Form No. 3445-180 Rev A Z Master® Professional 7500-D Series Riding Mower With 144in TURBO FORCE® Rear Discharge Mower Model No. 72144—Serial No. 400000000 and Up Register at www.Toro.com.
Introduction It is a violation of California Public Resource Code Section 4442 or 4443 to use or operate the engine on any forest-covered, brush-covered, or grass-covered land unless the engine is equipped with a spark arrester, as defined in Section 4442, maintained in effective working order or the engine is constructed, equipped, and maintained for the prevention of fire. This rotary-blade, riding lawn mower is intended to be used by professional, hired operators.
The safety-alert symbol (Figure 2) appears both in this manual and on the machine to identify important safety messages that you must follow to avoid accidents. This symbol will appear with the word Danger, Warning, or Caution. • Danger indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. • Warning indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Contents Draining the Fuel Filter/Water Separator ........... 48 Replacing the Water Separator ........................ 49 Checking the Fuel Lines and Connections.................................................. 49 Electrical System Maintenance ........................... 50 Electrical System Safety ................................... 50 Servicing the Battery......................................... 50 Servicing the Fuses .......................................... 52 Drive System Maintenance .............
Safety This machine has been designed in accordance with ANSI standard B71.4-2017. General Safety This product is capable of amputating hands and feet and of throwing objects. Always follow all safety instructions to avoid serious personal injury or death. • Read and understand the contents of this Operator’s Manual before starting the engine. • Keep bystanders and children away. • Do not allow children or untrained people to operate or service the machine.
Slope Indicator g011841 Figure 3 You may copy this page for personal use. 1. The maximum slope you can operate the machine on is 15 degrees. Use the slope chart to determine the degree of slope of hills before operating. Do not operate this machine on a slope greater than 15 degrees. Fold along the appropriate line to match the recommended slope. 2. Align this edge with a vertical surface, a tree, building, fence pole, etc. 3.
Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or missing. decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery. 1. Explosion hazard 6. Keep bystanders away from the battery. 2. No fire, open flame, or smoking 7. Wear eye protection; explosive gases can cause blindness and other injuries. 3. Caustic liquid/chemical burn hazard 4.
decal117-3276 117-3276 decal109-6036 109-6036 Rear Discharge Machines Only 1. Engine coolant under pressure 3. Warning—do not touch the hot surface. 2. Explosion hazard—read the Operator's Manual. 4. Warning—read the Operator's Manual. 1. Read the Operator’s Manual. 2. Remove the key and read the instructions before servicing or performing maintenance. 3. Height of cut decal112-9028 112-9028 1. Warning—stay away from moving parts; keep all guards and shields in place.
decal126-8383 126-8383 Note: This machine complies with the industry standard stability test in the static lateral and longitudinal tests with the maximum recommended slope indicated on the decal. Review the instructions for operating the machine on slopes in the Operator’s Manual as well as the conditions in which you would operate the machine to determine whether you can operate the machine in the conditions on that day and at that site.
decal135-0670 135-0670 1. Crushing hazard, hand—read the instructions before servicing or performing maintenance. decal135-1432 135-1432 2. Warning—lock the deck wings and read the instructions before servicing or performing maintenance. decal135-0679 135-0679 decal135-0664 135-0664 1. Thrown object hazard—keep bystanders away. 1. Rotating driveline hazard/entanglement hazard; belt—stay away from moving parts; keep all guards and shields in place. 2.
decal142-3903 142-3903 1. Front of the mower deck decal142-3953 142-3953 1. Machine speed 4. Neutral 2. Fast 3. Slow 5. Reverse 6. Parking brake—engaged decal142-3952 142-3952 1. Machine speed 4. Neutral 2. Fast 3. Slow 5. Reverse 6. Parking brake—engaged decal142-3956 142-3956 1. Engine—Off 5. Raise the center deck and wings 2. Engine—On 6. High range 3. Engine—Start 7. Transmission 4. Lower the center deck and 8.
decal142-6728 142-6728 1. Chassis (15 A) 4. Power port (15 A) 2. Accessory (15 A) 5. Fan, photo relay 3. Main (25 A) decal142-7835 142-7835 1. Read the instructions before servicing or performing maintenance. 2. Time interval 9. Check the air cleaner 10. Grease the idler pivots; refer to the Operator's Manual for further instructions (3 locations) 3. Check the engine-oil level. 11. Grease the front caster wheel bearings; refer to the Operator's Manual for further instructions (4 locations) 4.
