Form No. 3435-837 Rev B Z Master® Professional 5000 or 6000 Series Riding Mower with 48in, 52in, 60in, or 72in TURBO FORCE® Mower Model No. Model No. Model No. Model No. Model No. Model No. Model No. Model No. Model No. Model No. Register at www.Toro.com. Original Instructions (EN) 72904—Serial No. 72906—Serial No. 72918—Serial No. 72926—Serial No. 72928—Serial No. 72930—Serial No. 72943—Serial No. 72945—Serial No. 72951—Serial No. 72955—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.
Contents This manual uses 2 words to highlight information. Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention. Safety ....................................................................... 5 General Safety ................................................... 5 Slope Indicator ................................................... 6 Safety and Instructional Decals .......................... 7 Product Overview .......................
Leveling the Mower Deck.................................. 73 Removing the Mower Deck............................... 76 Replacing the Grass Deflector .......................... 77 Cleaning .............................................................. 78 Cleaning under the Mower Deck ....................... 78 Cleaning the Suspension System ..................... 78 Disposing of Waste........................................... 78 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 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.
decal110-2067 110-2067 decal112-9028 112-9028 1. Warning—stay away from moving parts; keep all guards and shields in place. Machines with MyRide™ Only 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.
decal133-8062 133-8062 Machines without MyRide™ Only decal116-5988 116-5988 1. Parking brake—engaged 2. Parking brake—disengaged decal117-0346 117-0346 1. Fuel leak hazard—read the Operator's Manual; do not attempt to remove the roll bar; do not weld, drill or modify the roll bar in any way. decal116-8726 116-8726 1. Read the Operator’s Manual for the recommended hydraulic fluid. decal117-3848 117-3848 1. Thrown object hazard—keep bystanders away. 2.
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 Rear Discharge Only g224114 126-5641 1. PTO 4. Operator-presence switch 2. Parking brake 5. See user’s guide for operating condition code 3. Neutral decal140-1198 140-1198 1. Rotate the nut clockwise to remove. 2. Attention—read the Operator’s Manual. decal126-7875 126-7875 1. Fuse location 4. Auxiliary, 15A 2. Relay location 5. Start relay 3. Main, 20A 6. Not used Machines with Side Discharge Only decal127-6663 127-6663 1. Warning—read the Operator's Manual.
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. Tall, dense grass; wet conditions Machines with MyRide™ Only decal132-5063 132-5063 1. Cam lock 2.
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.
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.
Controls Product Overview Become familiar with all the controls before you start the engine and operate the machine. Control Panel g232246 Figure 5 g029631 Figure 4 Side Discharge Machine Shown 1. Side-discharge deflector 8. Rear-shock assembly (machines with MyRide™ only) 2. Height-of-cut deck-lift pedal 9. Seat belt 3. Parking-brake lever 10. Fuel cap 4. Transport lock 11. Mower deck 5. Controls 6. Motion-control levers 12. Caster wheel 13.
the machine (Figure 27). Always position the motion-control levers into the NEUTRAL-LOCK position when you stop the machine or leave it unattended. Refer to the Software Guide for more information. Parking-Brake Lever Whenever you shut off the engine, engage the parking brake to prevent accidental movement of the machine. Fuel-Shutoff Valve Close the fuel-shutoff valve when transporting or storing the machine; refer to Using the Fuel-Shutoff Valve (page 37). g231075 Figure 6 1.
Specifications Note: Specifications and design are subject to change without notice.
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 10 Smart hour meter shown 1. Indicators display when the interlock components are in the correct position.
5. Positioning the Seat 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 can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable (Figure 11).
Machines without MyRide™ Suspension System Adjusting the Rear-Shock Assemblies To unlatch the seat, push the seat latch forward (Figure 13). Machines with MyRide™ Suspension System Only The MyRide™ suspension system adjusts to provide a smooth and comfortable ride. You can adjust the rear 2-shock assemblies to quickly and easily change the suspension system. Position the suspension system where you are most comfortable. The slots for the rear-shock assemblies have detent positions for reference.
During Operation During Operation Safety General Safety • The owner/operator can prevent and is responsible g030024 • • • • • • • • • • g030019 Figure 16 • • 24 for accidents that may cause personal injury or property damage. Use your full attention while operating the machine. Do not engage in any activity that causes distractions; otherwise, injury or property damage may occur. Do not operate the machine while ill, tired, or under the influence of alcohol or drugs.
• Before backing up or turning the machine, look – Shut off the engine and remove the key. down and all around for small children. – Wait for all moving parts to stop. • Do not carry children on the machine, even when • Operate the engine only in well-ventilated areas. the blades are not moving. Children could fall off and be seriously injured or prevent you from safely operating the machine.
