Form No. 3435-841 Rev C Z Master® Commercial 3000 Series Riding Mower with 48in, 52in, 60in, or 72in TURBO FORCE® Side Discharge Mower Model No. Model No. Model No. Model No. Model No. Model No. Model No. Register at www.Toro.com. Original Instructions (EN) 72932—Serial No. 400000000 and Up 72936—Serial No. 400000000 and Up 72949—Serial No. 406397819 and Up 72949HD—Serial No. 400000000 and Up 72950—Serial No. 400000000 and Up 72952—Serial No. 400000000 and Up 72959—Serial No.
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. Visit www.Toro.com for product safety and operation training materials, accessory information, help finding a dealer, or to register your product.
Operating the Choke ........................................ 25 Starting the Engine ........................................... 26 Shutting Off the Engine..................................... 26 Using the Motion-Control Levers....................... 27 Driving the Machine .......................................... 27 Using the Side Discharge ................................. 28 Adjusting the Height of Cut ............................... 29 Adjusting the Anti-Scalp Rollers........................
Safety Inspecting the Belts .......................................... 62 Replacing the Mower Belt ................................. 62 Replacing the Hydraulic Pump-Drive Belt................................................................ 63 Controls System Maintenance ............................. 64 Adjusting the Control-Handle Position .............. 64 Adjusting the Motion-Control Linkage ............... 65 Adjusting the Motion-Control Damper ...............
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.
decal114-4466 114-4466 1. Main, 25A 3. Charge, 25A 2. PTO, 10A 4. Auxiliary, 15A decal116-1716 116-1716 1. Fuel 2. Empty 6. Hour meter 7. PTO 3. Half 8. Parking brake 4. Full 5. Battery decal107-3069 107-3069 9. Neutral 10. Operator presence switch 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.
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. 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. decal126-2055 126-2055 1. Wheel lug nut—torque to 129 N∙m (95 ft-lb). 2.
decal126-4398 126-4398 1. Read the Operator’s Manual. 2. Lock 3. Unlock decal121-7551 121-7551 1. Power takeoff (PTO) 4. Continuous variable setting 2. Choke 3. Fast 5. Slow decal127-0326 127-0326 1. Read the Operator's Manual. 2. Height of cut 9 3. Remove the key and read the Operator's Manual before performing maintenance.
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.
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.
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.
Controls Product Overview Become familiar with all the controls before you start the engine and operate the machine. Control Panel g029631 Figure 4 g008951 1. Side-discharge deflector 2. Height-of-cut deck-lift pedal Figure 5 8. Rear-shock assembly (machines with MyRide™ only) 1. Blade-control switch (power takeoff) 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. is running. Use these times for scheduling regular maintenance (Figure 6). 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 33). g008950 Figure 6 1.
Specifications Note: Specifications and design are subject to change without notice.
Fuel Safety Operation • Fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property. Note: Determine the left and right sides of the machine from the normal operating position. – To prevent a static charge from igniting the fuel, remove the machine from the truck or trailer and refuel it on the ground, away from all vehicles.
Adding Fuel 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 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.
Machines without MyRide™ Suspension System Positioning the Seat The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable (Figure 10). To unlatch the seat, push the seat latch forward (Figure 12). g008956 Figure 12 g019754 Figure 10 1. Seat latch Unlatching the Seat 2.
Adjusting the Rear-Shock Assemblies 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. g030024 The slots for the rear-shock assemblies have detent positions for reference. You can position the rear-shock assemblies anywhere in the slot, not just in the detent positions.
During Operation – Engage the parking brake. – Shut off the engine and remove the key. – Wait for all moving parts to stop. During Operation Safety • Operate the engine only in well-ventilated areas. Exhaust gases contain carbon monoxide, which is lethal if inhaled. General Safety • Never leave a running machine unattended. • Attach towed equipment to the machine only at • The owner/operator can prevent and is responsible for accidents that may cause personal injury or property damage.
• Before backing up or turning the machine, look – 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. down and all around for small children. • Do not carry children on the machine, even when the blades are not moving.
Operating the Parking Brake 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. g221745 Figure 17 1. Safe Zone—use the machine here on slopes less than 15° or flat areas. 2. Danger Zone—use a walk-behind mower and/or a hand trimmer on slopes greater than 15° and near drop-offs or water. 4. W = Width of the machine 5. Keep a safe distance (twice the width of the machine) between the machine and any hazard.
Operating the Mower Operating the Choke Blade-Control Switch (PTO) Use the choke to start a cold engine. The blade-control switch (PTO) starts and stops the mower blades and any powered attachments. Engaging the Blade-Control Switch (PTO) 1. Pull up the choke knob to engage the choke before using the key switch (Figure 24). 2. Push down the choke knob to disengage the choke after the engine has started (Figure 24).
Starting the Engine Important: Do not engage the 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. Note: You may need multiple attempts to start the engine the first time after adding fuel to an empty fuel system. g027337 Figure 26 Important: Make sure that the fuel-shutoff valve is closed before transporting or storing the machine, as fuel leakage may occur.
