Owner's Manual
This manual contains important safety instructions for the gasoline engine powered
lawnmower models: 54ZS, 62ZS
READ SAFETY WARNINGS AND OPERATING INSTRUCTIONS CAREFULLY.
SAVE THIS MANUAL.
Need Help?
Parts, Service
and Technical Assistance call:
1-919-550-3259
www.gxioutdoorpower.com
When you call the help-line you will need to have the following information:
Date of Purchase:
Location of Purchase:
Serial # - Mower:
Serial # - Engine:
Serial # - Hydro Trans (L)
Serial # - Hydro Trans (R)
54ZS,62ZS
Copyright@ 2009 by GXi Outdoor Power, LLC.All rights reserved.
No part of this publication can be reproduced or distributed without prior written permission of GXi Outdoor Power, LLC
Clayton, NO 27520USA.
is a registered trademark of The Stanley Works or its affiliates and
is used under license by GXi Outdoor Power, LLC
GXi Outdoor Power, LLCreserves the right to discontinue or change specifications or design at any time without notice
and without incurring any obligation whatsoever.
The information and specifications included in this publication were in effect atthe time of approval for printing.
This manual contains important safety instructions for Finish Mowers
READ SAFETYWARNINGS AND OPERATING INSTRUCTIONS CAREFULLY
SAVE THESE INSTRUCTIONS.
This owner's manual is considered a permanent part of the finish mower and should
remain with the finish mower if resold.
Rev:JUN2011 STANLEY Finish Mower 2
Check out our other great products byvisiting our web site at
www.gxioutdoorpower.com
36-inch & 54-inch Walk
Behind Mower
36-inch & 45-inch Snow
Blower
48-inch, 54-inch &
62-inch Zero-Turn
Mower
36-inch Brush Mower
Chipper/Shredder
with 2-Way Feed
lO0-inch Tow Behind Mower
Contents
Safety Information and Warnings ..........................................................................1
Preparation Safety Precautions .............................................................................2
Operation Safety Precautions ..............................................................................3,4
Slope Diagram ............................................................................................................5
Safety Decals .............................................................................................................6
Product Specifications .............................................................................................7
Control Panel and Lawn Mower Components .....................................................8
Missing Parts Request Form ....................................................................................9
Operating Instructions
Starting the Engine ..........................................................................................10
Operating the Mower .......................................................................................11
Changing the Height of Cut .............................................................................12
Disengaging Hydrostatic Drive Units ............................................................13
Return to Neutral .............................................................................................13
General Maintenance .....................................................................................14
Maintenance Schedule ..........................................................................................15
54ZS,62ZS
Service Adjustments
Engine-to-Blade Belt Adjustment ...................................................17,18,19,20
Spindle Break Inspection and Replacement ...............................................21
Removing the Blades .......................................................................................21
Engine-to-Hydrostatic Drives Belt Adjustment ...........................................22
Hydro System Adjustment ...............................................................................23
Safety System Adjustment ..............................................................................24
Lubrication Points ............................................................................................25
Battery .................................................................................................................25
Storage Instructions ................................................................................................26
Troubleshooting ...................................................................................................27,28
Limited Warranty and Service ..............................................................................29
Aboutthe STANLEYMower Manual
Congratulations on the purchase of your new STANLEY commercial mower. We at GXi Outdoor Power are confident that
this mower will provide excellent performance, outstanding quality, and great durability when operated and maintained
as directed in this manual.
1. This manual contains assembly, operating, safety, adjustment, maintenance, and troubleshooting instructions.
BEFOREOPERATING YOUR LAWN MOWER, CAREFULLYREADTHIS MANUAL IN ITS ENTIRITY.
2. This owner's manual is considered a permanent part of the mower. It must be available to all operators and/or
person(s) servicing the mower. Should the mower be resold, this manual must remain with the mower.
3. All information, illustrations, and specifications contained in this manual were in effect at the time of the
publication. GXi Outdoor Power reserves the right to add, delete or modify specifications and/or designs without
notice.
4. If you ever have questions in regards to the operation, maintenance or safety of your mower, please contact the
GXi Parts & Service, LLC at 1-919-550-3259.
Rev:JUN2011 STANLEY Finish Mower 4
Safety Information and Warnings 54ZS,62ZS
Safety Information
STANLEY lawn mowers are designed to give safe
and dependable service if operated according to
instructions. Read and understand this owner's
manual before operating your lawn mower.
Emission Control System Information
The U.S. and California Clean Air Acts
EPA and California regulations require all
manufacturers to furnish written instructions
describing the operation and maintenance of
emission control systems.The following instructions
and procedures must be followed in order to keep
the emissions from your engine within the emission
standards.
Safety Label Locations
Safety labels are located on your mower to warn
you of potential hazards. Read them carefully. If a
label comes off or becomes hard to read, contact
your GXi Parts and Service, LLCfor a replacement.
Operator Responsibility
It isthe owner's responsibility that all operators and
mechanics must be trained and read this manual
before operating the mower as well as being
physically able individuals. They should be
instructed about safe operating and mechanical
procedures. If they can not read or understand
English, it is the owner's responsibility to explain all
safety operating instructions. The owner or
operator is responsible for accidents or injuries
occurring to themselves, other people or property.
Potential misfortunate incidents can be prevented
by the owner/user.
2. Look for signs of damage or excessive wear.
Check the tightness of all nuts, bolts, pins, and
screws. Tighten any that may be loose and
replace any that are missing.
3. Be sure the safety interlock controls are
operating properly so that the engine cannot be
started unless the ground speed control lever is
in neutral and the blades are disengaged.
4. Check the mower blades for any damage or
abnormal wear. If replacement is required,
replace in sets so that they are balanced.
5. Check the tire pressure on all four tires. Do not
exceed the recommended maximum indicated
on the tire.
6. Checkthe belts for wear and correct tension.
See page 15 for instructions.
7. Check engine oil and air filters as recommended
in the engine manufacturer's manual.
Children
1. Never allow children to operate or ride on mowers.
2. Always keep children at a safe distance when
operating or servicing a mower
3. Make sure to always look out for children before
you make turns or reverse.