– Evaluate the site conditions of the day to determine if the slope is safe for machine operation. Use common sense and good judgment when performing this evaluation. 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. The machine could suddenly roll over if a wheel goes over the edge or the edge collapses.
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.
Operating the Throttle You can move the throttle control between FAST and SLOW positions (Figure 24). Always use the FAST position when engaging the PTO.
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.
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. Disengage the parking brake. 2.
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 30). 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 34 Adjust the anti-scalp rollers as shown in Figure 32, Figure 33, and Figure 34. 1. Anti-scalp roller 4.
g024244 Figure 37 1. Carriage bolt 3. Nut 2. Skid g024243 Figure 36 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 43). 4. Back the machine up the ramp (Figure 44). g028043 Figure 44 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. muffler, drives, grass catcher, and engine compartment to prevent fires.
Maintenance Service Interval Maintenance Procedure Every 200 hours • Change the engine-oil filter (more often in dirty or dusty conditions). • Check the spark plug(s). • Replace the fuel filter (more often in dirty or dusty conditions). Every 250 hours • After the initial change—change the hydraulic-system filters and fluid when using Mobil 1 15W50 fluid. (Change it more often under dirty or dusty conditions) Every 300 hours • Replace the primary air 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 47 Greasing the Mower Deck Note: Scrape any paint off the front of the fitting(s).
g024207 Figure 51 Machines with Rear Discharge Only g192516 Figure 49 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 50). 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 52).
Greasing the Caster Pivots 6. Service Interval: Every 400 hours/Yearly (whichever comes first) (more often in dirty or dusty conditions). Remove a spacer nut from the axle assembly in the caster wheel. Note: Thread-locking compound has been applied to lock the spacer nuts to the axle. Yearly—Repack the caster-wheel bearings (more often in dirty or dusty conditions). 7. Remove the axle (with the other spacer nut still assembled to it) from the wheel assembly. 1.
Engine Maintenance Engine Safety 6. Release the latches on the air cleaner and pull the air-cleaner cover off the air-cleaner body (Figure 55). 7. Clean the inside of the air-cleaner cover with compressed air. 8. Gently slide the primary filter out of the air-cleaner body (Figure 55). • Keep your hands, feet, face, clothing, and other body parts away from the muffler and other hot surfaces. Allow engine components to cool before performing maintenance.
2. Servicing the Engine Oil Inspect the primary filter for damage by looking into the filter while shining a bright light on the outside of the filter. If the primary filter is dirty, bent, or damaged, replace it. Service Interval: Before each use or daily Every 100 hours (more often in dirty or dusty conditions). Note: Holes in the filter appear as bright spots. Do not clean the primary filter. Every 200 hours—Change the engine-oil filter (more often in dirty or dusty conditions).
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 58). g008804 g008804 g194611 Figure 57 g027734 Figure 58 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 59). g008804 g194610 Figure 59 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 60).
Servicing the Spark Plug(s) 4. Remove the spark plug. Service Interval: Every 200 hours—Check the spark plug(s). Every 500 hours—Replace the spark plug(s). Type: Champion XC12YC Air Gap: 0.76 mm (0.03 inch) g008803 Removing the Spark Plug(s) 1. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 2. Disengage the PTO, move the motion-control levers to the NEUTRAL-LOCK position, and engage the parking brake. 3.
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. Servicing the Electronic Fuel-Injection System g027661 Figure 64 This machine contains an electronic fuel-injection system. It controls the fuel flow under different operating conditions.
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. g008963 Figure 65 1. Fuel filter 2. Hose clamp Servicing the Battery 3.
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 66. 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 Jump-Starting the Machine Note: Position the battery in the tray with the terminal posts opposite from the hydraulic tank (Figure 68). 1. Check and clean corrosion from the battery terminals before jump-starting. Ensure that the connections are tight. CAUTION Corrosion or loose connections can cause unwanted electrical voltage spikes at any time during the jump-starting procedure.
machines do not touch and that both electrical systems are off and at the same rated system voltage. These instructions are for negative ground systems only. 3. Connect the positive (+) cable to the positive (+) terminal of the discharged battery that is wired to the starter or solenoid as shown in Figure 70. g024213 g013117 g012785 Figure 71 Figure 70 1. Positive (+) cable on discharged battery 5. Booster battery 2. Positive (+) cable on booster battery 6. Discharged battery 3.
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. Checking the Roll-Bar Knobs Service Interval: Before each use or daily 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.
