Form No. 3441-386 Rev A Z Master® Professional 5000 Series Riding Mower with 60in or 72in TURBO FORCE® Mower Model No. Model No. Model No. Model No. Model No. Register at www.Toro.com. Original Instructions (EN) 72910—Serial No. 72911—Serial No. 72912—Serial No. 72921—Serial No. 72922—Serial No.
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.
information and Note emphasizes general information worthy of special attention. Contents 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. Safety ....................................................................... 5 General Safety ................................................... 5 Slope Indicator .........................
Servicing the Cutting Blades ............................. 76 Leveling the Mower Deck.................................. 79 Removing the Mower Deck............................... 82 Replacing the Grass Deflector .......................... 84 Cleaning .............................................................. 85 Cleaning under the Mower Deck ....................... 85 Disposing of Waste........................................... 85 Storage ..................................................................
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. • 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.
decal110-2067 110-2067 decal112-9028 112-9028 1. Warning—stay away from moving parts; keep all guards and shields in place. decal107-3069 107-3069 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.
decal116-5988 116-5988 1. Parking brake—engaged decal117-3848 117-3848 2. Parking brake—disengaged 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. 3. Cutting/dismemberment hazard of hand or foot, mower blade—stay away from moving parts; keep all guards and shields in place. decal116-8726 116-8726 1. Read the Operator’s Manual for the recommended hydraulic fluid.
decal125-9383 125-9383 1. Check hydraulic fluid every 50 operating hours. 3. Check the tire pressure every 50 operating hours. 2. Read the Operator’s Manual for information on lubricating the machine. 4. Read the Operator’s Manual before servicing or performing maintenance. decal126-2055 126-2055 1. Wheel lug nut—torque to 129 N∙m (95 ft-lb). 2. Wheel hub nut—torque to 319 N∙m (235 ft-lb). 3.
Machines with a standard hour meter only Machines with a smart hour meter only g224114 126-5641 1. PTO 4. Operator-presence switch 2. Parking brake 5. See user’s guide for operating condition code 3. Neutral Machines with a Kawasaki Engine Only decal114-4466 114-4466 1. Main, 25A 3. Charge, 25A 2. PTO, 10A 4. Auxiliary, 15A Machines with a Kohler Engine Only decal121-7551 121-7551 1. Power takeoff (PTO) 4. Continuous variable setting 2. Choke 3. Fast 5.
Machines with Side Discharge Only decal127-6663 127-6663 1. Warning—read the Operator's Manual. decal127-0326 127-0326 3. Remove the key and read the Operator's Manual before performing maintenance. 1. Read the Operator's Manual. 2. Crushing hazard—engage the parking brake, shut off the engine, and remove the key; support the machine using jackstands. Machines with a standard hour meter only 2. Height of cut Machines with Rear Discharge Only decal116-1716 116-1716 1. Fuel 2. Empty 6.
Machines with Side Discharge Only Machines with Side Discharge Only decal136-5508 136-5508 decal131-1180 1. Belt routing 131-1180 1. Read the Operator's Manual. 2. Short, light grass; dry conditions 3. Bagging setting 4.
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. 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.
Machines with a smart hour meter only decal137-9208 137-9208 1. Fast 4. Engine—stop 2. Slow 5. Engine—run 3. PTO 6. Engine—start Machines with Rear Discharge Only decal136-5522 136-5522 1. Belt routing; read the Operator’s Manual for greasing information.
Product Overview g027333 Figure 4 Side-Discharge Machine Shown 1. Deck-lift pedal 6. Roll bar 2. Transport lock 7. Seat belt 3. Parking-brake lever 8. Fuel cap 4. Controls 5. Motion-control levers 9. Mower deck 10.
Hour Meter Controls Machines with a Standard Hour Meter Become familiar with all the controls before you start the engine and operate the machine. 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 6). Control Panel g233557 Figure 5 1. Blade-control switch (power takeoff) 4. Hour meter/Safety-interlock display 2. Choke control 5. Key switch g008950 Figure 6 3. Throttle control 1.