Product Overview g362295 Figure 4 1. Center deck height-of-cut pin 6. Audible alarm 11. Anti-scalp roller 2. Wing deck height-of-cut pin 7. Fuel gauge 12. Center deck 3. Motion-control lever 8. Fuel-tank cap 13. Machine caster wheel 4. Display monitor 9. Wing deck caster wheel 14. Mirror 5. Roll bar 10.
Controls Horizon Display Monitor Become familiar with all the controls before you start the engine and operate the machine. Refer to the Software Guide for detailed information explaining the operator interface that allows you to access information, reset counters, modify system settings, and troubleshoot the equipment. Control Panel g362360 Figure 5 1. Deck lift and wing deck fold/unfold switch 2. Key switch g362697 Figure 6 Horizon Display Monitor 4. High-Low speed range switch 5.
Blade-Control Switch (Power Takeoff) • Solid green—indicates normal operating activity • Blinking red—indicates an active fault • Blinking green and orange— indicates that a The blade-control switch (PTO) engages and disengages power to the mower blades (Figure 5). clutch reset is required Refer to the Software Guide for more information. Alarm The LCD indicator appears on the information screen when the PTO switch is disengaged.
Deck Lift and Wing Deck Fold/Unfold Switch Specifications Working width—368.1 cm (144-7/8 inches) Push the top of the switch (Figure 5) to raise the center deck and fold the wing decks. Push the bottom of the switch to lower the center deck and unfold the wing decks. Motion-Control Levers Overall width Transport width set at the 3-inches height of cut—211 cm (83 inches) Overall length 257.
Fuel Safety Operation • Fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property. Note: Determine the left and right sides of the machine from the normal operating position. – To prevent a static charge from igniting the fuel, remove the machine from the truck or trailer and refuel it on the ground, away from all vehicles.
Adding Fuel 5. Fill the fuel tank to the bottom of the filler neck (Figure 9). Note: Do not fill the fuel tank completely full. Recommended Fuel The empty space in the tank allows the fuel to expand. The engine runs on clean, fresh diesel fuel with a minimum cetane rating of 40. Purchase fuel in quantities that can be used within 30 days to ensure fuel freshness. Use summer-grade diesel fuel (No. 2-D) at temperatures above -7°C (20°F) and winter-grade diesel fuel (No. 1-D or No.
Using the Rollover Protection System (ROPS) WARNING To avoid injury or death from rollover, keep the roll bar in the fully raised, locked position and use the seat belt. Ensure that the seat is secured to the machine. WARNING There is no rollover protection when the roll bar is in the down position. g225804 Figure 10 • Lower the roll bar only when absolutely necessary. 1. Upper part of the roll bar 4. Rotate the knob out 90° to hold it in the unlatched position.
Adjusting the Mirrors While in the operating position, the mirrors should provide a wide-angle view to assist with blind spots. Adjust the left and right mirror to ensure that you have an optimal viewing angle. Using the Motion-Control Levers g004532 Figure 12 1. Motion-control levers—NEUTRAL-LOCK position 4. Reverse 2. Center, unlocked position 5. Front of the machine 3.
Checking the Safety-Interlock System Service Interval: Before each use or daily WARNING If the safety-interlock switches are disconnected or damaged, the machine could operate unexpectedly, causing personal injury. • Do not tamper with the interlock switches. • Check the operation of the interlock switches daily and replace any damaged switches before operating the machine. Note: If machine does not pass any of these tests, do not operate the machine. Contact an Authorized Service Dealer.
Checking the Engine-Starting Circuit Chart Note: In the Checking the Engine-Starting Circuit Chart, the state of system item that is in bold text is being checked in each scenario.
Checking the Shutdown-Circuit Chart Note: The state of the system items in bold text are being checked in each scenario.
Running idle (1/3 throttle or efficient mode) Both levers moved in, or right or left lever moved in = Parking Brake Disengaged Engaged and Deck wings up State of System 24 Operator in the seat PTO must begin shutdown within 1 second; engine stays running.
Positioning the Seat Changing the Seat Suspension The seat moves forward and backward. Position the seat where you have the best control of the machine and are most comfortable. The seat is adjustable to provide a smooth and comfortable ride. Position the seat where you are most comfortable. To adjust, move the lever sideways to unlock the seat (Figure 13). To adjust it, turn the knob in front either direction to provide the best comfort (Figure 15).
