can have all the benefits of mulching with the ability to easily change to the side-discharge mode when needed.

MulchControl limitations

While in the side-discharge mode, MulchControl will still mulch about one third of the material. Therefore, the side-discharge mode is essentially a partial-mulch mode. This can be an advantage when side discharging, as it helps to reduce the amount of material being discharged. Other times this could work as a disadvantage:

• When cutting strong southern grasses, such as Zoysia and Bermuda
• When cutting in wet, high-growth conditions, such as those found in the Pacific Northwest United States
• When optimum lawn clean-up is desired

MulchControl compatibility

MulchControl is a field-installed attachment. Mulching blades are included:

• MulchControl is for 2015 and later EZtrakâ„¢ Z665 Mower (SN 170,001-) and ZTrakâ„¢ Z540R Mower.

Order:

• BM25258 MulchControl attachment (60 HC)

Electric PTO switch

A heavy-duty electric PTO clutch is controlled by a convenient, dash-mounted control.

Heavy-duty PTO clutch

PTO clutch

The PTO clutch is designed to operate through many on/off cycles.

Unitized transmissions set low in vehicle (right side shown)

Unitized hydrostatic transmission

Dual unitized transmissions efficiently power the ZTrakâ„¢ forward and reverse and give steering capability:

• Transmissions are set low in the vehicle for excellent hillside stability.
• Tuff Torq® TZT7-M transmissions are reliable and durable.
  • Beefed-up 1-in. (2.5-cm) axles for greater strength
  • Have heavier-duty components to stand up to the higher loads from the larger tires and greater weight of Z500R Series ZTrak Mowers
• Maintenance-free, unitized transmissions are sealed and have no hose connections to leak hydraulic fluid.
• Four-bolt hubs provide a reliable and convenient wheel-mounting system.

Transmission expansion tank and tow-valve lever

Tow valve control lever

Tow-valve controls are provided for each transmission and located on the transmissions near the expansion tanks:

• Easy to reach and use
• Allow the vehicle to be moved without the engine running

Tuff Torq is a trademark of Tuff Torq Corporation.