Once the MIL illuminates, make initial troubleshooting checks; refer to the MIL section under Troubleshooting (page 87). Refer to the Software Guide for more information. If these checks do not correct the problem, further diagnosis and servicing by an Authorized Service Dealer is necessary. There are symbols on the hour meter that indicate with a black bar that the interlock component is positioned correctly (Figure 7).
Specifications Note: Specifications and design are subject to change without notice. Machines with Side Discharge Machines with Rear Discharge Width: Width: Without Deck Deflector Up Deflector Down 60-inch Deck 72-inch Deck 135 cm 150 cm (53 inches) (59 inches) 157 cm 187 cm (62 inches) (74 inches) 192 cm 222 cm (76 inches) (88 inches) 60-inch Mower Deck 72-inch Mower Deck 134.6 cm 150.1 cm (53.0 inches) (59.1 inches) 168.4 cm 199.0 cm (66.3 inches) (78.
Fuel Safety Operation • Fuel is extremely flammable and highly explosive. Note: Determine the left and right sides of the machine from the normal operating position. Before Operation Before Operation Safety General Safety • Do not allow children or untrained people to operate or service the machine. Local regulations may restrict the age of the operator. The owner is responsible for training all operators and mechanics.
Adding Fuel Note: Do not fill the fuel tank completely full. The empty space in the tank allows the fuel to expand. Recommended Fuel • For best results, use only clean, fresh (less than 30 days old), unleaded gasoline with an octane rating of 87 or higher ((R+M)/2 rating method). • Ethanol: Gasoline with up to 10% ethanol (gasohol) or 15% MTBE (methyl tertiary butyl ether) by volume is acceptable. Ethanol and MTBE are not the same. Gasoline with 15% ethanol (E15) by volume is not approved for use.
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. • Lower the roll bar only when absolutely necessary. • Do not wear the seat belt when the roll bar is in the down position. • Drive slowly and carefully. • Raise the roll bar as soon as clearance permits.
Using the Safety-Interlock System 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. g231781 Figure 11 Smart hour meter shown 1. Indicators display when the interlock components are in the correct position.
5. Changing the Seat Suspension Sit on the seat, disengage the parking brake, move the blade-control switch (PTO) to the OFF position, and move the motion-control levers to the NEUTRAL-LOCK position. Try starting the engine; the engine should not start. The seat is adjustable to provide a smooth and comfortable ride. Position the seat where you are most comfortable. Positioning the Seat To adjust it, turn the knob in front either direction to provide the best comfort (Figure 14).
• Do not mow with the discharge deflector raised, removed, or altered unless there is a grass-collection system or mulch kit in place and working properly. • Do not mow in reverse unless it is absolutely necessary. Always look down and behind you before moving the machine in reverse. g229846 Figure 15 • Use extreme care when approaching blind 1. Wear hearing protection. corners, shrubs, trees, or other objects that may block your view.
• Check carefully for overhead objects before you grass, across slopes, or downhill may cause the machine to lose traction. Loss of traction to the drive wheels may result in sliding and a loss of braking and steering. The machine can slide even if the drive wheels are stopped. drive under them, and do not contact them. • Replace damaged ROPS components. Do not repair or alter them. • There is no rollover protection when the roll bar • Remove or mark obstacles such as ditches, holes, is down.
Operating the Parking Brake Operating the Mower Blade-Control Switch (PTO) Always engage the parking brake when you stop the machine or leave it unattended. The blade-control switch (PTO) starts and stops the mower blades and any powered attachments. Engaging the Parking Brake Engaging the Blade-Control Switch (PTO) Park the machine on a level surface. Note: Engaging the blade-control switch (PTO) with the throttle position at half or less causes excessive wear to the drive belts.
Starting the Engine Shutting Off the Engine Important: Do not engage starter for more 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. CAUTION 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 engine the first time after adding fuel to an empty fuel system.
Using the Motion-Control Levers WARNING The machine can spin very rapidly. You may lose control of the machine and cause personal injury or damage to the machine. • Use caution when making turns. • Slow the machine down before making sharp turns. Driving Forward Note: The engine shuts off when you move the traction-control with the parking brake engaged. To stop the machine, pull the motion-control levers to the NEUTRAL position. 1.
