Form No. 3436-663 Rev A Z Master® Professional 7000 Series Riding Mower With 132cm or 152cm TURBO FORCE® Mower Model No. 72264TE—Serial No. 406427909 and Up Model No. 72265TE—Serial No. 406427926 and Up Model No. 72279TE—Serial No. 406397919 and Up Register at www.Toro.com.
This product complies with all relevant European directives; for details, please see the separate product specific Declaration of Conformity (DOC) sheet. Gross or Net Torque: The gross or net torque of this engine was laboratory rated by the engine manufacturer in accordance with the Society of Automotive Engineers (SAE) J1940 or J2723. As configured to meet safety, emission, and operating requirements, the actual engine torque on this class of mower will be significantly lower.
Checking the Engine-Coolant Level.................. 59 Cleaning the Hydraulic-Fluid Cooler and Radiator Screen ............................................ 60 Changing the Engine Coolant ........................... 60 Brake Maintenance ............................................. 61 Adjusting the Parking Brake.............................. 61 Belt Maintenance ................................................ 61 Inspecting the Belts .......................................... 61 Replacing the Mower Belt .....
General Safety Safety This machine is capable of amputating hands and feet and of throwing objects. Toro designed and tested this lawn mower to offer reasonably safe service; however, failure to comply with safety instructions may result in injury or death. This machine has been designed in accordance with EN ISO 5395:2013. Safety Alert Symbol • Read, understand, and follow all instructions and warnings in the Operator’s Manual and other training material, on the machine, engine, and attachments.
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 1. Thrown object hazard—keep bystanders away. 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.
Side Discharge Machines Only decal131-1180 131-1180 1. Read the Operator's Manual. 2. Short, light grass; dry conditions decal107-3069 107-3069 3. Bagging setting 1. Warning–there is no rollover protection when the roll bar is down. 2. To avoid injury or death from a rollover accident, keep the roll bar in the raised and locked position and wear the seat belt. Lower the roll bar only when absolutely necessary; do not wear the seat belt when the roll bar is down. 3.
decal107-3962 107-3962 1. Height of cut in millimeters decal107-3961 107-3961 1. Height of cut in millimeters decal107-3963 107-3963 1. Cutting/dismemberment hazard, mower blade—do not carry passengers and keep bystanders away. 3. Thrown object 2. Cutting/dismemberment hazard—keep bystanders hazard of hand or foot, away; keep the deflector in mower blade—remove place. the key and read the instructions before servicing or performing maintenance; stay away from moving parts. 8 4.
decal107-3964 107-3964 1. Warning—do not use drugs or alcohol. 3. Warning—engage the parking brake, shut off the engine, and remove the key before leaving the machine. 2. Warning—read the Operator's Manual and receive training. 4. Warning—wear hearing protection. 5. Read the Operator's Manual. decal107-7719 107-7719 1. Cutting/dismemberment hazard, fan and entanglement hazard, belt—stay away from moving parts. 2.
decal108-5981 108-5981 decal140-4359 1. Belt routing 140-4359 1. Read the Operator’s Manual. 2. Height of cut 2. Belt routing decal110-0820 110-0820 1. Fast 5. Warning—read the Operator's Manual. 2. Slow 6. Poison and caustic liquid/chemical burn hazard—keep children away from the battery. 3. Neutral 7. Explosion hazard—no fire, open flames, or smoking; avoid sparks. 4. Reverse 8.
decal110-3853 110-3853 decal115-4212 1. Cutting/dismemberment hazard, fan and entanglement hazard, belt. 115-4212 2. Remove the key from the key switch and read the instructions before servicing or performing maintenance. 1. Hydraulic fluid level 3. Warning—do not touch the hot surface. 2. Read the Operator's Manual. Rear Discharge Machines Only decal112-3858 112-3858 1. Read the Operator's Manual. 3. Remove the key before adjusting the height of cut. 2.
Rear Discharge Machines Only decal117-3848 117-3848 1. Thrown object hazard—keep bystanders away. 2. Thrown object hazard, raised deflector—do not operate without the deflector, discharge cover, or grass collection system in place. decal121-7562 121-7562 3. Cutting/dismemberment hazard of hand or foot, mower blade—stay away from moving parts; keep all guards and shields in place. 1. Push to start 4. Variable speed control 2. Read the Operator’s Manual for more information on preheating the engine.