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 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. • Never remove the grass deflector from the mower deck because the grass deflector routes material down toward the turf.
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 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. 3. g029957 Figure 34 Adjust the anti-scalp rollers as shown in Figure 32, Figure 33, and Figure 34. 1. Anti-scalp roller 4. Flange nut 2. Spacer 5. Bolt 3.
Positioning the Flow Baffle 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 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. 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.
Using the Drive-Wheel-Release Valves After Operation After Operation Safety General Safety WARNING Hands may become entangled in the rotating drive components below the engine deck, which could result in serious injury. • Engage the parking brake, shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operator’s position. Allow the machine to cool before servicing, adjusting, fueling, cleaning, or storing it.
Transporting the Machine Use a heavy-duty trailer or truck to transport the machine. Use a full-width ramp. Ensure that the trailer or truck has all the necessary brakes, lighting, and marking as required by law. Please carefully read all the safety instructions. Knowing this information could help you or bystanders avoid injury. Refer to your local ordinances for trailer and tie-down requirements.
1. If using a trailer, connect it to the towing vehicle and connect the safety chains. 2. If applicable, connect the trailer brakes and lights. 3. Lower the ramp, ensuring that the angle between the ramp and the ground does not exceed 15 degrees (Figure 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 • Never tamper with safety devices. Check their • If you leave the key in the switch, someone could • Clean grass and debris from the cutting unit, • • • • Adjust and service it as required. proper operation regularly. accidently start the engine and seriously injure you or other bystanders. Remove the key from the switch before you perform any maintenance.
Maintenance Service Interval Maintenance Procedure Every 100 hours • Lubricate the mower deck-lift pivots. • For Kawasaki engines—change the engine oil (more often in dirty or dusty conditions). • For Kawasaki engines—replace or clean and gap the spark plug. • For Kohler engines—change the engine oil and oil filter (more often in dirty or dusty conditions). • Check and clean engine-cooling fins and shrouds.
Lubrication Greasing the Mower Deck Service Interval: Yearly—Grease the pump-belt-idler arm. 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. 1.
Greasing the Caster Pivots Note: Keep the dust cap off until greasing is done. Service Interval: Every 400 hours/Yearly (whichever comes first) (more often in dirty or dusty conditions). 6. Remove the hex plug. 7. Thread a grease fitting into the hole. 8. Pump grease into the fitting until it oozes out around the top bearing. 9. Remove the grease fitting in the hole. 10. Yearly—Repack the caster-wheel bearings (more often in dirty or dusty conditions).
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 surfaces. Allow engine components to cool before performing maintenance. • Keep your hands, feet, face, other body parts, • Do not change the engine governor speed or and clothing 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 48). g230252 Figure 48 1. Kawasaki engine 2.
Servicing the Air Cleaner Inspecting the Filters 1. Service Interval: Every 250 hours—For Kawasaki engines—replace the primary air filter (more often in dirty or dusty conditions). Inspect the safety filter. If it is dirty, replace both the safety and primary filters. Important: Do not attempt to clean the safety filter. If the safety filter is dirty, then the primary filter is damaged. Every 250 hours—For Kawasaki engines—check the safety air filter (more often in dirty or dusty conditions). 2.
• Kawasaki FX751 and FX801 engines—2.3 L (78 fl oz) with a filter change; 2.1 L (71 fl oz) without a filter change • Kawasaki FX921 engines—1.9 L (64 fl oz) with a filter change; 1.7 L (57 fl oz) without a filter change Viscosity: See the table below. g008804 g037096 Figure 51 Note: Although 10W-40 engine oil is recommended for most conditions, you may need to change oil viscosity to accommodate atmospheric conditions. Using 20W-50 engine oil in higher ambient temperatures can reduce oil consumption.
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 53). 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 54). g008804 g194610 Figure 54 7. Start the engine and drive to a flat area. 8. Check the oil level again. Changing the Engine-Oil Filter g027734 Figure 53 44 1.
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. g008804 Type of Spark Plug: • Kawasaki FX751 and FX801 engines—NGK® BPR4ES or equivalent • Kawasaki FX921 engines—NGK® BPR5ES or equivalent Air Gap: 0.75 mm (0.
Servicing a Kohler® Engine If you see light brown or gray on the insulator, the engine is operating properly. A black coating on the insulator usually means the air cleaner is dirty. This section is only for machines with Kohler engines. If your engine looks like the one shown in Figure 59, you have a Kohler engine. Set the gap to 0.75 mm (0.03 inch). Important: Refer to your engine owner’s manual for additional maintenance procedures.
4. Clean the air-inlet screen and cover. 5. Install the air-inlet cover and secure it with the latches (Figure 60). g012997 Figure 61 g012996 Figure 60 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 61). 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 61). 1. Inner filter 2.
Installing the Filters Checking the Engine-Oil Level Important: To prevent engine damage, always Note: Check the oil when the engine is cold. operate the engine with both air filters and the cover installed. 1. Important: If you overfill or underfill the engine crankcase with oil and run the engine, you may damage the engine. If you are installing new filters, check each filter for shipping damage. Note: Do not use a damaged filter. 2.