During Operation • Operate the engine only in well-ventilated areas. During Operation Safety • Never leave a running machine unattended. • Attach towed equipment to the machine only at Exhaust gases contain carbon monoxide, which is lethal if inhaled. the hitch point. General Safety • Do not operate the machine unless all guards • The owner/operator can prevent and is responsible and safety devices, such as the deflectors, are in place and functioning properly.
off and be seriously injured or prevent you from safely operating the machine. Children who have been given rides in the past could appear in the operating area without warning and be run over or backed over by the machine. Changes in the terrain, such as moisture, can quickly affect the operation of the machine on a slope. • Identify hazards at the base of the slope. Do not operate the machine near drop-offs, ditches, embankments, water, or other hazards.
Lowering the Wing Decks Important: You must unfold the wing decks before you can engage the PTO. 1. Remove the clevis pin and hairpin cotter that secures each wing in the upright position and place them in the storage position (Figure 18 and Figure 19). 1 g221745 Figure 17 1. Safe Zone—use the machine here on slopes less than 15° or flat areas. 2. Danger Zone—use a walk-behind mower and/or a hand trimmer on slopes greater than 15° and near drop-offs or water. 4. W = Width of the machine 5.
Operating the Mower Blade-Control Switch (PTO) The blade-control switch (PTO) starts and stops the mower blades and any powered attachments. 2 Engaging the Blade-Control Switch (PTO) 1 Note: Engaging the blade-control switch (PTO) with the throttle position at half or less causes excessive wear to the drive belts. g008945 Figure 20 g363150 Figure 19 1. Clevis pin 2. Hairpin 2. Ensure that all persons are clear of the deck wings. 3.
Starting the Engine Shutting Off the Engine Important: Do not engage the starter for more CAUTION than 5 seconds at a time. If the engine fails to start, wait 15 seconds between attempts. Failure to follow these instructions can burn out the starter motor. Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. Note: You may need multiple attempts to start the Always remove the key and engage the parking brake when leaving the machine unattended.
Raising and Locking the Wing Decks 1. Ensure that all persons are clear of the deck wings. 2. Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake. 3. Press and hold the top of the deck-control switch; the center deck will raise first, then the wing decks. 4. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 5.
Driving the Machine The drive wheels turn independently, powered by hydraulic motors on each axle. You can turn 1 side in reverse while you turn the other forward, causing the machine to spin rather than turn. This greatly improves the machine maneuverability but may require some time for you to adapt to how it moves. The throttle control regulates the engine speed as measured in rpm (revolutions per minute). Place the throttle control in the FAST position for best performance.
Adjusting the Height of Cut The cutting height of the mower deck can be adjusted from 2.54 cm to 14 cm (1 to 5-1/2 inches) in 6.4 mm (1/4 inch) increments. 1. 6. E. Lock the cam lock. F. Repeat for the other wing deck. If you desire additional height-of-cut range, adjust the front and rear gauge wheels on the wing deck as follows: Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake. A. Remove the mounting hardware from the gauge wheel. 2.
Adjusting the Anti-Scalp Rollers For maximum deck flotation, install the rollers 1 hole position lower. Rollers should maintain a 6 mm (1/4 inch) clearance to the ground. Do not adjust the rollers to support the deck. 1. Park the machine on a level surface. 2. Disengage the blade-control switch (PTO), move the motion-control levers to the NEUTRAL-LOCK position, and engage the parking brake. g243016 Figure 31 3.
Operating with the Overheat Sensor slows in mid summer, mow less frequently. If you cannot mow for an extended period, first mow at a high cutting height, then mow again 2 days later at a lower height setting. The PTO disengages, an alarm sounds, and a bar graph displays the engine temperature when it reaches an overheat condition. The PTO does not engage until the engine has cooled and you manually shut off the PTO and engage it.
Using the Drive Train Brake Release After Operation After Operation Safety The drive train brake releases are located on each of the wheel-motor gearboxes. General Safety Releasing the drive train brake allows you to push the machine without the engine running. • Engage the parking brake, shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operator’s position. Allow the machine to cool before servicing, adjusting, fueling, cleaning, or storing it. 1.