Side Discharge Machines Only decal127-0326 127-0326 1. Read the Operator's Manual. 3. Remove the key and read the Operator's Manual before performing maintenance. 2. Height of cut decal132-0871 132-0871 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.
Side Discharge Machines Only Rear Discharge Machines Only decal140-4363 decal140-4362 140-4363 140-4362 10. Every 25 hours—change 1. Read the Operator’s the engine coolant Manual before performing maintenance. 2. Remove the key. 11. Every 200 hours—grease 10. Every 25 hours—change 1. Read the Operator’s the engine coolant Manual before performing maintenance. 2. Remove the key. 11. Every 200 hours—grease 12. Every 25 hours—grease 3. Hydraulic fluid—Mobil 1 15W-50 4. Engine oil—SAE 10W-30 13.
Controls Product Overview Become familiar with all the controls before you start the engine and operate the machine. Control Panel g019888 Figure 4 Side Discharge Machine 1. Height-of-cut deck lift pedal 6. Roll bar 2. Transport lock 7. Seat belt 3. Parking-brake lever 8. Fuel cap 4. Controls 5. Motion-control lever g010363 Figure 6 1. Hour meter 9. Mower deck 10. Caster wheel 6. Glow-plug light 2. Key switch 7. Engine-temperature light 3. Fuel-selector valve 4. Audible alarm 5.
Hour Meter Audible Alarm The hour meter records the number of hours the engine has operated. It operates when the engine is running. Use these times for scheduling regular maintenance (Figure 7). This machine has an audible alarm that alerts the user to shut off the engine; otherwise, engine damage can occur from over heating. Refer to Operating with the Overheat Sensor (page 33).
Fuel Safety Operation Use extreme care when handling fuel. Note: Determine the left and right sides of the machine from the normal operating position. DANGER In certain conditions fuel is extremely flammable and vapors are explosive. Before Operation A fire or explosion from fuel can burn you, others, and cause property damage. Before Operation Safety • Fill the fuel tank outdoors on level ground, in an open area, when the engine is cold. Wipe up any fuel that spills.
• Keep engine and engine area free from DANGER accumulation of grass, leaves, excessive grease or oil, and other debris which can accumulate in these areas. In certain conditions during fueling, static electricity can be released causing a spark which can ignite fuel vapors. A fire or explosion from fuel can burn you and others and cause property damage. • Always place fuel containers on the ground away from your vehicle before filling.
Switching the Fuel Tanks • Painted surfaces may be damaged by biodiesel blends. Use B5 (biodiesel content of 5%) or lesser blend in cold weather. Monitor seals, hoses, gaskets in contact with fuel as they may degrade over time. Fuel filter plugging may be expected for a time after converting to biodiesel blends. Contact your distributor for more information on biodiesel. • • • • Important: Do not allow the machine to run out of fuel, as this can damage the machine.
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. g004954 Figure 10 1. Full-down position WARNING There is no rollover protection when the roll bar is in the down position. 2. Down position with the bagger installed Important: Ensure that you secure the rear part of the seat with the seat latch.
Using the Safety-Interlock System Test the safety-interlock system before you use the machine each time. If the safety system does not operate as described below, have an Authorized Service Dealer repair the safety system immediately. 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.
Unlatching the Seat 1. During Operation Move the seat to the most rearward position. During Operation Safety Note: This prevents interference when you raise the seat. 2. Push the seat latch rearward to unlatch the seat. 3. Raise the seat up (Figure 14). General Safety The operator must use their full attention when operating the machine. Do Not engage in any activity that causes distractions; otherwise, injury or property damage may occur. Note: This allows access to the machine under the seat.
• Be sure all drives are in neutral and parking brake • • • • is engaged before starting engine. Use seat belts with the roll bar in the raised and locked position. Start the engine carefully according to instructions with feet well away from the blades. Never operate the mower with damaged guards, shields, or covers. Always have safety shields, guards, switches and other devices in place and in proper working condition. Keep clear of the discharge opening at all times.