4. Never let children or untrained people operate or
service the equipment. Local regulations may
restrict the age of the operator
I WARNING I
WARNING! Do not use your STANLEY lawn mower to
Mower Inspection
For your safety, inspect the lawn mower before each
use. Before you begin your inspection, be sure the
following conditions are met: the lawn mower should
be on a level surface, with the ignition switch off, the
key removed, the break set, and the blades disengaged.
carry passengers. Keep bystanders, helpers, pets and
children at a safe distance from the machine while it is
in operation. Inspect the area where the equipment is
to be used and remove all objects such as rocks, toys,
and wires which can be thrown bythe machine causing
serious injury or death.
Also, disconnect the spark plug wires from the spark
plugs and ground them against the engine to prevent
inadvertent starting.
.
Walk around the mower and look for any fluid
spills or leaks on or underneath the mower.
Remove any and all excessive debris, dirt, and
fluids.
Wear appropriate clothing including hard hat, safety
glasses and hearing protection. Long hair, loose
clothing or jewelry may get tangled in moving parts.
Rev:JUN2011 STANLEY Finish Mower 1
Preparation Safety Precautions 54ZS,62ZS
Preparation--Safety Precautions
I. Evaluate the terrain to determine what
accessories and attachments are needed to
properly and safely perform the job. 0nly use
accessories and attachments approved by
STANLEY.
2. Inspect the area where the equipment is to be
used and remove all objects such as rocks,
toys, and wire which can be thrown bythe
machine causing serious injury or death.
3. People, pets, and most importantly children
must not be near the area being mowed. Do
not operate the mower in their presence.
4. Never operate mower with damaged guards,
shields or covers.
5. All users of the mower must be alert and pay
attention to safety alerts, symbols, and safety
signs.
6. Be sure to inspect mower before each use.
7. Always use roll bar when possible and never
remove or modify the roll bar in any way or
form.
8. Check the controls and shields to make sure
that they are functioning properly before
operating. Do not operate if any are damaged
or missing.
9. Never operate with discharge deflector raised,
removed or altered, unless a grass catcher is
being used.
10. Install, and maintain in working order, a spark
arrester before using equipment on forest-
covered, grass-covered, or brush-covered
unimproved land.
Gasoline and other fuels--Safety Precautions
Use extra care when handling gasoline and other
fuels as they are flammable and vapors can explode.
1. Only use gasoline approved containers for storage
and keep out of reach from children.
2. Do not fill fuel tank completely full. Overfilling may
result in fuel leakage. Leave a reasonable amount
of space for fuel to expand.
3. If fuel is spilled, do not startthe engine. Movethe
mower away from the area, wipe up the spill
thoroughly and wait until fuel vapors have
evaporated before starting engine.
4. Do not fill gasoline containers inside a vehicle or on
a truck/trailer bed.
5. Never remove gas cap or add fuel when engine is
running.
6. Avoid prolonged breathing of gasoline vapors.
7. Never refuel or drain the machine indoors.
8. Keep face away from nozzle and gas tank opening.
9. Keep gas and other fuels away from skin and eyes.
10. Never use the mouth to siphon gas.
11. Never refuel the mower until all moving parts on the
mower have stopped.
12. Never smoke when handling fuels and stay away
from an open flame where fumes can be ignited by
a spark.
13. Always place gasoline containers on the ground
away from your vehicles prior to filling.
14. Gasoline is harmful or fatal if swallowed.
I
DANGER: GASOLINE IS HIGHLY FLAMMABLE AND
EXPLOSIVE. Do not add fuel while the engine is
running or is hot. Keep open flames, sparks, and heat
away from the fuel and store fuel in containers
specifically designed for that purpose. ADD FUEL
OUTDOORS ONLY. IF THE FUEL IS SPILLED, DO NOT
START THE ENGINE. Manually push the mower away
from the spill and wipe up immediately.
DANGER
Rev:JUN2011 STANLEY Finish Mower 2
Operation Safety Precautions 54ZS,62ZS
Equipment Operation--Safety Precautions
1. Do not operate the engine in a confined space
where dangerous carbon monoxide fumes can
collect. Carbon monoxide is odorless,
tasteless, and can be fatal.
2. Mow only in daylight or under good lighting
conditions.
3. Make sure the mower is in neutral, parking
brake is engaged, blades are disengaged, seat
belt on, roll bar is raised and the operator is
sitting in the proper position before attempting
to start the engine.
4. Never operate on wet grass.
5. Watch for pedestrian or vehicular traffic when
moving the mower while not in use (i.e.,
loading, unloading or transporting).
6. Never operate the mower with defective
guards or shields, or without the safety devices
securely mounted in place and functioning
properly.
7. Be aware of discharge and never direct
discharge of material toward bystanders nor
allow anyone, especially children, near the
mower during operation.
8. Do not change the governor settings or over
speed the engine.
9. Always stop the engine when you leave the
mower, even for a moment.
10. To help reduce fire hazard, keep the engine
and the area around the engine free of grass,
leaves or any other type of foreign material.
11. Beware of cutting edges. For safety always
wear gloves when performing blade
maintenance activities. Beware on multiple
blade units since the rotation of one blade may
cause the rotation of the other blade.
12. Do not operate the mower with the grass chute
deflector in the raised position. Serious injury
could occur.
13. If lightning is seen or thunder is heard in the
operators vicinity, do not operate machine.
Instead find shelter, as lightning may cause
injury/death.
14. Never raise the mower deck while the blades
are running.
15. Stop on a level ground, disengage drive,
engage parking brake, and shut off engine
before leaving operator's position for any
reason including clearing grass catcher or
unclogging the chute.
16. Stop the mower immediately and inspect blades
after striking objects or if an abnormal vibration
occurs and discontinue use until repaired.
17. Keep hands and feet away from cutting unit.
This product is capable of amputating hands
and feet and throwing objects.
18. Be alert and slow down when making turns.
Also look left, right, and behind before changing
directions and reversing to be sure there is a
clear path.
19. Disengage blades, slow down, and drive
cautiously when crossing roads and side walks.
20. Never operate mower under the influence of
alcohol and drugs.
21. Use care when loading or unloading the
machine into a trailer or truck.
22. Use care when approaching blind corners,
shrubs, trees, or other objects that may
obstruct vision.
23. Always disengage blades when not in use.
24. Never listen to music with headphones/
earphones while operating the mower.
Rev:JUN2011 STANLEY Finish Mower 3
Operation Safety Precautions 54ZS,62ZS
Slope Operation--Safety Precautions
1. Do not mow on slopes greater than 15degrees.
2. Be extremely careful when operating the
mower on a slope. Reduced traction could
cause sliding.