Using the Wing Deck Fold Release Valve 4. Secure the wing using the transport-lock pin. WARNING 5. The wing decks are very heavy. Lifting the wing decks by hand could result in serious injury or death. If the engine loses power, you can manually fold or unfold the wing decks. 1. Using lifting equipment with at least a 227 kg (500 lb) lifting capacity to hold the wing deck up, remove the transport-lock pin, and carefully lower the wing deck. 2.
Transporting the Machine Use a heavy-duty trailer or truck to transport the machine. Use a full-width ramp. Ensure that the trailer or truck has all the necessary brakes, lighting, and marking as required by law. Please carefully read all the safety instructions. Knowing this information could help you or bystanders avoid injury. Refer to your local ordinances for trailer and tie-down requirements.
1. If using a trailer, connect it to the towing vehicle and connect the safety chains. 2. If applicable, connect the trailer brakes and lights. 3. Lower the ramp, ensuring that the angle between the ramp and the ground does not exceed 15 degrees (Figure 35). 4. Back the machine up the ramp (Figure 36). g028043 Figure 36 1. Back the machine up the ramp. 2. Drive the machine forward down the ramp. 5. Shut off the engine, remove the key, and engage the parking brake. 6.
Maintenance • Check the parking brake operation frequently. Maintenance Safety • Never tamper with safety devices. Check their • If you leave the key in the switch, someone could • Clean grass and debris from the cutting unit, • • • • Adjust and service it as required. proper operation regularly. accidently start the engine and seriously injure you or other bystanders. Remove the key from the switch before you perform any maintenance.
Maintenance Service Interval Maintenance Procedure • • • • Every 400 hours • • • • • • Grease the deck-idler pivots. Grease the caster pivots (more often in dirty or dusty conditions). Service the air cleaner (More frequently in extremely dusty or dirty conditions). Change the engine oil and filter if using Toro Premium Engine Oil (API classification CK-4 or higher) more often in dirty and dusty conditions.
Lubrication Greasing the Machine Service Interval: Every 400 hours/Yearly (whichever comes first)—Grease the deck-idler pivots. Yearly—Grease the deck drive PTO. Grease more frequently when operating conditions are extremely dusty or sandy. Grease Type: No. 2 lithium or molybdenum grease 1. Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake. 2.
Lubricating the Drive U-Joints and Splined Slip Joint Greasing the Caster Pivots Service Interval: Every 400 hours/Yearly (whichever comes first) (more often in dirty or dusty conditions). Yearly—Repack the caster-wheel bearings (more often in dirty or dusty conditions). Service Interval: Every 50 hours—Grease the drive U-joints and splined slip joint. Note: For easier access to the drive U-joints and 1.
Greasing the Caster-Wheel Hubs 13. With the open end of the wheel facing up, fill the area inside the wheel around the axle full of general-purpose grease. Service Interval: Yearly 14. Insert the second bearing and new seal into the wheel. 1. Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake. 15. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
Engine Maintenance Servicing the Air Cleaner Note: If the foam gasket in the cover is damaged, replace it. Engine Safety Important: Avoid using high-pressure air, which could force dirt through the filter into the intake tract. • Keep your hands, feet, face, other body parts, and clothing away from the muffler and other hot surfaces. Allow engine components to cool before performing maintenance. Important: Do not clean the used filter to avoid damaging the filter media.
Servicing the Engine Oil Engine-Oil Specifications The engine ships with oil in the crankcase; however, check the oil level before and after you first start the engine. Check the oil level before operating the machine each day or each time you use the machine. Crankcase capacity: 6.
Changing the Engine Oil and Filter Service Interval: After the first 200 hours—Change the engine oil and filter. Every 200 hours—Change the engine oil and filter if not using Toro Premium Engine Oil, but any oil meeting API classification CJ-4 or higher or as stated in Engine-Oil Specifications. Every 400 hours—Change the engine oil and filter if using Toro Premium Engine Oil (API classification CK-4 or higher) more often in dirty and dusty conditions.
Fuel System Maintenance WARNING Fuel-system components are under high pressure. The use of improper components can result in system failure, fuel leakage, and possible explosion. Use only approved fuel lines and fuel filters. Draining the Fuel Filter/Water Separator Service Interval: Every 50 hours—Drain the fuel filter/water separator. 1. Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake. 2.