Using the Side Discharge Machines with Side Discharge Only The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. DANGER Without a grass deflector, discharge cover, or a complete grass-catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris. Contact with rotating mower blade(s) and thrown debris will cause injury or death.
Adjusting the Height of Cut Adjusting the Height-of-Cut Pin Using the Transport Lock The height-of-cut is adjusted from 25 to 140 mm (1 to 5-1/2 inches) in 6 mm (1/4 inch) increments by relocating the clevis pin into different hole locations. The transport lock has 2 positions, and is used with the deck-lift pedal. There is a LOCK position and an UNLOCK position for the transport position of the mower deck (Figure 27). 1. Move the transport lock to the lock position. 2.
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.
Mowing at Correct Intervals Grass grows at different rates at different times of the year. To maintain the same cutting height, mow more often in early spring. As the grass growth rate 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. Using a Slower Cutting Speed To improve cut quality, use a slower ground speed in certain conditions.
Stopping the Machine Using the Fuel-Shutoff Valve If you must stop the forward motion of the machine while mowing, a clump of grass clippings may 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. The fuel-shutoff valve is located under the seat. Move the seat forward to access it. Close the fuel-shutoff valve for transport, maintenance, and storage.
Transporting the Machine The drive-wheel-release valves are located in the back of each hydraulic-drive unit, under the seat. 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 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 • Check the parking brake operation frequently. • Maintenance Safety • • If you leave the key in the switch, someone could • • • • accidently start the engine and seriously injure you or other bystanders. Remove the key from the switch before you perform any maintenance. Before you leave the operator’s position, do the following: – Park the machine on a level surface. – Disengage the drives. – Engage the parking brake. – Shut off the engine and remove the key.
Maintenance Service Interval Maintenance Procedure Every 200 hours • For Kawasaki engines—change the engine-oil filter (more often in dirty or dusty conditions). • For Kohler engines—change the engine-oil filter (more often in dirty or dusty conditions). • For Kohler engines—change the engine-oil filter (more often in dirty or dusty conditions). • For Kohler engines—check the spark plug(s). • Replace the fuel filter (more often in dirty or dusty conditions).
Lubrication Greasing the Machine Grease the machine more often in dirty or dusty conditions. 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. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Clean the grease fittings with a rag. g017050 Figure 44 Greasing the Mower Deck Note: Scrape any paint off the front of the fitting(s).
g024207 Figure 48 Machines with Rear Discharge Only g192516 Figure 46 Machine with Rear Discharge Shown 4. 6. Remove the dust cap and adjust the caster pivots. Note: Keep the dust cap off until greasing is Grease the drive-belt idler arms (Figure 47). done. 7. Remove the hex plug. 8. Thread a grease fitting into the hole. 9. Pump grease into the fitting until it oozes out around the top bearing. 10. Remove the grease fitting in the hole. 11. Install the hex plug and dust cap (Figure 49).
Greasing the Caster Pivots 6. 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). 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.
Engine Maintenance Engine Safety surfaces. Allow engine components to cool before performing maintenance. • Keep your hands, feet, face, clothing, and other • Do not change the engine governor speed or body parts away from the muffler and other hot overspeed the engine. Identifying the Engine Use the following graphic to identify the engine you have and proceed to the section listed below for service (Figure 51). g230252 Figure 51 1. Kawasaki engine 2.
Servicing a Kawasaki® Engine This section is only for machines with Kawasaki engines. If your engine looks like the one shown in Figure 52, you have a Kawasaki engine. Important: Refer to your engine owner’s manual for additional maintenance procedures. g001883 Figure 53 1. Air-cleaner body 4. Air-cleaner cover 2. Primary filter 5. Safety filter 3. Latch 4. Clean the inside of the air-cleaner cover with compressed air. 5. Gently slide the primary filter out of the air-cleaner body (Figure 53).