3. Do not stop or start suddenly when going
uphill.
4. Slow down and use caution when making turns
and when changing direction on slopes.
5. Do not operate a riding mower near steep
slopes, ditches, or water. Use a walk behind
mower or a hand trimmer for these areas.
6. Roll bar should be raised and locked with seat
belt bucked even before engine is turned on.
7. Should it be necessary to lower the roll bar,
seat belt should not be used.
8. If tires lose traction, disengage the blades and
drive slowly and cautiously off the slope.
9. Use extreme care with attachments as they can
change the stability of the mower and cause
loss of control.
10. Slow down and drive extra carefully on
hillsides. Be sure to drive in the recommended
direction on hillsides. Turf conditions can
affect the machine's stability.
11. The parking brake may not hold the mower if
parked on a slope.
f
;ER: Do not bypass, modify, alter or |
disconnect the safety system. Make sure that
the safety interlock system is fully operational
each time before mowing.
ure you are familiar with all of the
I Before attempting to use your mower, make |
omponents and have read the manual.
Before setting up your STANLEY mower,
disconnect the spark plug wires from the
spark plugs and ground them against the
engine to prevent inadvertent starting. This
step should be taken as a precaution
whenever you are working on this machine.
Need Help?
Parts, Service
and Technical Assistance call:
1-919-550-3259
www.gxioutdoorpower.com
Rev:JUN2011 STANLEY Finish Mower 4
54ZS,62ZS
The maximum slope angle you can safely operate your mower on is 15 degrees. Do not exceed 15degrees with your
mower.
1. Line upthe side of this page with avertical object to gauge the angle of the slope.
2. Fold this sheet along the dotted line and verify the slope is not in excess of 15degrees.
Rev:JUN2011 STANLEY Finish Mower 5
Safety Decals 54ZS,62ZS
Safety Decal Identification
The labels shown below are located on your mower to warn you of potential hazards and provide you with important
safety information. If these decals become difficult to read or are missing from the mower, please contact 6Xi Parts &
Service, LLC at 1-919-550-3259 or www.gxioutdoorpower.com for a replacement.
Rev:JUN2011 STANLEY Finish Mower 6
Product Specifications 54zs,62zs
Models
Feature 54ZS 62ZS
Product Type Commercial, 0-turn Commercial, 0-turn
Cutting Width 54-inch 62-inch
Engine See engine manufacturer's manual See engine manufacturer's manual
Engine Start Electric Electric
Transmission Type Dual hydrostatic Dual hydrostatic
Transmission Mfg Peerless Peerless
Mower Speeds Infinitely variable Infinitely variable
Deck Type Floating, quick change Floating, quick change
Cutting Height 1.5- 5 inches( ½-inch increments) 1.5- 5 inches( ½-inch increments)
Blade Engagement Manual clutch Manual clutch
Blade Tip Speed 18,750ft/min 18,750ft/min
Anti-Scalping Rollers 3 front/2 rear 3 front/2 rear
No. Blades/Length 3, 18.5-inch blades 3,21-inch blades
Control System Dual Control Lever Dual Control Lever
Fuel/Capacity Gasoline/7.5 gals. Gasoline/7.5 gals.
Rear Drive Tires 22-inch X 10-inch turf tread 22-inch X 10-inch turf tread
Front Caster Tires 15-inch X 6-inch smooth tread 15-inch X 6-inch smooth tread
Brake System Internal hydraulic and mechanical park Internal hydraulic and mechanical park
Weight Approx. 1,000 Ibs. Approx. 1,000 Ibs.
Height/Length 72 inches x 83 inches 72 inches x 83 inches
Note: product specifications may
change without notice.
Rev:JUN2011 STANLEY Finish Mower 7
Control Panel and Lawn Mower Components 54zs,62zs
Throughout this manual, instructions are given onthe operation of your STANLEY mower. We recommend that while
going through this manual, you have your mower available for quick and easy access in order to orient yourself with the
controls, maintenance and orientation of different parts. Please read through the manual before operating.
Control Panel
Below, youwill find a diagramof the control panel.Pleasetakethe time to familiarize yourself with the mower controls.
Key Switch
Choke
Lawn Mower Component Identification
(Somecomponentsmay appear different than shown, depending onthe model.)
Handle Bar (Steerin!
Lights
Hour meter
Roll Bar and Adjuster
Blade Control Lever
Hydro brake /
Seat Adjustor
Blade Height Leve
Pulley g
Side discharge chute .............................................................................................;:
Anti-scalping wheels
Handle bar height adjustment
Cup Holders
Control Panel
Headlights
Rev:JUN2011 STANLEY Finish Mower 8
Missing PartsRequestForm 54ZS,62ZS
Pleaseindicatethe part that youare missing:
[] Other
[] Dateofpurchase
Model#:
[] Serial#:
Comments:
Name
Address
Phone
Email
IMPORTANT:Please include your receipt. Without a receipt, your orderwill be
delayed. Youmay also email us at:
customerservice@gxioutdoorpower.com
Fax: 1-919-550-3277
If emailing, please scan in your proofof purchase.
Rev:JUN2011 STANLEY Finish Mower 9
Operating Instructions 54ZS,62ZS
Starting the Engine
i DANGER
DANGER: Exhaust contains poisonous carbon monoxide, a
colorless and odorless gas. Breathing exhaust can cause loss
of consciousness and may lead to death. Do not operate the
engine in a confined space where dangerous carbon
monoxide fumes can collect.
NOTE: Be sure to add fresh unleaded gasoline and fill the engine
to the proper level with manufacturers recommended motor oil
before starting your mower.
1. Make sure the shut off valve, located at the bottom of the
tank, is inthe ON position.
.
Make sure the brake is set and the 2 control handles are
spread open into their neutral position.
.
Make sure the blade control lever is inthe OFFposition.
4. Pull CHOKEand set the throttle to its mid-point.
5. Turn the key clockwise to the START position and allow it to
return to the ON position when the engine starts.
6. When the engine starts to run and the key returns to the ON
position, push CHOKEoff.
Rev:JUN2011 STANLEY Finish Mower 10
Operating Instructions 54ZS,62ZS
Operating the Mower
1. Make sure the brake has been moved to the OFF
Position.
2. Pull both control handles to the center.
.