Replacing the Water Separator Service Interval: Every 400 hours—Replace the fuel-filter canister for the water separator (more often in dirty and dusty conditions). g233831 Figure 47 1. Filter locations Checking the Fuel Lines and Connections Service Interval: Every 400 hours Inspect the fuel lines for deterioration, damage, chaffing, or loose connections. g031412 Figure 46 The engine has 2 fuel filters as shown in Figure 47.
Electrical System Maintenance Electrical System Safety • Disconnect the cable from the negative terminal of the battery before repairing the machine. • Charge the battery in an open, well-ventilated area, away from sparks and flames. Unplug the charger before connecting or disconnecting the battery. Wear protective clothing and use insulated tools. Servicing the Battery DANGER Battery electrolyte contains sulfuric acid, which is fatal if consumed and causes severe burns.
Charging the Battery Jump-Starting the Machine 1. WARNING Charging the battery produces gasses that can explode. You must clean it off prior to jump-starting. Clean and tighten connections as necessary. Never smoke near the battery and keep sparks and flames away from battery. CAUTION Corrosion or loose connections can cause unwanted electrical voltage spikes at anytime during the jump-starting procedure. Important: Always keep the battery fully charged (1.265 specific gravity).
3. Servicing the Fuses Connect the positive (+) cable to the positive (+) terminal of the discharged battery that is wired to the starter or solenoid (Figure 49). The electrical system is protected by fuses. It requires no maintenance, however, if a fuse blows check component/circuit for malfunction or short. 1. Unlatch the engine hood and raise the engine hood to gain access to the fuse block. 2. To replace the fuses, pull out on the fuse to remove it. 3. Install a new fuse (Figure 50).
Drive System Maintenance 9. Align the levers in the front-to-rear position by bringing the levers together to the NEUTRAL position, and slide them until they are aligned, then tighten the bolts (Figure 52). Checking the Seat Belt Service Interval: Before each use or daily Inspect the seat belt for wear, cuts, and proper operation of the retractor and buckle. Replace the seat belt if it is damaged. Adjusting the Tracking 1. 2. 3. 4. 5. 6. 7. 8. Disengage the blade-control switch (PTO).
Adjusting the Caster-Pivot Bearing Checking the Tire Pressure Service Interval: Every 50 hours/Monthly (whichever comes first) Service Interval: Every 500 hours/Yearly (whichever comes first) Rear tire air pressure specification: 152 kPa (22 psi) 1. Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake. 2. Low tire pressure decreases machine side-hill stability. This could cause a rollover, which may result in personal injury or death.
Changing the Gearbox Oil Servicing the Gearbox Service Interval: After the first 200 hours Checking the Gearbox-Oil Level Every 400 hours Service Interval: Every 50 hours If the oil becomes contaminated, contact your Toro Distributor because the system must be flushed. Contaminated oil looks milky or black when compared to clean oil. Use SAE 75W-90 synthetic gear lube. 1. Park the machine on a level surface and engage the parking brake. 2. Lower the mower deck to the 25 mm (1 inch) height of cut.
Checking the Drive Wheel Gearbox Oil Changing the Drive Wheel Gearbox Oil Service Interval: Every 400 hours Service Interval: After the first 50 hours 1. 2. 3. 4. 5. Every 800 hours Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
Cooling System Maintenance Cooling System Safety • Swallowing engine coolant can cause poisoning; keep out of reach from children and pets. • Discharge of hot, pressurized coolant or touching a hot radiator and surrounding parts can cause severe burns. – Always allow the engine to cool at least 15 minutes before removing the radiator cap. g227787 Figure 58 – Use a rag when opening the radiator cap, and open the cap slowly to allow steam to escape. 1. Expansion-tank cap 3. Add line 2.
Allow some room (approximately 12.7 mm (1/2 inch)) for expansion. Add 50/50 coolant mix to the overflow bottle on the left side of the engine as required to bring the level up to the indicator line on the bottle. If the radiator is clean, proceed to step 8. 7. Cover the engine with a piece of cardboard or a plastic sheet. Squirt water through the fins. Blow through with low-pressure air from both directions. 9. Note: If debris remains, repeat until clean. 8. Lower the hood. 9.
Belt Maintenance 8. Remove the belt from the mower deck pulleys (Figure 61). Inspecting the Belts Service Interval: Every 50 hours Check the belts whenever they squeal while rotating, the blades slip while cutting grass, or if the belts have frayed edges, burn marks, or cracks. If any of these conditions occur, replace the belts.