3. Checking the Engine-Oil Level Carefully slide the primary filter over the safety filter (Figure 53). Note: Check the oil when the engine is cold. Note: Ensure that the primary filter is fully Important: If you overfill or underfill the engine crankcase with oil and run the engine, you may damage the engine. seated by pushing on the outer rim while installing it. Important: Do not press on the soft, inside area of the filter. 4. Install the air-cleaner cover and secure the latches (Figure 53). 1.
4. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 5. Drain the oil from the engine (Figure 56). g008804 g008804 g194611 Figure 55 g027734 Figure 56 Changing the Engine Oil Note: Dispose of the used oil at a recycling center. 1. Start the engine and let it run for 5 minutes. Note: This warms the oil so that it drains better. 2.
6. Slowly pour approximately 80% of the specified oil into the filler tube and slowly add the additional oil to bring it to the Full mark (Figure 57). g008804 g194610 Figure 57 7. Start the engine and drive to a flat area. 8. Check the oil level again. Changing the Engine-Oil Filter 1. Drain the oil from the engine; refer to Changing the Engine Oil (page 47). 2. Change the engine-oil filter (Figure 58).
Servicing the Spark Plug(s) Service Interval: Every 100 hours Ensure that the air gap between the center and side electrodes is correct before installing the spark plug. Use a spark plug wrench for removing and installing the spark plug and a gapping tool or feeler gauge to check and adjust the air gap. Install a new spark plug if necessary. g206628 Figure 60 Type of Spark Plug: NGK® BPR4ES or equivalent Air Gap: 0.75 mm (0.03 inch) Installing the Spark Plug(s) Removing the Spark Plug(s) 1.
Servicing a Kohler® Engine This section is only for machines with Kohler engines. If your engine looks like the one shown in Figure 62, you have a Kohler engine. Important: Refer to your engine owner’s manual for additional maintenance procedures. g012996 Figure 63 1. Air-inlet cover 3. Air-cleaner body 2. Air-inlet screen 4. Latch 6. Release the latches on the air cleaner and pull the air-cleaner cover off the air-cleaner body (Figure 64). 7.
Installing the Filters Important: To prevent engine damage, always operate the engine with both air filters and the cover installed. 1. If you are installing new filters, check each filter for shipping damage. Note: Do not use a damaged filter. 2. If you are replacing the inner filter, carefully slide it into the filter body (Figure 64). 3. Carefully slide the primary filter over the safety filter (Figure 64).
Checking the Engine-Oil Level Changing the Engine Oil Note: Check the oil when the engine is cold. Note: Dispose of the used oil at a recycling center. 1. Important: If you overfill or underfill the engine crankcase with oil and run the engine, you may damage the engine. 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.
6. Slowly pour approximately 80% of the specified oil into the filler tube and slowly add the additional oil to bring it to the Full mark (Figure 68). g008804 g194610 Figure 68 7. Start the engine and drive to a flat area. 8. Check the oil level again. g027477 Figure 69 Changing the Engine-Oil Filter Service Interval: Every 200 hours—For Kohler engines—change the engine-oil filter (more often in dirty or dusty conditions). 1.
Removing the Spark Plug Installing the Spark Plug 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. Clean the area around the base of the plug(s) to keep dirt and debris out of the engine. 4. Locate and remove the spark plug(s) as shown in Figure 70.
Checking the Spark Arrester Fuel System Maintenance For Machines with a Spark Arrester WARNING Fuel-system components are under high pressure. The use of improper components can result in system failure, fuel leakage, and possible explosion. Service Interval: Every 50 hours WARNING Hot exhaust-system components may ignite fuel vapors even after you shut off the engine. Hot particles exhausted during engine operation may ignite flammable materials, resulting in personal injury or property damage.
Electrical System Maintenance 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. Unplug the charger before connecting or disconnecting the battery. Wear protective clothing and use insulated tools. g333362 Figure 73 1. Fuel filter 3. Fuel line to the engine 2.
2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Charging the Battery 3. Remove the battery as shown in Figure 74. Charging the battery produces gasses that can explode. WARNING 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.