To drive the mower forward, push both handle bars
forward away from the chest. The forward speed is
directly proportional to the degree these handles
are moved forward.
4. To turn the mower left, push to the right handle in
front of the left handle or the left handle more
towards the neutral position than the right handle.
5. To turn the mower right, perform the handle
movements described in step 4 above with except
with the opposite handle position.
6. To stop the forward motion of the mower, move
both the handles to the center/neutral position.
.
To drive the mower backwards, pull both handle
bars backwards toward the chest.
.
To turn backwards to the right or left, repeat the
steps in 4 or 5 above except in the opposite
direction.
.
To zero degree turn to the right, push the left handle
forwards and the right handle backwards.
10.
To zero degree turn to the left, push the right handle
forwards and the left handle backwards.
11.
When in the neutral position, the hydraulic system
prevents the mower from moving easily. However,
on a grade, the mower can move very slowly (with
the engine off or running). Be sure to set the
manual parking brake anytime the mower is left
unattended or is being transported.
12.
When the handles are in the middle position they
can be pushed away from each other to lock the
mower in the neutral.
Rev:JUN2011 STANLEY Finish Mower 11
Operating Instructions 54ZS,62ZS
Changing the Height of Cut
Your mower is equipped with an easily
adjustable floating deck, which can be
adjusted for cut heights of 1½inches to 5
inches in ½-inch increments. The deck
height adjuster is located onthe right side of
the mower.
How to Change the Cut Height
1. Extend the blade control lever by
it up.
2. Pullthe lever outtothe leftto shiftthe
deck up or down to the desired height.
3. When desired height is chosen Iockthe
deck by pushing the handle back into
the lock position.
4. After deck height is changed the lever
should be pushed back down to its
original position.
Mowing
WARNING
I
WARNING! Thoroughly inspect the area
where you plan to use the mower. Look for
items such as stones, sticks, wire, and
other foreign objects. If struck by the
mower, these and other objects may
become projectiles that could lead to
serious injury or death. Clear area of all
debris.
Keep people and pets at a safe distance.
I
WARNING! Do not operate the mower
with defective guards, shields, or without
the safety devices securely in place.
WARNING
I
Note: After mowing, remember to pull the
deckto its highest position to avoid scraping
and any other kind of damage to the blades
or deck.
1. When the mower is in position on the
area to be mowed, move the throttle
to its full speed.
2. SLOWLY push the blade control lever
forward to the ON position.
,
Begin mowing as described on the
previous page, always using safe/
comfortable speeds.
%
4.
To stop the blades, pull the blade
control lever backto the OFFposition.
Rev:JUN2011 STANLEY Finish Mower 12
Operating Instructions 54ZS,62ZS
Disengaging Hydrostatic Drive Units
Before physically moving the mower when the engine is
NOT running, the hydrostatic drive units need to be
disengaged into free-wheel mode.
To disengage these hydro units:
1. Unscrew both of the bolts that keep in the hydro
system.
Return to Neutral
DANGER I
DANGER! Make certain the engine comes to a
complete stop before putting you hands in the
access panel.
If the mower creeps or will not stop as desired when
the handles are in neutral position, adjustments are
necessary.
CAUTION: Be sure the engine is OFF before you
open the hydro access panel.
1. Remove the bolts to access
hydro panel.
.
Using an 8 mmwrench, reach
through the bottom of the
hydro panel to the return-to-
neutral set pin bolts. Loosen
bolts on the side that needs adjusting.
.
If necessary bump the bottom part of the mower with
a tool lightly where the hydro systems are located to
ensure the system is disengaged
CAUTION! Never bump, hit or push the actual hydros.
To return to operation mode:
1. Place the bolts back in place onthe back of the
mower.
2. Screwthem backto how they were originally.
.
Be sure the brake is in the OFFposition. In a safe
operator position, start the engine.
.
With the engine running, slowly move the handle
on the side needing adjustment until that side
comes to a complete stop. If the mower creeps
forward, pull handle in
reverse, If the mower creeps
backward, pull the handle
forward.
.
When the mower stops
moving completely the hydro
is in the neutral position.
6. Turn off the engine.
7. Slowly tighten the bolts without moving the plate.
8. With the bolts tightened, move to a safe operator
position and start the engine.
9. Ifthe creep has returned, repeatthe process.
Multiple iterations may be required.
Rev:JUN2011 STANLEY Finish Mower 13
54ZS,62ZS
The Importance of Maintenance
Regular maintenance is essential to ensure your
mower continues to deliver safe and high-quality
performance.
To help you properly care for your mower, the following
pages include a recommended maintenance schedule,
routine inspection procedures, and simple
maintenance procedures using basic hand tools.
Maintenance is the responsibility of the owner and
must be performed regularly. More difficult service
tasks or tasks that require special tools are best
handled by a recommended service technician or other
qualified mechanic.
The maintenance schedule described on page 14
applies to mowers used under normal operating
conditions. If you operate your mower under severe
conditions, such as sustained prolonged use or high-
temperature operations, or use it in unusually wet,
dusty or rocky conditions, consult your servicing dealer
for recommendations applicable to your individual
needs and use.
Be sure to use genuine STANLEY mower replacement
parts when servicing your mower to assure the best
quality, safety and performance.
Need Help? Parts, Service and Technical Assistance
Call: 1-919-550-3259 orwww.gxioutdoorpower.com
I
CAUTION! Before making any adjustments and/or servicing to
your STANLEY mower, make sure the mower is on a level
surface, with the ignition switch off, the key removed, the brake
set, and the blades disengaged. Also, disconnect the spark plug
wires from the spark plugs and ground them against the engine
to prevent inadvertent starting.
If you are performing adjustments or maintenance after
operating the mower, allow the unit to cool and always wear
protective clothing.
Tire Pressure
Incorrect tire pressure may cause the mower to pull to one side
and/or result in uneven cut. Use caution when filling the tires.
NEVER exceed the recommended maximum tire pressure as
stated on the tires.
Air Filter
Refer to the Engine Owner's Manual for the recommended
maintenance.
Engine Oil
CHECKENGINE 01L BEFOREEACHUSE. Refer to the Engine
Owner's Manual for the type of oil to use, oil change intervals,
CAUTION
I
I DANGER
Fuel
DANGER: Gasoline is highly flammable and
explosive. Do not add fuel while the engine is
running or is hot. Keep open flames, sparks, and
heat away from the fuel and store fuel in containers
specifically designed for that purpose. Add fuel
outdoors only and if the fuel is spilled, do not start
the engine. Manually push the mower away from the
spill and wipe up immediately.