Changing the Engine Oil 6. Note: Dispose of the used oil at a recycling center. 1. Start the engine and let it run for 5 minutes. 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 65). Note: This warms the oil so that it drains better. 2. Park the machine so that the drain side is slightly lower than the opposite side to ensure that the oil drains completely. 3.
Removing 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 67.
Checking the Spark Arrester Installing the Spark Plug For Machines with a Spark Arrester 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. Do not refuel or run the engine unless the spark arrester is installed. g028109 Figure 69 51 1.
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 Fuel Safety (page 16) for a complete list of fuel related precautions. Replacing the Fuel Filter Service Interval: Every 200 hours (more often in dusty, dirty conditions). Every 500 hours/Yearly (whichever comes first) (more often in dusty, dirty conditions).
Electrical System Maintenance 3. Remove the battery as shown in Figure 71. Electrical System Safety • Disconnect the cable from the negative terminal of the battery before repairing the machine. Charge the battery in an open, well-ventilated area, away from sparks and flames. Unplug the charger before connecting or disconnecting the battery. Wear protective clothing and use insulated tools.
Installing the Battery Charging the Battery Note: Position the battery in the tray with the terminal posts opposite from the hydraulic tank (Figure 73). 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 the component/circuit for a malfunction or short. Checking the Seat Belt The fuses are located on the console to the right of the seat (Figure 74). 1. To replace the fuses, pull out on the fuse to remove it. 2. Install a new fuse (Figure 74).
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 Tire Pressure For Machines with Pneumatic Tires Only Service Interval: Every 50 hours/Monthly (whichever comes first) For machines with pneumatic tires only. Maintain the air pressure in the caster tires and 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. g024121 Figure 79 1.
3. Using an air compressor, blow out any debris from under the brake pole and around the brake spacers (Figure 82). g010868 Figure 82 g001297 Figure 80 1. Spring washers 4. 3. Dust cap 2. Locknut Check the condition of the wire-harness leads, connectors, and terminals. Note: Clean or repair as necessary. 5. Verify that 12 V is present at the clutch connector when the blade-control switch (PTO) switch is engaged. 6. Measure the gap between the rotor and armature.
• If the gap is less than 0.25 mm (0.01 inch), then install the shim. • If the gap is sufficient, proceed to the safety check in step F. F. Perform the following safety check: i. Sit on the seat and start the engine. ii. Make sure that the blades do not engage with the blade-control switch (PTO) in the OFF position, and that the clutch is disengaged. g010871 Figure 84 1. Shim If the clutch does not disengage, install the shim again. C.
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 89). 5. Position the seat.
12. Tighten the jam nut on the rear linkage (Figure 90). 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 33). 16. Install the rear tires and torque the lug nuts to 129 N∙m (95 ft-lb). 17. Remove the jack stands.
g027730 Figure 93 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 Hydraulic Pump-Drive Belt Figure 92 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 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2.
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 95). 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 100). 7. Wipe the dipstick off and thread the dipstick into the reservoir. 8. Remove the dipstick and look at the end (Figure 100). • 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 102). 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 103 • 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 104). g014974 Figure 106 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 108). Note: If the blade is not balanced, file some metal off the end of the sail area only (Figure 109).
g298850 Figure 112 1. Top spindle nut 3. Blade bolt g027343 Figure 113 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 114 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 g027345 Figure 116 1. Bolts at the bottom of the height-of-cut plate 12. 10. Fine-tune the adjustment nut on the front deck-lift assembly by turning it (Figure 115). Note: To increase the height, turn the adjustment nut clockwise; to decrease the height, turn the nut counterclockwise.
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 114. Note: The measurement should read 8.3 cm (3-1/4 inches) 16. Fine tune the screw adjuster by turning it to get 8.3 mm (3-1/4 inches) height (Figure 115). To increase the height, turn the adjustment nut clockwise; to decrease, turn counterclockwise. 17. Measure until all 4 sides are the correct height. 18.
8. Raise the deck struts and secure them in the raised position. 9. Slide the deck out to the right side of the machine. 6. Important: The grass deflector must be able to rotate. Lift the deflector up to the full open position and ensure that it rotates into the full down position. Replacing the Grass Deflector 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.
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.
Storage 12. Check the condition of the blades; refer to Servicing the Cutting Blades (page 69). 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 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 pulls to the left or right (with the motion-control levers fully forward). The machine does not drive. The machine vibrates abnormally. The cutting height is uneven. Possible Cause 1. The tracking needs adjustment 1. Adjust the tracking. 2. The tire pressure in the drive tires is not correct. 2. Adjust the tire pressure in the drive tires. 1. The bypass valves are not closed tight. 1. Tighten the bypass valves. 2. The pump belt is worn, loose, or broken. 3.
Schematics g009180 Electrical Schematic—Kawasaki Engines (Rev.
g020788 Electrical Schematic—Kohler Engines (Rev.
Notes:
Notes:
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.