Installing the Battery Servicing the Fuses Note: Position the battery in the tray with the terminal posts opposite from the hydraulic tank (Figure 76). For Machines with a Standard Hour Meter The electrical system is protected by fuses. It requires no maintenance, however, if a fuse blows check the component/circuit for a malfunction or short. The fuses are located on the console to the right of the seat (Figure 77). 1. To replace the fuses, pull out on the fuse to remove it. 2.
Servicing the Fuses DANGER Jump-starting a weak battery that is cracked or frozen or has a low electrolyte level or an open/shorted battery cell can cause an explosion, resulting in serious personal injury. For Machines with a Smart Hour Meter The electrical system is protected by fuses. It requires no maintenance, however, if a fuse blows check the component/circuit for a malfunction or short. The fuses are located on the console to the right of the seat (Figure 78).
Drive System Maintenance 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. g012785 Figure 79 1. Positive (+) cable on discharged battery 5. Booster battery 2. Positive (+) cable on booster battery 6. Discharged battery 3. Negative (–) cable on the booster battery 7. Engine block Checking the Roll-Bar Knobs Service Interval: Before each use or daily 4.
Adjusting the Tracking 1. Disengage the blade-control switch (PTO). 2. Drive to an open flat area, move the motion-control levers to the NEUTRAL-LOCK position. 3. Move the throttle midway between the FAST and SLOW positions. 4. Move both motion-control levers all the way forward until they both hit the stops in the T-slot. 5. Check which way the machine tracks. 6. Engage the parking brake, shut off the engine, and remove the key. 7. Adjust the stop plates as needed.
Checking the Wheel-Hub Slotted Nut Checking the Tire Pressure For Machines with Pneumatic Tires Only Service Interval: After the first 100 hours Every 500 hours Service Interval: Every 50 hours/Monthly (whichever comes first) For machines with pneumatic tires only. Check and ensure that the torque of the slotted nut is 286 to 352 N∙m (211 to 260 ft-lb). Maintain the air pressure in the rear tires at 90 kPa (13 psi). Uneven tire pressure can cause uneven cut.
Important: Make sure that the spring 1. washers are installed correctly as shown in Figure 86. 5. 2. Install the dust cap (Figure 86). 3. Park the machine on a level surface, disengage the blade-control switch (PTO), 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. Using an air compressor, blow out any debris from under the brake pole and around the brake spacers (Figure 88).
B. Using needle-nose pliers, or by hand, hold the tab and remove the shim (Figure 90). Note: Do not discard the shim until the clutch is functioning properly. g010873 Figure 92 1. Feeler gauge • If the gap is less than 0.25 mm (0.01 g010871 Figure 90 inch), then install the shim. • If the gap is sufficient, proceed to the 1. Shim safety check in step F. C. Using a pneumatic line, blow out any debris from under the brake pole and around the brake spacers. D. Torque each bolt (M6 x 1) to 12.
Cleaning the Engine-Cooling Fins and Shrouds Cooling System Maintenance Cooling System Safety Service Interval: Every 100 hours/Yearly (whichever comes first) • Swallowing engine coolant can cause poisoning; keep out of reach from children and pets. 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.
Brake Maintenance Checking and Cleaning the Hydraulic-Unit Shrouds Adjusting the Parking Brake 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. Move the seat forward. 4. Clean the debris and grass from the hydraulic-unit shrouds (Figure 95). 5. Position the seat.
12. Tighten the jam nut on the rear linkage (Figure 96). Belt Maintenance 13. Ensure that the wheel hub moves freely between the caliper brake pads. Inspecting the Belts 14. Repeats steps 8 to 13 for the right side. Service Interval: Every 50 hours 15. Rotate the drive wheel release handle to the operating position; refer to Using the Drive-Wheel-Release Valves (page 36). 16. Install the rear tires and torque the lug nuts to 129 N∙m (95 ft-lb). 17. Remove the jack stands.