Refer to the Engine Owner's Manual for the type of fuel
to use.
Afuel shut off valve is located on the bottom of the fuel
tank. It is recommended that the fuel be shut off when
transporting between job sites and when storing the
mower for extended periods of time.
Rev:JUN2011 STANLEY Finish Mower 14
Blades
Inspect blades on a daily basis for nicks, bends, and excessive
wear. If the blades are worn, cracked, bent, or damaged,
replace them before using the mower. Choose genuine
STANLEY mower replacement blades to ensure quality and
performance. (See page 16 for blade removal instructions.)
When sharpening the blades, sharpen only the cutting edges
and tryto maintain the original angle of the blade. Do not make
the cutting edge razor sharp. Remove the same amount from
each side ofthe blade so that balance in maintained.
I
CAUTION: Always wear work gloves when performing
blade maintenance and beware of the cutting edges.
Be sure the engine is off, the key removed, and the
spark plug wires are disconnected from the spark
plugs to prevent inadvertent starting.
CAUTION
item
Procedure
Maintenance Schedule 54ZS,62ZS
Break-in Every 8 hrs Every 40 hrs Every 100 hrs Every 200 hrs
first 5 hrs) (daily) (weekly) (Bi-weekly) (monthly)
Belts
Blades
Engine Air Filter
Engine Cooling Areas
Engine Oil
Engine Oil Filter
Engine Spark Plug
Inspect (adjust if
needed)
Inspect and/or
Sharpen
Inspect (see Engine
Owner's Manual)
Clean (see Engine
Owner's Manual)
Check (see Engine
Owner's Manual)
Change (see Engine
Owner's Manual)
Change (see Engine
Owner's Manual)
Inspect (see Engine
Owner's Manual)
Fuel Filter
Fuel Line
Grease Fittings
Hardware
Mower Main Frame
Safety Interlock System
Tires
Spindle/Blade Brakes
Replace
Check
Refer to page 19
Check for proper
tightness
Remove debris from
under belt cover
Check Operations
and Switches
Check Air Pressure
Rev:JUN2011 STANLEY Finish Mower 15
62ZS
31HP FX850V Kawasaki V-Twin Engine
Service Adjustments 54ZS,62ZS
Air Filter Location
Battery
Fuel Filter Location
54ZS
16HP GXV530
Fuel Fill Location
Valve Location
Honda V-Twin Engine
Fuel Fill Location
Battery
Fuel Valve Location
Air Filter Location
Filter Location
Rev:JUN2011 STANLEY Finish Mower 16
Deck Belt Tension
It is recommended to check and adjust if necessary the
deck belt tension after the initial 5 hours of use on the hour
meter. The new belt will seat into pulley grooves and may
need adjusting. After the initial break in period, it is
recommended to inspect belt tension and adjust if
necessary every 8 hours. Follow the steps below to inspect
belt tension. Follow ALL safety precautions mentioned in
this manual when doing any maintenance on your mower.
Note: Failure to inspect and adjust the deck belt tension
can result in poor mowing performance and pre-mature
belt wear.
Figure 1
Figure 1:
• Ensure the blade engagement handle is
in the "OFF" position.
• Open the floorboard and locate the
idle/clutch pulley(I) and turnbuckle(2).
• Set your deck heightto its LOWEST
setting (1.5 inches)
I
54ZS,62ZS
DANGER
ure 2
Figure 2:
• Check the clutch linkage pre-load.
• If the spring and linkage assembly
(3 & 4) is too tight, the clutch will not
contact the return stop bolt (5). The
clutch pivot arm (2) should stop within
a 1/4" of the stop bolt (5).
• If the spring and linkage assembly is
too loose, the spring will contact the
deck surface, or have more than 2" of
vertical movement between the linkage
(3) and the spring(4).
• To adjustthe pre-load, remove the cot-
ter pin and slide the linkage off the
arm(6). Thead the linkage pivot in or out
to set pre-load as stated above.
Rev:JUN2011 STANLEY Finish Mower 17
Deck Belt Tension
It is recommended to check and adjust if necessary the
deck belt tension after the initial 5 hours of use on the hour
meter. The new belt will seat into pulley grooves and may
need adjusting. After the initial break in period, it is
recommended to inspect belt tension and adjust if
necessary every 8 hours. Follow the steps below to inspect
belt tension. Follow ALL safety precautions mentioned in
this manual when doing any maintenance on your mower.
Note: Failure to inspect and adjust the deck belt tension
can result in poor mowing performance and pre-mature
belt wear.
ure 3
Figure 3:
Move the blade engagement handle to
the "ON" position.
Using your hand, press the clutch pulley
(7) inthe direction indicated with about
20-251bsof pressure. Ensure that the
swing arm(8) stops within 1 inch to 1.5
inches from the stop bolt(9).
I
54ZS,62ZS
DANGER
Figure 4:
• If the swing arm reaches the stop bolt
(9),the tension is too loose. Move the
blade engagement handle to the "OFF"
position. Loosen the turn-buckle Iocknut
(10). Adjust the turnbuckle linkage(11),
extending the pulley. Move the blade
engagement handle back to the "ON"
position and repeat test by applying 20-
25 Ibs of pressure and checkthe stop
bolt clearance. The swing arm should be
1" - 1.5" away from the stop bolt.
• Iftheswing arm hasa clearance
greater than 1.5" the tension is too tight.
This may result in pre-mature belt wear,
as well excess stress on the springs of
the clutch. Adjust the turnbuckle as
mentioned above.
Figure 4
Rev:JUN2011 STANLEY Finish Mower 18
54ZS,62ZS
Deck Belt
It is recommended to do a quick visual inspection of the
deck belt retainers atthe same interval as inspecting the
deck belt tension. This check should be performed every 8
hours. The engine pulley retainer should be inspected
when replacing the deck belt, or if the belt is slipping off
the engine pulley.
Figure 1
Verifying Deck Belt Retainers
Figure 1 :
The 54ZS has 6 main deck retainers.
• 4 "J" shaped retainers (1, 2,3, 4)
• 2 idle pulley retainers (5,6)
• To adjust the retainers, loosen the top
nut slightly and rotate the retainer into
place. After adjusting hold the retainer
in place and tighten the nut.