Rollover Protection System (ROPS) Safety distance (twice the width of the machine) between the machine and any hazard. Use a walk behind machine or a hand trimmer to mow the grass in these areas. A Rollover Protection System (roll bar) is installed on the machine. WARNING There is no rollover protection when the roll bar is down. Wheels dropping over edges, ditches, steep banks, or water can cause rollovers, which may result in serious injury, death or drowning. • Do Not remove the ROPS.
Engaging the Blade-Control Switch (PTO) Operating the Parking Brake Note: Engaging the blade-control switch (PTO) with the throttle position at half or less causes excessive wear to the drive belts. Always engage the parking brake when you stop the machine or leave it unattended. Engaging the Parking Brake Park the machine on a level surface.
Starting the Engine in Normal Weather Starting the Engine in Cold Weather (Below 23°F or -5°C) Important: Use starting cycles of no more than 30 seconds per minute to avoid overheating the starter motor. Use the correct engine oil for the starting temperature; refer to Engine-Oil Specifications (page 47). Note: Additional starting cycles may be required when starting the engine for the first time after the fuel system has been completely without fuel.
Using the Motion-Control Levers Shutting Off the Engine CAUTION Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. Always remove the key and engage the parking brake when leaving the machine unattended. g004532 Figure 25 1. Motion-control lever—NEUTRAL-LOCK position 4. Backward 2. Center, unlocked position 5. Front of machine 3.
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.
Using the Side Discharge Adjusting the Height of Cut Machines with Side Discharge Only Adjust the height of cut from 38 to 127 mm (1-1/2 to 5 inches) in 6 mm (1/4 inch) increments by moving the clevis pin into different hole locations. The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. 1. Raise the height-of-cut lever to the TRANSPORT position (also the 127 mm (5 inch) cutting-height position) (Figure 28).
Adjusting the Anti-Scalp Rollers Machines with Side Discharge Whenever you change the height-of-cut, adjust the height of the anti-scalp rollers. 1. Park the machine on a level surface, disengage the blade-control switch, 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. g029957 3. Figure 31 Adjust the anti-scalp rollers as shown in Figure 29, Figure 30, and Figure 31. 1. Anti-scalp roller 4.
g024244 Figure 34 1. Carriage bolt 3. Nut 2. Skid g024243 Figure 33 1. Bolt 3. Anti-scalp roller 2. Bushing 4. Flange nut 4. Move each skid to the desired position and secure them with the carriage bolts and nuts. Note: Only use the top or center sets of holes to adjust the skids. The bottom holes are used when switching sides on the mower deck, at which time they become the top holes on the other side of the mower. Adjusting the Skid(s) For Machines with Rear Discharge 5.
Positioning the Flow Baffle Position B For Machines with Side Discharge Use this position when bagging. Always align it with the blower opening. The following figures are recommendations only. Adjustments vary by grass type, moisture content, and the height of the grass. Note: If the engine power draws down and the mower ground speed is the same, open the baffle. Position A This is the fully-rear position.
Operating Tips Using the Fast Throttle Setting For best mowing and maximum air circulation, operate the engine at the FAST position. Air is required to thoroughly cut grass clippings, so do not set the height-of-cut so low as to totally surround the mower deck in uncut grass. Always try to have 1 side of the mower deck free from uncut grass, which allows air to be drawn into the mower deck.
After Operation drop onto your lawn. To avoid this, move onto a previously cut area with the blades engaged or you can disengage the mower deck while moving forward. After Operation Safety Keeping the Underside of the Mower Deck Clean General Safety • Park machine on level ground, disengage drives, Clean clippings and dirt from the underside of the mower deck after each use. If grass and dirt build up inside the mower deck, cutting quality will eventually become unsatisfactory.
Pushing the Machine by Hand Changing to Machine Operation Rotate the bypass valves clockwise 1 turn to operate machine (Figure 39). Important: Always push the machine by hand. Note: Do not over-tighten the bypass valves. Never tow the machine because hydraulic damage may occur. Important: The machine does not drive unless bypass valves are turned in. Pushing the Machine 1. Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake. 2.