Checking the Alternator-Belt Tension Service Interval: Every 100 hours 1. Apply 44 N (10 lb) of force to the alternator belt, midway between the pulleys. 2. If the deflection is not 10 mm (3/8 inch), loosen the alternator mounting bolts (Figure 63). g243947 Figure 62 1. Spring-loaded idler pulley 3. Spring 2. Square hole in the idler arm for the ratchet 4. Center deck mower belt 7. Install the new belt around the mower deck pulleys. 8.
Controls System Maintenance Adjusting the Control-Handle Position There are 2 height positions for the control levers—high and low. Remove the bolts to adjust the height for the operator. 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Loosen the bolts and flange nuts installed in the levers (Figure 64). 4.
4. Raise the rear of the machine up and support it with jack stands (or equivalent support) just high enough to allow the drive wheels to turn freely. 5. Remove the electrical connection from the seat safety switch, located under the bottom cushion of the seat. Note: The wheels should stop turning or slightly creep in reverse. Note: The switch is a part of the seat assembly. 6. Temporarily install a jumper wire across the terminals in the connector of the main wire harness. 7.
Hydraulic System Maintenance Servicing the Hydraulic System Hydraulic System Safety Hydraulic-Fluid Specifications Hydraulic-tank capacity: approximately 13.2 L (14 US qt) • Seek immediate medical attention if fluid is injected into skin. Injected fluid must be surgically removed within a few hours by a doctor. Recommended fluid: Toro Premium Transmission/Hydraulic Tractor Fluid (available in 5-gallon pails or 55-gallon drums.
Every 800 hours—Change the hydraulic fluid and filter if using Toro Premium Transmission/Hydraulic Tractor Fluid. g227849 Figure 68 1. Hydraulic-tank cap 1. Disengage the PTO, move the motion-control levers to the NEUTRAL-LOCK position, and engage the parking brake. 2. Move the throttle lever to the SLOW position, shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Raise the seat. 4.
8. Start the engine for approximately 1 minute, then shut it off. 9. Start the engine and check for oil leaks. Mower Deck Maintenance Move the motion-control levers to the full speed and run for several minutes. 10. Shut down the machine. 11. Check the hydraulic-fluid level; refer to Checking the Hydraulic-Fluid Level (page 63). Blade Safety • Inspect the blades periodically for wear or damage. • Use care when checking the blades.
DANGER A blade that is bent or damaged could break apart and could seriously injure or kill you or bystanders. • Always replace bent or damaged blade with a new blade. • Never file or create sharp notches in the edges or surfaces of blade. g006530 Figure 71 1. Cutting edge 3. Wear/slot forming 2. Curved area 4. Crack Removing the Blades Replace the blades if they hit a solid object, or if the blade is out of balance or bent. Checking for Bent Blades 1.
Sharpening the Blades 1. 2. Use a file to sharpen the cutting edge at both ends of the blade (Figure 74). Install the bushing/blade assembly into the spindle shaft (Figure 77). Note: Maintain the original angle. Note: The blade retains its balance if the same amount of material is removed from both cutting edges. g000276 Figure 74 1. Sharpen at original angle. 2. Check the balance of the blade by putting it on a blade balancer (Figure 75).
Hold the switch down until both wings are completely folded. 2. Position the mower to the 102 mm (4 inches) height-of-cut position. 3. Unlock the left and right wing deck cam locks (Figure 78). 4. Remove and retain the wing deck height-of-cut lynch pin (Figure 78). g239055 Figure 78 1. Cam lock 3. Lynch pin 2. Clevis pin 5. Insert the height-of-cut pin into the 102 mm (4 inches) location and install the lynch pin. 6. Lock the each wing deck cam lock. 7. Start the engine.
Note: In most conditions, you should adjust the rear tips on the blades 6.4 mm (1/4 inch) higher than the front. 3. Measure until all 4 sides are at the correct height. 4. Tighten all the nuts on the deck-lift arm assemblies. 5. If the 4 deck adjusters (Figure 80) do not have enough adjustment to achieve the accurate height of cut with the desired rake, you can utilize the single-point adjustment to gain more adjustment. 6.
Checking the Wing Deck Bushings Service Interval: Every 400 hours 1. Disengage the blade-control switch (PTO), move the motion-control levers to the NEUTRAL-LOCK position, and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Raise the center deck and fold the wings by pressing down the deck-lift switch. Hold the switch down until both wing decks are completely folded. g240665 4.