I
DANGER
Figure 2:
The 62ZS has 8 main deck retainers.
• 6 "J" shaped retainers (1, 2,3, 4, 5, 6)
• 2 idle pulley retainers (7,8)
• To adjust the retainers, loosen the top
nut slightly and rotate the retainer into
place. After adjusting hold the retainer
in place and tighten the nut.
Deck Belt Routing
54ZS
• Serial#s beginning with 54ZS10XXX use
a MXV5 1430V Belt.
• Serial#s beginning with 54ZSllXXXuse
a MXV5 1480V Belt.
Figure 2
Figure 3
EnginePulley
Clutch Pulley
Idle Pulleys
62ZS
• Serial#s beginning with 62ZS10XXX use
a MXV5 1630V Belt.
• Serial#s beginning with 62ZSllXXXuse
a MXV5 1680V Belt
1die Pulleys
Rev:JUN2011 STANLEY Finish Mower 19
54ZS,62ZS
Deck Belt
Follow ALL safety precautions mentioned in this manual
when doing any maintenance on your mower.
The clearances for the retainers are listed below, and
measured with the blades engaged and engine OFF.
Verifying Deck Belt Retainers
Figure 4:
The clearance for the "J" shaped re-
tainers is 3/16"
To adjust the retainers, loosen the top
nut slightly and rotate into position. Hold
the retainer in place while tightening the
bolt.
Figure 4
I
DANGER
Figure 5:
The clearance for the idle pulley retain-
ers is 1/8"
To adjust the idle pulley retainers,
loosen the nut on the top of the pulley
and bottom slightly. Slide the retainer
into place and tighten the nuts back.
Figure 5
Rev:JUN2011 STANLEY Finish Mower 20
54ZS,62ZS
Spindle Brake Inspection and Replacement
Blade and pulley brake inspections should be
performed every 50 blade on and off cycles.
Before beginning service, park the Z-BEAST on a level
surface, turn the blades off, turn the engine off, set the
brake, take the key out of the switch, wait an adequate
time to make certain no blades are turning, and remove
spark plug wires from spark plugs.
1. Engage the blade handle (make certain the engine
cannot start) to pull the brakes off of the pulleys.
2. Remove the pulley guard from the deck.
3. Visually inspect the brake pads for wear. Make
certain that no metal is touching the pulleys.
9. Disengage the blade handle and inspect the brake
contact surface. All of the brake pad contacting material
should be contacting the bottom of the pulley.
Note: Springs may vary from those pictured based on the
particular application.
Removingthe Blades
Requiredtools: Two (2)15/16"box endwrenches
J CAUTION
CAUTION!Beware ofthecuttingedgesonthe blades.
The rotationofoneblademaycausetheotherblade(s)to
rotate.Always wear work gloveswhen handlingblades.
1. Park the mower on level ground, set the brake and block
the rear wheels to prevent accidental rollback.
2. Raise the front end of the mower and place on a jack
stand.
3. Use one wrench to loosen nutAwhile holding bolt B
with the other wrench. (See adjacent photo.)
.
Slide the blade bolt down through the mower deck and
.
The brake pad material should be approximately 1/8-
inch thick. Replace the brakes if the material is less
than 1/16-inch thick.
Note: Replacing all brake pads is recommended if
replacement of one brake is required.
out.
5.
To reinstall, insert the blade bolt through the cutting
deck.
6.
Install the blade spacers that were removed, back onto
the blade bolt followed by the nut and tighten. (See
figure below.)
IMPORTANT: The number of spacers should always be
5. To replace the brake, use a pair of pliers to remove
the springs.
6. Remove the two mounting bolts and
the same on each blade bolt. NEVERput the spacers
below the blade and NEVER straighten or weld the
blades.
disconnect the spring from the cable.
7. Discard all of these parts. DONOT reuse springs.
New brakes are equipped with new springs for
proper braking.
8. Install the new brakes by reversing the procedure in
steps5 and 6.
Rev:JUN2011 STANLEY Finish Mower 21
Engine-to-Hydrostatic Drives Belt
Adjustment (Hydro Input Belt)
• The hydro input belt is located
underneath the chassis atthe rear
of the mower. The belt should move
approximately 1/8 to 3/16-inch with
three (3) to five (5) pounds of
pressure applied to the belt midway
between the hydrostatic drive
pulleys when initially installed. After
approximately 1 hour of running
time, verify that the belt tension is
still correct and tighten if necessary
Service Adjustments 54ZS,62ZS
Important:Donot over-tightenthe
belt.
• To adjust the belt, turn the nut on
the threaded tension rod found on
the right, rear corner of the mower.
• Do not over-tighten. This could
cause damage to the hydraulic drive
systems.
• The hydro input belt is an 8PK 1690
multi ribbed v belt.
View from above
En_e Pul-
Pul-
Rear of
Hydro input belt diagram
Rev:JUN2011 STANLEY Finish Mower 22
54ZS,62ZS
Hydro System Adjustment
The hydrostatic drives are coupled to the output drives with a multi-v belt. Occasional re-tensioning of the belt may
be necessary. If performance decreases or hydro control handles are activated and the wheels do not turn, inspect
the multi-v belt. Before beginning the following test, read all warnings in this manual. If you are uncomfortable
with this procedure please contact GXi to be set up for service.
1. Adjust the hydro adjustment bolts by tightening the two large 21mm nuts on the rear of the mower. Tighten the
final drive belt so there is approximately 3/4" belt deflection in the center of the belt with about 101bsof pressure
applied.
The next step is to perform a "wall test." Drive the mower against a padded
stationary object. For accurate results, a smooth brushed concrete surface
works best. Stand next to the mower with one hand on the seat. Start the
mower with one hand on the seat to engage the safety switch. Engage the
left side handle into drive position. Quickly move the handle to full forward
position for about half a second. Now perform the same procedure on the
right side. If the belt squeals and the wheel does not spin on either side,
tighten the hydro adjustment bolt a half turn on each side at the same time.
Repeat the test until both tires will break traction and spin.
Once you have the tension set so each wheel will just barely break traction,
mark the bolt on one side of the hex head as shown. Now loosen the bolt
(turn counter-clockwise) half of a rotation, so the mark is now on the other
side. This will set tension so the belt does not squeal, and provides ample
torque for driving and mowing without causing belt or hydro damage.