Selecting a Trailer WARNING Loading a machine onto a trailer or truck increases the possibility of tip-over and could cause serious injury or death (Figure 40). • Use only a full-width ramp; do not use individual ramps for each side of the machine. • Do not exceed a 15-degree angle between the ramp and the ground or between the ramp and the trailer or truck. • Ensure that the length of the ramp is at least 4 times as long as the height of the trailer or truck bed to the ground.
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 40). 4. Back the machine up the ramp (Figure 41). g028043 Figure 41 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 WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury. Fluid accidentally injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result. Maintenance Safety WARNING While maintenance or adjustments are being made, someone could start the engine. Accidental starting of the engine could seriously injure you or other bystanders.
• Carefully release pressure from components with WARNING stored energy. Contact with moving parts or hot surfaces may cause personal injury. • Keep hands and feet away from moving parts. If possible, Do Not make adjustments with the engine running. If the maintenance or adjustment procedure require the engine to be running and components moving, use extreme caution. Keep your fingers, hands, and clothing clear of rotating components and hot surfaces.
Maintenance Service Interval Maintenance Procedure Every 250 hours • Check and/or replace the air filter (more often in dirty or dusty conditions). • Change the hydraulic filter and hydraulic fluid when using Mobil® 1 fluid. Every 400 hours • Grease the caster pivots (more often in dirty or dusty conditions). • Replace the fuel filter (more often in dirty or dusty conditions). Every 500 hours Monthly Yearly • • • • • Check the wheel lug-nut torque. Check the wheel hub castle nut.
4. Driving off the Z Stand Swing the stand foot out front and slide it toward machine, into the bottom of slot (Figure 43 and Figure 44). 1. Remove the chocks or blocks. 2. Raise the latch to the unlocked position (Figure 45). g001812 Figure 44 1. Z Stand (positioned in slot) 3. Latch resting on pivot tab 2. Crack in side walk or turf g001813 5. 6. 7. Figure 45 Set the foot of the stand on the ground and rest the latch on the pivot tab (Figure 44). 1. Z Stand 3.
Lubrication Releasing the Mower-Deck Curtain Greasing the Machine Loosen the bottom bolt of the curtain to release the mower-deck curtain and get access to the top of the mower deck (Figure 46). After performing maintenance, install the curtain and tighten the bolt. Grease the machine more often in dirty or dusty conditions. Refer to Figure 48 or Figure 49 for the location of grease fittings. Grease Type: No. 2 lithium or molybdenum grease 1.
Rear-Discharge Machines Service Interval: Every 150 hours Use light oil or spray lubricant to lubricate the machine in the following areas: • Seat-switch actuator • Brake-handle pivot • Brake-rod bushings • Motion-control bronze bushings Greasing the Mower Deck and Belt Idlers Service Interval: Every 25 hours—Grease the mower deck and spindles. Grease Type: No.
g187362 Figure 51 Side Discharge Machines g007170 Figure 53 10. Install the sheet-metal guard. 11. Tighten the bottom bolt holding the mower-deck curtain to the mower deck. 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). g194085 Figure 52 Rear Discharge Machines 8. Grease the PTO-drive belt idler arm (Figure 53). 9.
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 Engine Safety • Shut off the engine before checking the oil or adding oil to the crankcase. • Keep your hands, feet, face, clothing, and other body parts away the muffler and other hot surfaces. Servicing the Air Cleaner Service Interval: Every 250 hours (more often in dirty or dusty conditions). Note: Check the filters more frequently if operating conditions are extremely dusty or sandy. Removing the Air Filter 1.
Servicing the Engine Oil Service Interval: Before each use or daily—Check the engine-oil level. After the first 50 hours—Replace the engine oil. Every 100 hours—Replace the engine oil. After the first 50 hours—Change the engine-oil filter. Every 200 hours—Change the engine-oil filter. Engine-Oil Specifications Oil Type: High-quality detergent oil classified API Service CJ-4 or higher for diesel engines. Do not use special additives with recommended oils. Crankcase Capacity: 3.7 L (3.
Checking the Engine-Oil Level (Figure 40). If you add oil too fast or block the hole, the oil could back up and foul the air intakes, causing engine damage. Note: Check the oil when the engine is cold. 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. Check the engine-oil level (Figure 58). g000955 Figure 59 1.