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. Checking the Tire Pressure Service Interval: Every 50 hours/Monthly (whichever comes first) 3. Move the throttle midway between the FAST and SLOW positions. Maintain the air pressure in the rear tires at 90 kPa (13 psi). Uneven tire pressure can cause uneven cut. Check the tires when they are cold to get the most accurate pressure reading. 4.
Checking the Wheel-Hub Slotted Nut Important: Make sure that the spring washers are installed correctly as shown in Figure 77. 5. Service Interval: After the first 100 hours Install the dust cap (Figure 77). Every 500 hours Check and ensure that the torque of the slotted nut is 286 to 352 N∙m (211 to 260 ft-lb). Note: Do not use anti-seize compound on wheel hub. g001297 Figure 77 1. Spring washers 3. Dust cap 2.
1. 2. 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 79). B. Using needle-nose pliers, or by hand, hold the tab and remove the shim (Figure 81). Note: Do not discard the shim until the clutch is functioning properly.
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 g010873 a hot radiator and surrounding parts can cause severe burns. Figure 83 1. Feeler gauge – Always allow the engine to cool at least 15 minutes before removing the radiator cap. • If the gap is less than 0.25 mm (0.
Cleaning the Engine-Cooling Fins and Shrouds Checking and Cleaning the Hydraulic-Unit Shrouds Service Interval: Before each use or daily Service Interval: Every 100 hours/Yearly (whichever comes first) 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2. 2.
Brake Maintenance Note: To lengthen the linkage, rotate the clevis 1 turn outward. Adjusting the Parking Brake Service Interval: After the first 100 hours Every 500 hours Check to ensure that parking brake is adjusted properly. This procedure must be followed after the first 100 hours or when a brake component has been removed or replaced. 1. Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake. 2.
Belt Maintenance Inspecting the Belts Service Interval: Every 50 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. Replacing the Mower Belt for Side-Discharge Mower Decks 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2.
g027730 Figure 90 1. Position the belt cover. 3. Ensure that the tab is under the metal catch. 2. Slide the belt cover under the side catches. g024145 Figure 91 Replacing the Mower Belt for Rear-Discharge Mower Decks 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. Lower the mower to the 76 mm (3 inches) height of cut.
9. Rotate and ensure the belt-guide tab hits against the pivot hub (Figure 93). 10. Using the ratchet in the square hole, install the belt around the spring-loaded idler pulley (Figure 93). Seat the spring ends in the anchor grooves. 11. Install the belt covers (Figure 94). g027729 Figure 92 5. Remove the counter-rotating belt; refer to Replacing the Counter-Rotating Belt (page 63). 6. Use a ratchet in the square hole in the idler arm to remove tension on the idler spring (Figure 93). 7.
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 96). 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 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. Start the engine, run it at full throttle, and disengage the parking brake.
11. Adjusting the Motion-Control Neutral-Lock Pivot 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. Note: The wheels should stop turning or slightly creep in reverse. 12. Shut off the machine. 13. Remove the jumper wire from the wire harness and plug the connector into the seat switch. 14. Remove the jack stands. 15.
Hydraulic System Maintenance Hydraulic System Safety 6. Remove 1 dipstick from the hydraulic reservoir (Figure 101). 7. Wipe the dipstick off and thread the dipstick into the reservoir. 8. Remove the dipstick and look at the end (Figure 101). • Seek immediate medical attention if fluid is injected Important: Do not overfill the hydraulic into skin. Injected fluid must be surgically removed within a few hours by a doctor. units with fluid, as damage may occur.
Changing the Hydraulic Fluid and Filters 5. Place a drain pan under the filter, remove the old filter, and wipe the surface clean (Figure 103). 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.
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 104 • 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 105). g014974 Figure 107 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 109). Note: If the blade is not balanced, file some metal off the end of the sail area only (Figure 110).
g298850 Figure 113 1. Top spindle nut 3. Blade bolt g027343 Figure 114 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 115 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 117 6000 Series Machines Fine-tune the adjustment nut on the front deck-lift assembly by turning it (Figure 116 or Figure 117). Note: To increase the height, turn the adjustment nut clockwise; to decrease the height, turn the nut counterclockwise.
g017036 Figure 120 1. Single-point adjustment bolt g027345 Figure 118 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 118). 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 115.
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 123 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 122 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. 8. Raise the deck struts and secure them in the raised position. 9.
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. g015594 Figure 124 1. Bolt 5. Spring installed 2. Spacer 6. Grass deflector 3. Locknut 7. J-hook end of spring Cleaning the Suspension System 4.
Storage 12. Check the condition of the blades; refer to Servicing the Cutting Blades (page 70). 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 g357854 Electrical Schematic (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.