Now drive the mower on a grassy surface. Perform several Zero Turns. Drive the unit aggressively. If the perform-
ance is "sloppy" or you have excessive belt chirping, tighten the bolt 1/6th of a rotation and re-test. Re-Install the
hydro retainer clips after adjustments.
If the mower is too nimble, or you want to reduce the power output to prevent damage to the turf, loosen the bolt
1/6th of a rotation and re-test. Occasional belt chirping is permitted. If the belt squeals excessively tighten 1/6th of a
rotation and re-test.
Rev:JUN2011 STANLEY Finish Mower 23
Safety SystemAdjustments
I
WARNING
I
Service Adjustments 54ZS,62ZS
Method 2: Adjust location using adjustment nuts on
switch body
WARNING: Do not bypass, modify, alter, or
disconnect the safety system. Make sure that the
safety interlock system is fully operational each time
before mowing. Failure to do so could present danger
to you and others around you.
There are generally three (3)ways to adjust the
sensitivity of a safety switch. The most appropriate way
to adjust each switch depends upon the application,
location, and the nature of the problem you are
encountering.
Method 1: Adjust location using the mounting screws
1. Move the blade control lever to OFF.
2. Loosen screws (A) until safety switch (B) moves
freely.
3. Slide safety switch (B)firmly against blade bell
crank (C).
1. Loosen locking nut(C) on the sensor shaft.
2. Adjust switch location by turning the nuts.
3. Tighten the locking nut when proper adjustment is
achieved.
Method 3: Relocate mounting holes
In rare cases where the components become
misaligned, the easiest means of adjusting the location is
to elongate the existing holes or add new holes to
achieve a tighter fit between the activation rod and the
sensor.
4. Tighten screws (A) and check that safety switch (B)
does not move.
Rev:JUN2011 STANLEY Finish Mower 24
Lubrication Points 54zs,62zs
To ensure proper lubrication of moving parts, GXi recommends that you lubricate the following components with ahigh-
quality, EP2 high-temperature-based grease or equivalent. Should the conditions of operation be more severe than
normal, the lubrication interval may need to be shortened. GTR/0PE grease is the recommended lubricant.
Lubrication Point Locations
54-inch & 62-inch mowers have mowers have 10lubrication
points.
Lubricate after every 50 hours of usage
1. Front wheels (2 locations, 1 on each
wheel shaft)
2. Spindles (3 locations on 54-inch & 62-inch mower
decks).
Note: The lower spindle bearing is sealed on the
bottom and open on the top. The upper spindle
bearing is sealed on both sides. Failure to frequently
replenish grease will cause premature lower
bearing failure. Frequent application of grease to
this bearing is critical to achieving long spindle life
in harsh duty environments.
3. Mower deck clutch pulley pivot
Changing Battery
When disconnecting the battery make sure to
disconnect the negative terminal first and the positive
last. When reconnecting, connect the positive first
and the negative last.
Charging Battery
Always charge battery in an open well ventilated area,
away from sparks and flames. Unplug charger before con-
necting or disconnecting from battery and always wear pro-
tective clothing and use insulated tools.
I
DANGER: Battery electrolyte has sulfuric acid
which can cause severe burns and is a deadly
poison. Never drink and always avoid contact by
wearing gloves and safety glasses when servicing
the battery.
I
WARNING: Do not allow battery terminals to
touch any metal parts of the mower when remov-
ing the battery. Never allow metal tools to short
between the battery terminals and metal parts of
the mower as this may cause sparks. Sparks can
also cause the battery gasses to explode which
can result in injury/death.
DANGER
WARNING
I
I
Rev:JUN2011 STANLEY Finish Mower 25
Storage Instructions 54zs,62zs
Short Term Storage
• Let engine cool before storing and do not store
near flame, high heat, and possible ignitions from
sparks.
• Always clean off all flammable material as well as
grime and dirt before storage.
• Never use a pressure washer and avoid drenching
the control panel, motor, engine, and hydro pumps
with water.
• Wash with mild detergent and water only.
• After washing the machine engage the engine at
high and let the mower run for 5 minutes.
• Shut offfuel for storing or transporting.
• Carefully release pressure from components with
stored energy.
• Store mower only on the ground.
• Do not drain fuel indoors or near a flame.
• Use jack stands to support components when
required.
• Always park machine on level ground and setthe
parking brake when storing.
• Store the machine in a clean and dry environment.
• Always remove the key from the ignition.
• Add a petroleum based conditioner in the gas tank
and run for 5 minutes to distribute through mower.
Extended Storage
• Change air filter.
• Make sure all fuel is drained before storing.
• To ensure all fuel is drained from the mower, run
the mower until it runs out of gas before storage.
• Check the spark plugs condition and pour two
tablespoons of engine oil in the spark plug holes
and leave the spark plugs off.
• Cover the machine when in storage.
• Remove Battery and clean terminals and cable
connectors. Store battery in a cool dry place.
• Everything mentioned in short term storage
should also be applied to extended storage.
Rev:JUN2011 STANLEY Finish Mower 26
Troubleshooting 54zs,62zs
Problem
Enginewill not start
Engine will not keep
running/quits
Possible Causes Solution
1. Key in the OFFposition
2. Insufficient fuel in the tank
3. Air bubble in the fuel line
4. Fuel valve in OFFposition
5. Choke not ON
6. Choke linkage out of adjustment
7. Low engine oil
8. Blade control in ON position
9. Loose spark plug wire
10. Fouled spark plug
11. Plugged or dirty air filter
12. Bad gasoline
13. Plugged or dirtyfuel filter
14. Safety switches out of
alignment or loose
15. Dead battery (electric start
models)
1. Water in the fuel
2. Loose safety switch
3. Fuel valve is OFF
4. Dirty fuel filter
5. Dirty air filter
6. Low engine oil
1. Turn keyto ON position
2. Add gasoline
3. Prime engine or shake bubble out
4. Turn valve ON
5. Turn choke ON
6. Referto Engine Owner's Manual
7. Add engine oil
8. Push lever to OFFposition
9. Tighten wire or connections
10. Clean or replace the plug
11. Clean or replace the air filter
12. Brain and replace with fresh gasoline
13. Replace the fuel filter
14. Adjust or tighten switches (p. 18)- read warnings!
15. Recharge or replace battery
1. Drain and replace with fresh fuel
2. Adjust switch (p. 18)
3. Turn fuel valve ON
4. Replace fuel filter
5. Clean or replace air filter
6. Add engine oil
Engine stops when blades
are engaged
Blades do not turn 1. Broken belt
Belts squeal when blades 1. Incorrectbelttension
are engaged 2. Excessive belt wear
Belts slip when blades are 1. Incorrectbelttension
engaged 2. Excessive belt wear
1. Loose safety switch
2. Belt tension too high
3. Blades jammed with foreign
material
2. Loose belt
3. Blade activation linkage out of
adjustment.