Draining the Engine Oil 1. Changing the Engine-Oil Filter Start the engine and let it run for 5 minutes. Note: This warms the oil so it drains better. 2. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 3. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 1. Drain the oil from the engine; refer to Draining the Engine Oil (page 49). 2. Change the engine-oil filter (Figure 61).
Changing the Engine Oil Adding Engine Oil 1. Service Interval: After the first 50 hours Every 100 hours 1. Tilt the seat forward and remove the front engine panel (Figure 63). Start the engine and let it run for 5 minutes. Note: This warms the oil so it drains better. 2. 3. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 4. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 5.
Fuel System Maintenance DANGER In certain conditions, fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property. Refer to Adding Fuel (page 18) for a complete list of fuel related precautions. Servicing the Fuel Filter and Water Seperator g001163 Figure 65 1. Engine oil 2. Funnel and hose Service Interval: Every 40 hours—Drain the water separator.
g007169 Figure 67 1. Drain valve 2. Water separator 3. Back of machine Changing the Fuel Filter Never install a dirty fuel filter if it is removed from the fuel line. 1. Allow the machine to cool down. 2. Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake. 3. g007697 Figure 68 1. Fuel filter 2. Hose clamp Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 4. Left side of machine 5.
Electrical System Maintenance 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove the battery as shown in Figure 69. Electrical System Safety • Disconnect the battery before repairing the machine. Disconnect the negative terminal first and the positive last. Connect the positive terminal first and the negative last. • Charge the battery in an open, well-ventilated area, away from sparks and flames.
Installing the Battery Charging the Battery Note: Position the battery in the tray with the terminal posts opposite from the hydraulic tank (Figure 71). WARNING Charging the battery produces gasses that can explode. Never smoke near the battery and keep sparks and flames away from the battery. Important: Always keep the battery fully charged (1.265 specific gravity). This is especially important to prevent battery damage when the temperature is below 0°C (32°F). 1.
Servicing the Fuses Drive System Maintenance 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 fuse holder (Figure 72). 2. To replace the fuses, pull out on the fuse to remove it. 3. 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.
Checking the Wheel Lug Nuts Check and torque the wheel lug nuts to 122 to 129 N∙m (90 to 95 ft-lb). Torquing the Wheel Hub Castle Nut Service Interval: After the first 100 hours Every 500 hours thereafter 1. Remove the cotter pin. 2. Torque the castle nut to 319 N∙m (235 ft-lb). 3. Continue to tighten the nut slowly until the next slot aligns with the cross hole in the wheel motor shaft. 4. Insert the cotter pin and bend 1 tine over the end of the shaft.
g001297 Figure 75 1. Spring washers 3. Dust cap 2. Locknut g001156 Figure 76 Servicing the Gearbox 1. Gearbox 3. Pulley 2. Side plug 4. Rear plug Checking the Gearbox-Oil Level Service Interval: Every 100 hours Changing the Gearbox Oil Use SAE 75W-90 synthetic gear lube. Service Interval: After the first 100 hours 1. Yearly Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake. 2.
Adjusting the Electric Clutch Service Interval: Every 500 hours The clutch is adjustable to ensure proper engagement and proper braking. 1. Park the machine on a level surface, disengage the blade-control switch, 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. Unlatch the seat and tip it forward. 4. Loosen the front engine panel knobs and remove the panel. 5.
16. Install the rubber clutch strap to the mower frame with the 2 previously removed bolts and nuts (Figure 78). 17. Pull up on the spring-loaded idler for the PTO-drive belt and install it onto the clutch pulley (Figure 77). 18. Plug in the electric connection for the clutch (Figure 78). 19. Install the front engine panel and tighten the knobs. 20. Lower down the seat. Cooling System Maintenance DANGER The rotating shaft and fan can cause personal injury.
g001103 g001104 Figure 80 1. Antifreeze overflow bottle Figure 81 2. Indicator line on side of overflow bottle 1. Hydraulic-fluid cooler 3. Radiator screen 2. Left rear tire Cleaning the Hydraulic-Fluid Cooler and Radiator Screen Changing the Engine Coolant Service Interval: Yearly Service Interval: Before each use or daily Contact an Authorized Service Dealer for changing the coolant. Before each use, check and clean the radiator screen and oil cooler.