g027730 Figure 99 1. Position the belt cover. 3. Ensure that the tab is under the metal catch. 2. Slide the belt cover under the side catches. g009038 Replacing the Mower Belt for Rear-Discharge Mower Decks Figure 98 1. Clutch pulley 2. Mower belt 5. Square hole in the idler arm for the ratchet 6. Idler-grease fitting 3. Spring-loaded idler pulley 7. Belt guide 4. Ratchet 10. Install the belt guide on the idler arm (Figure 98). 11.
g027729 Figure 101 g024145 Figure 100 1. Idler spring 4. Idler pulley 2. Counter-rotating belt 5. Square hole in the idler arm for the ratchet 5. Remove the counter-rotating belt; refer to Replacing the Counter-Rotating Belt (page 68). 6. Use a ratchet in the square hole in the idler arm to remove tension on the idler spring (Figure 102). 7. Remove the belt from the mower-deck pulleys and the clutch pulley. 8.
9. Rotate and ensure the belt-guide tab hits against the pivot hub (Figure 102). 10. Using the ratchet in the square hole, install the belt around the spring-loaded idler pulley (Figure 102). Seat the spring ends in the anchor grooves. 11. Install the belt covers (Figure 103). g009039 Figure 104 1. Idler pulley 5. Left hydraulic-pump pulley 2. Clutch pulley 6. Square hole in the idler arm 7. Idler spring 3. Pump-drive belt 4.
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 105). 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. 11. Move the motion-control levers to the REVERSE position and while applying slight pressure to the lever, allow the reverse-indicator springs to bring the levers back to neutral.
Adjusting the Motion-Control Neutral-Lock Pivot Hydraulic System Maintenance Hydraulic System Safety You can adjust the flanged nut to obtain the desired motion-control lever resistance when moving it to the NEUTRAL-LOCK position. See Figure 109 for adjustment options. • Seek immediate medical attention if fluid is injected into skin. Injected fluid must be surgically removed within a few hours by a doctor.
7. Wipe the dipstick off and thread the dipstick into the reservoir. 8. Remove the dipstick and look at the end (Figure 110). Changing the Hydraulic Fluid and Filters Service Interval: After the first 250 hours—Change the hydraulic filters and hydraulic fluid. Every 250 hours—After the initial change—change the hydraulic-system filters and fluid when using Mobil 1 15W50 fluid.
5. Place a drain pan under the filter, remove the old filter, and wipe the surface clean (Figure 112). g008968 Figure 112 Bottom view of the machine 1. Filter locations 2. Hydraulic filter 6. Apply a thin coat of hydraulic fluid to the rubber gasket on the replacement filter (Figure 112). 7. Install the replacement hydraulic filter. 8. Install the pump-drive belt and the mower belt. 9. Remove the jack stands and lower the machine (Figure 111). 10.
Mower Deck Maintenance Blade Safety • Inspect the blades periodically for wear or damage. • Use care when checking the blades. Wrap the g006530 blades or wear gloves, and use caution when servicing the blades. Only replace or sharpen the blades; never straighten or weld them. Figure 113 • On multi-bladed machines, take care as rotating one blade can cause other blades to rotate. • Replace worn or damaged blades and bolts in sets to preserve balance.
Checking for Bent Blades Note: The machine must be on a level surface for the following procedure. 1. Raise the mower deck to the highest height-of-cut position. 2. While wearing thickly padded gloves, or other adequate hand protection, slowly rotate the blade into a position that allows you to measure the distance between the cutting edge and the level surface the machine is on (Figure 114). g014974 Figure 116 1. Blade (side previously measured) 2. Measurement (position used previously) 3.
Removing the Blades Note: If the blade stays in a horizontal position, the blade is balanced and can be used. Replace the blades if they hit a solid object, or if the blade is out of balance or bent. 1. Place a wrench on the flat of the spindle shaft or hold the blade end using a rag or thickly padded glove. 2. Remove the blade bolt, bushing, and blade from the spindle shaft (Figure 118). Note: If the blade is not balanced, file some metal off the end of the sail area only (Figure 119).
g298850 Figure 122 1. Top spindle nut 3. Blade bolt g027343 Figure 123 2. Flat of the spindle shaft 1. Deck-lift pedal 3. 4. Apply copper-based lubricant or grease to the threads of the blade bolt as needed to prevent seizing. Install the blade bolt finger-tight. 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). Leveling the Mower Deck 1.