1. Adjust switch (p. 18)
2. Adjust belt (p. 15)
3. Remove foreign material
Note: Firmly pushing the blade control lever into the
OFFposition to ensure the safety switch is fully
engaged can sometimes resolve this problem.
1. Replace belt
2. Adjust belt (p. 15)
3. Adjust linkage (p. 16)
1. Adjust belt tension
2. Replace belt
1. Adjust belt tension
2. Replace belt
Rev:JUN2011 STANLEY Finish Mower 27
Troubleshooting 54zs,62zs
Problem Possible Causes Solution
Mower will not move 1. Brake ON 1. Release brake on control panel
forward or reverse 2. Bypass levers pulled out 2. Ensure bypass pins are retracted
Cannot move mower 1. Bypass not engaged 1. Pull left and right bypass pins and set them in slots
when the engine is off in the chassis (p. 12)
Engine is overheating 1. Dirt in the fuel line 1. Replace fuel filter and flush tank
2. Dirty air filter 2. Clean or replace the air filter
3. Low engine oil 3. Add engine oil
4. Fouled spark plug 4. Replace spark plug
5. Misuse of the mower 5. Mowslower, wait for grass to dry out
6. Dull blades 6. Sharpen cutting blades
7. Spindle bearing failure 7. Take in for service
Grass not cut smoothly or
cleanly
Mower always pulls to
one side
1. Dull blades
2. Mowing too fast for conditions
3. Grass is wet or bent over
4. Blade is bent
5. Tire pressure not equal
6. Deck is set at uneven heights
7. Blades are set upside down
8. Excessive grass and debris
build up underneath the deck
1. Controls out of adjustment
2. Transmission failure
1. Sharpen blades
2. Slow down while cutting
3. Let grass dry to stand up
4. Replace blade
5. Add air pressure tolowtires
6. Set deck at equal heights
7. Take blades off and install correctly
8. Clean out debris
1. Adjust controls (p. 12)
2. Take in for service
Rev:JUN2011 STANLEY Finish Mower 28
Limited Warranty & Service 54ZS,62ZS
Length of Warranty: *(from the date of original retail purchase)
Products Covered by this
Warranty
Engine
Transmission
Mower frame
Belts,Tires, Battery
Attachments
*LENGTHOFWARRANTY:Batteries suppliedwith applicable products as standard, original equipment arecovered bythis warranty
for a periodof 90days fromthe date of original retail product purchase. Consumableparts such as oil,spark plugs,filters, and
blades are not covered bythis warranty.
To QualifyforthisWarranty
Theproduct must bepurchased inthe UnitedStatesfrom a dealerauthorized by GXiOutdoorPower, LLCto sell those products. This
warranty applies to first retail purchaser/owner during the applicable warranty time period. SAVEYOURPROOFOFPURCHASE
RECEIPT.
What GXi Outdoor Power Will Repair or Replace under Warranty
GXiwill repair or replace, at its option, any partthat is provento bedefective in material or workmanship under normal use during
the applicable warranty time period subject to the exclusions stated herein. Thiswarranty is void if the owner failsto follow the
prescribed maintenance andoperating procedures described in this manual.This specifically refersto ensuring routine lubrications
and oil changes are made,that fuel stabilizer is usedwhen the product is stored andthat the product is not overloaded.
Residential
Manufacturer's warranty Manufacturer's warranty Manufacturer's warranty
Manufacturer's warranty Manufacturer's warranty Manufacturer's warranty
Lifetime (original owner only) Lifetime (original owner only) 90days
90days 90days 90days
1yr limited 1yr limited 30day limited
Commercial Rental
GXihasthe rightto recover warranty administration costsfrom the owner ifthe root cause ofthe malfunction isfound to be other
than defective material or workmanship. In particular, this warranty does not cover: contaminants inthe fuel oroil; damage caused
by notfollowing the prescribed warnings and operating practices; failure to follow proper maintenance andstorage procedures; and
physical damage dueto misuse, shipping,handling or storage.
Warranty repairs will be madewithout charge for parts and laborfor the first year.
Anything replaced underwarranty becomes the property of GXi. Parts replaced underwarranty will be considered aspart of the
original product andany warranty onthose parts will expire coincident with the original product warranty.
To Obtain Warranty Service
Youmusttake the STANLEYproduct, accessory, replacement part, apparel orthe power equipment onwhich the accessory or
replacement part is installed, and proof of purchase,at your expense,to any STANLEYservice location in the UnitedStates,who is
authorized to service that product, during the service location's normal business hours. If you are unableto obtain warranty service,
or aredissatisfied with the warranty service you receive,take the following steps: First,contact the manager ofthe service center
involved; normallythis will resolve the problem. However, if you should require further assistance, write or call the GXiParts&
Service, LLC1-919-550-3259.
Exclusions
Thiswarranty does not cover: normalwear, contaminants inthe fuelor oil; damageas aresult of use in anapplication for which the
product was not designed; damage caused by incorporation or useof unsuitable attachments or parts, unauthorizedalteration, or
other misuse and neglector; damagecaused byfailure to follow the prescribed warnings, operating practices, proper maintenance
and storage procedures; parts affected or damaged byaccident and/or collision; damagedueto shipping, handling,storage or any
causes other than defects inmaterial or workmanship ofthe product.
Disclaimer of Consequential Damage and Limitation of Implied Warranties
GXidisclaims any responsibility for lossoftime or use ofthe product,transportation,commercialloss,oranyotherincidentalor
consequentialdamage.Any impliedwarrantiesarelimitedtotheduration ofthiswritten limitedwarranty.
THISWARRANTYISVOIDIFTHEMANUFACTURINGDATEAND THESERIALNUMBERONTHEEQUIPMENTHAS BEENREMOVED
ORTHEEQUIPMENTHASBEENMODIFIED.
Rev:JUN2011 STANLEY Finish Mower 29
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