Changing the Wing Deck Bushings Note: Do not pull the wing decks into the operating position in order to remove the cylinder pins. 1. Disengage the blade-control switch (PTO), move the motion-control levers to the NEUTRAL-LOCK position, and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove and retain the clevis pins and hairpin cotters from each wing deck storage location. 4.
g351417 Figure 87 g351363 Figure 86 1. Upper pivot point bushing 3. Deck pin assembly 2. Lower pivot point bolt 4. Bushing 15. Apply a thin bead of Loctite® 680 to the entire circumference of the rear edge of the new bushings. 16. Insert and gently tap the new bushings into the opening and properly seat them into place. 17. Place a block of wood under the inside edge of the center deck to make it easier to work on the lower pivot point bushings. 18.
Cleaning Cleaning the Engine and Exhaust System Area Service Interval: Before each use or daily—Clean the engine and exhaust system area. Important: Do not use water to clean the engine. Use low-pressure compressed air. See the engine owner's manual. 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Open the hood. 4.
Storage Prepare the machine for storage when non-use occurs over 30 days. Prepare the machine for storage as follows: Storage Safety A. Run the engine to distribute conditioned fuel through the fuel system for 5 minutes. B. Shut off the engine, allow it to cool, and drain the fuel tank. • Shut off the engine, remove the key, and wait for all moving parts to stop before you leave the operator’s position. Allow the machine to cool before adjusting, servicing, cleaning, or storing it.
Troubleshooting Problem The starter does not crank. The engine does not start, starts hard, or fails to keep running. Possible Cause 1. The blade-control switch is engaged. 1. Disengage the blade-control switch. 2. The parking brake is disengaged. 3. The motion-control levers are not in the NEUTRAL-LOCK position. 4. You are not sitting in the operator’s seat. 5. The battery is dead. 6. The electrical connections are corroded or loose. 7. A fuse is blown. 8. A relay or switch is damaged. 2.
Problem The machine does not drive. The machine vibrates abnormally. The cutting height is uneven. Possible Cause 1. The bypass valves are not closed tight. 1. Tighten the bypass valves. 2. The pump belt is worn, loose, or broken. 3. The pump belt is off a pulley. 4. The idler spring is broken or missing. 5. The hydraulic fluid level is low or too hot. 2. Change the belt. 3. Change the belt. 4. Replace the spring. 5. Add hydraulic fluid to the reservoirs or let it cool down. 1.
RED/WHITE A B C ORANGE BLUE RED/WHITE RED/WHITE BLACK P02-6 KEY RUN B 5 2 6 4 3 1 SEAT SWITCH RED/WHITE GROUND SPEED RANGE SWITCH RED/WHITE VIOLET/WHITE 6 4 3 1 LOWER LIFT/LOWER SWITCH 5 2 BLUE RAISE RED/WHITE GREEN/YELLOW RED/WHITE ORANGE ORANGE 85 86 87a 87 ORANGE/WHITE BLACK GREEN WHITE/GREEN CENTER DECK RELAY 85 30 86 30 BRAKE RELAY 87a 87 BLUE GREEN/GRAY IN - GREEN P03-2 GREEN P03-4 GREEN P03-5 GREEN P03-6 - - BLACK GREEN P03-11 GREEN P03-10 - - G
Electrical Schematic—Machine with Horizon Display Monitor (Rev.
Hydraulic Schematic (Rev. A) g372017 79 T S2 S1 P X1 A L L1 B X1 B R L1 A TOW VALVE Port D(REV) 1.83/ 1.095 CID Port C(FWD) Port B(REV) TOW VALVE Port A(FWD) 1.83/ 1.095 CID YANMAR 3TNV88C 3000/1400 RPM 11.96:1 11.96:1 B A FLUSH VALVE 0.45 GPM MAX FLUSH VALVE 0.45 GPM MAX 4000 PSI 4000 PSI 4000 PSI 4000 PSI 0.031 in 0.031 in 1.1 CID 1.1 CID 1:0.691 1:1 1:1.025 1:1.
California Proposition 65 Warning Information What is this warning? You may see a product for sale that has a warning label like the following: WARNING: Cancer and Reproductive Harm—www.p65Warnings.ca.gov. What is Prop 65? Prop 65 applies to any company operating in California, selling products in California, or manufacturing products that may be sold in or brought into California.