g009196 Figure 124 1. 7.6 cm (3 inch) at position A is correct 2. 8.3 cm (3-1/4 inch) at position B is correct 3. Measure here from the blade tip to the hard surface 4. Measure at position A and B on both sides g027344 10. Figure 126 6000 Series Machines Fine-tune the adjustment nut on the front deck-lift assembly by turning it (Figure 125 or Figure 126). Note: To increase the height, turn the adjustment nut clockwise; to decrease the height, turn the nut counterclockwise.
g017036 Figure 129 1. Single-point adjustment bolt g027345 Figure 127 13. 1. Bolts at the bottom of the height-of-cut plate Tighten the 2 bolts at the bottom of the height-of-cut plate (Figure 127). Note: In most conditions, the back blade tip should be adjusted 6.4 mm (1/4 inch) higher than the front. 14. Torque the 2 bolts to 37 to 45 N∙m (27 to 33 ft-lb). 15. On both sides of the deck, measure from the level surface to the back tip of the blade (postion B) as shown in Figure 124.
Removing the Mower Deck Lock out the spring-loaded deck arms before servicing or removing the mower deck. WARNING Deck-lift arm assemblies have stored energy. Removing the deck with out releasing the stored energy can cause serious injury or death. Do not attempt to disassemble the deck from the front frame without locking out the stored energy. 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2.
g010252 Figure 132 1. Right stabilizer 2. Deck strut (right side shown) 3. Remove the shoulder bolt and nut. 4. Remove the shoulder bolt and nut. g024146 Figure 131 Rear-Discharge Machines 1. Clutch pulley 5. Belt guide 2. Mower belt 6. Spring-loaded idler pulley 3. Spring-loaded idler pulley 7. Square hole in the idler arm for the ratchet 8. Spring 4. Ensure that the belt-guide tab hits against the pivot hub. 7. Remove and retain the hardware on both sides of the deck as shown in Figure 132.
Replacing the Grass Deflector position and ensure that it rotates into the full down position. 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 mulch plate, discharge deflector, or grass collection system. 1.
Cleaning Cleaning under the Mower Deck Service Interval: After each use 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 12. Check the condition of the blades; refer to Servicing the Cutting Blades (page 76). Storage Safety 13. Prepare the machine for storage when non-use occurs over 30 days. Prepare the machine for storage as follows: • 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. A.
Troubleshooting Problem The malfunction-indicator light (MIL) comes on. Possible Cause 1. The engine is too hot. 1. Shut off the engine and let it cool. 2. There is old fuel in the fuel tank. 3. The fuel-shutoff valve is not open completely. 4. The air cleaner is dirty. 2. Use new fuel. 3. Open the fuel-shutoff valve. 5. The battery is not charged. 6. Incorrect fuel filters are being used or the fuel filters are dirty. 7.
Problem The engine loses power. The engine overheats. Possible Cause 1. The engine load is excessive. 1. Reduce the ground speed. 2. The air cleaner is dirty. 3. The oil level in the crankcase is low. 4. The cooling fins and the air passages above the engine are plugged. 5. The vent hole in the fuel cap is plugged. 6. There is dirt in the fuel filter. 7. There is dirt, water, or stale fuel in the fuel system. 2. Clean the air-cleaner element. 3. Add oil to the crankcase. 4.
Problem The blades do not rotate. Possible Cause 1. The mower deck belt is damaged, worn, loose, or broken. 1. Install a new deck belt. 2. The mower deck belt is off the pulley. 2. Install the mower belt on the deck pulley and check the idler pulley, idler arm, and spring for correct position and function. 3. Check the belt tension or install a new belt. 4. Replace the spring. 3. The pump drive belt is worn, loose, or broken. 4. The idler spring is broken or missing. The clutch does not engage.
Schematics g009180 Electrical Schematic—Kawasaki Engines (Rev.
Electrical Schematic—Kohler Engines (Rev.
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.