Brake Maintenance Belt Maintenance Adjusting the Parking Brake Inspecting the Belts Service Interval: Every 25 hours Every 200 hours Replace the belt if it is worn. The signs of a worn belt include squealing while the belt is rotating; the blades slipping while cutting grass; and frayed edges, burn marks, and cracks on the belt. Service Interval: Every 100 hours 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2.
9. Install the new belt around the mower pulleys and the gearbox pulley under the engine (Figure 84). 13. Install the sheet-metal guard. 14. Tighten the bottom bolt holding the mower-deck curtain to the mower deck. Rear Discharge Machines Important: The fasteners on the covers of this machine are designed to remain on the cover after removal. Loosen all of the fasteners on each cover a few turns so that the cover is loose but still attached, then go back and loosen them until the cover comes free.
g005911 Figure 86 1. Ratchet with short extension or breaker bar 2. 16.5 cm (6-1/2 inches) between the spring hooks 3. Spring-loaded idler pulley 4. Fixed Idler pulley 12. While holding the belt in tension, tighten the 2 bolts that secure the fixed idler arm. 13. Remove the ratchet or breaker bar from the square hole in the fixed idler arm. 14. Install the belt covers with the tabs in the slots. Install the screws and close the latches (Figure 87). g012506 Figure 87 1. Belt cover 2. Latch 15.
Replacing the PTO-Drive Belt Service Interval: Every 50 hours—Check the PTO-drive belt. 1. Park the machine on a level surface, disengage the blade-control switch, 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 front engine panel knobs and remove the panel (Figure 88). g007176 Figure 89 g001312 Figure 88 1. Knob 2. Front engine panel 4.
Replacing the Pump-Drive Belt Service Interval: Every 50 hours—Check the pump-drive belt. Note: Remove the PTO-drive belt first if the 2. Adjust the alternator to the outside until there is 7 to 9 mm (1/4 to 11/32 inch) deflection in the belt between the engine and the alternator pulleys with 10 kg (22.1 lb) of force (Figure 91). 3. Tighten the alternator bolts. 4. Check the deflection in the belt again and adjust the belt if needed. 5.
Controls System Maintenance Adjusting the Control Handle Neutral Position If the motion-control levers do not align or move easily into the console notch, adjust the levers. Adjust each lever, spring, and rod separately. Note: The motion-control levers must be installed correctly. g008932 1. Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake. 2.
9. Hydraulic System Maintenance While applying slight rearward pressure on the motion-control lever, turn the head of the adjustment bolt in the appropriate direction until the control lever is centered in the NEUTRAL-LOCK position (Figure 94). Hydraulic System Safety Note: Keeping rearward pressure on the lever keeps the pin at the end of the slot and allows the adjustment bolt to move the lever to the appropriate position. • Seek immediate medical attention if fluid is injected 10.
6. Run the machine at low idle for 15 minutes to allow any air to purge out of the system and warm the fluid; refer to Starting the Engine in Normal Weather (page 26). Note: Check the fluid level while the fluid is warm. The fluid should be between cold and hot. 7. If required, add fluid to the hydraulic tank. Note: The fluid level should be to the top of g001044 the hot level of the baffle, when the fluid is hot (Figure 95). 8. Figure 96 1. Hydraulic filter Install the cap on the filler neck. 4.
Setting the Hydraulic Pump Neutral Position Note: If 1 or both wheels do not drive, refer to Bleeding the Hydraulic System (page 69). 14. Check the fluid level while the fluid is warm. Note: Adjust the handle neutral first. That needs to be correct before the following adjustment can be made. Note: The fluid should be between cold and hot. 15. If required, add fluid to the hydraulic tank. Note: Do not overfill. This adjustment must be made with drive wheels turning.
4. Open the throttle to Setting the Left Hydraulic Pump Neutral Position FAST . Note: Make sure that the wheel remains stopped or slightly creeps in reverse; adjust if necessary. 1. Loosen the locknuts at the ball joints on the pump control rod (Figure 100). 2. Start the engine, open the throttle 1/2 way and disengage parking brake; refer to Starting the Engine in Normal Weather (page 26). Note: The motion-control lever must be in neutral while making any adjustments.
Mower Deck Maintenance WARNING The electrical system does not perform proper safety shut off with the jumper wire installed. Blade Safety • Remove the jumper wire from the wire harness connector and plug the connector into the seat switch when you complete the adjustment. A worn or damaged blade can break, and a piece of the blade could be thrown toward you or bystanders, resulting in serious personal injury or death.
g006530 Figure 101 1. Cutting edge 3. Wear/slot forming 2. Curved area 4. Crack g014973 Figure 103 1. Blade (in position for measuring) Checking for Bent Blades 2. Level surface 3. Measured distance between blade and the surface (A) Note: The machine must be on a level surface for the following procedure. 4. 1. Raise the mower deck to the highest height-of-cut position. 2.
g014973 Figure 105 1. Opposite blade edge (in position for measuring) 2. Level surface 3. Second measured distance between blade and surface (B) A. If the difference between A and B is greater than 3 mm (1/8 inch), replace the blade with a new blade; refer to Removing the Blades (page 73) and Installing the Blades (page 74). g295816 Figure 106 Note: If a bent blade is replaced with a new blade, and the dimension obtained continues to exceed 3 mm (1/8 inch), the blade spindle could be bent.
g000553 3. Apply copper-based lubricant or grease to the threads of the blade bolt as needed to prevent seizing. Install the blade bolt finger-tight. 4. Place a wrench on the flat of the spindle shaft and torque the blade bolt to 75 to 81 N∙m (55 to 60 ft-lb). Figure 108 1. Blade 3. 2. Balancer Leveling the Mower Deck at 3 Positions Repeat this procedure until the blade is balanced. Important: There are only 3 measuring positions Installing the Blades 1. needed to level the mower.
8. Loosen the jam nut under the rear-support arm and adjust the adjustment bolt to get a measurement of 80 to 83 mm (3-1/8 to 3-1/4 inches); refer to Figure 112. Note: It is recommended that both sides of the mower are adjusted the same distance. 9. 10. g006888 Figure 111 1. Measure here from blade to hard surface 2. 3. 4. 5. 6. 7. 2. Measure at B and C Measure the right blade at the B location, from a level surface to the cutting edge of the blade tip (Figure 111). Record this measurement.
Adjusting the Front-to-Rear Mower Deck Pitch 1. Adjusting the Compression Spring Position the right blade front-to-rear (Figure 113). 1. Raise the mower deck lift lever to the transport position. 2. Check the distance between the 2 large washers, it needs to be 28.2 cm (11-1/8 inches) for 52-inch mower decks, 26.7 cm (10-1/2 inches) for 60-inch mower decks, or 29.2 cm (11-1/2 inches) for 72-inch mower decks (Figure 114). g001041 Figure 113 1. Measure here from blade to hard surface 2. 2.
Replacing the Grass Deflector Side Discharge Machines Only WARNING An uncovered discharge opening could allow the machine to throw objects toward you or bystanders, resulting in serious injury. Also, contact with the blade could occur. • Never operate the machine unless you install a cover plate, a mulch plate, or a grass chute and catcher. g002519 Figure 115 • Make sure that the grass deflector is in the down position. 1.
Cleaning Cleaning under the Mower Deck Service Interval: Before each use or daily 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. Raise the mower deck to the TRANSPORT position. Disposing of Waste Engine oil, batteries, hydraulic fluid, and engine coolant are pollutants to the environment.
Storage A. Run the engine to distribute conditioned fuel through the fuel system for 5 minutes. Storage Safety B. Shut off the engine, allow it to cool, and drain the fuel tank; refer to Servicing the Fuel Tank (page 52). • Shut off the engine, remove the key, wait for all moving parts to stop, and allow the machine to cool before storing it. Do not store the machine or fuel near flames or drain the fuel indoors. Remove the key and store it in a safe place out of the reach of children.
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.
Schematics g012068 Wire Diagram (Rev.
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