Form No. 3435-847 Rev B Z Master® Professional 6000 Series Riding Mower with 122cm, 132cm, or 152cm TURBO FORCE® Mower Model No. Model No. Model No. Model No. Model No. Register at www.Toro.com. Original Instructions (EN) 72902TE—Serial No. 72919TE—Serial No. 72925TE—Serial No. 72942TE—Serial No. 72969TE—Serial No.
This product complies with all relevant European directives; for details, please see the separate product specific Declaration of Conformity (DOC) sheet. Please refer to the engine manufacturer’s information included with the machine. Gross or Net Torque: The gross or net torque of this engine was laboratory rated by the engine manufacturer in accordance with the Society of Automotive Engineers (SAE) J1940 or J2723.
Removing the Clutch Shim ............................... 58 Cooling System Maintenance .............................. 60 Cleaning the Engine Screen and Engine-Oil Cooler ........................................................... 60 Cleaning the Engine-Cooling Fins and Shrouds ........................................................ 61 Checking and Cleaning the Hydraulic-Unit Shrouds ........................................................ 61 Brake Maintenance .............................................
General Safety Safety This machine is capable of amputating hands and feet and of throwing objects. Toro designed and tested this lawn mower to offer reasonably safe service; however, failure to comply with safety instructions may result in injury or death. This machine has been designed in accordance with EN ISO 5395:2013. Safety Alert Symbol • Read, understand, and follow all instructions and warnings in the Operator’s Manual and other training material, on the machine, engine, and attachments.
Slope Indicator g011841 Figure 3 You may copy this page for personal use. 1. The maximum slope you can operate the machine on is 15 degrees. Use the slope chart to determine the degree of slope of hills before operating. Do not operate this machine on a slope greater than 15 degrees. Fold along the appropriate line to match the recommended slope. 2. Align this edge with a vertical surface, a tree, building, fence pole, etc. 3.
Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or missing. decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery. 1. Explosion hazard 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.
decal109-6036 109-6036 Rear Discharge Machines Only 1. Read the Operator’s Manual. 2. Remove the key and read the instructions before servicing or performing maintenance. 3. Height of cut 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.
decal116-1716 116-1716 1. Fuel 2. Empty 6. Hour meter 7. PTO 3. Half 8. Parking brake 4. Full 5. Battery Machines without MyRide™ Only decal114-4470 114–4470 1. Read the Operator's Manual. 2. Height of cut 9. Neutral 10. Operator presence switch 3. Locked 4. Unlocked Machines with MyRide™ Only decal116-5988 116-5988 1. Parking brake—engaged 2. Parking brake—disengaged decal115-9625 115-9625 1. Parking brake—disengaged 2. Parking brake—engaged decal116-8726 116-8726 1.
decal116-8283 116-8283 decal117-3848 117-3848 1. Warning—read the Operator's Manual for instructions on torquing the blade bolt/nut to 75 to 81 N∙m (55 to 60 ft-lb). 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. decal120-5897 120-5897 1.
decal120-5898 120-5898 1. Choke 2. Fast 4. Slow 5. Power take-off (PTO), Blade control switch decal127-0326 127-0326 3. Continuous variable setting 1. Read the Operator's Manual. 2. Height of cut 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. Read the Operator’s Manual before performing maintenance; check the torque after the first 100 hours and every 500 hours after. decal126-4659 126-4659 1.
Machines with Side Discharge Only decal136-5508 136-5508 1. Belt routing decal131-1180 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.
Rear Discharge Machines Only Rear Discharge Machines Only decal136-5522 decal140-1198 136-5522 140-1198 1. Belt routing; read the Operator’s Manual for greasing information. 1. Rotate the nut clockwise to remove. 2. Attention—read the Operator’s Manual. decal133-8062 133-8062 decal114-4468 114-4468 1. Warning—read the Operator's Manual. 5. Loss of traction/control hazard, slopes—loss of traction/control on a slope, disengage the blade control switch (PTO), proceed off the slope slowly. 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 25). 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 37). g008950 Figure 6 1.
Specifications Note: Specifications and design are subject to change without notice.
Machines with Rear Discharge Operation Width Note: Determine the left and right sides of the machine from the normal operating position. 152 cm (60-inch) Deck Without the deck With the deck 135 cm (53 inches) Before Operation 168 cm (66 inches) Before Operation Safety Length Roll bar up Roll bar down 152 cm (60-inch) Deck General Safety 222 cm • Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job.
Fuel Safety DANGER In certain conditions during fueling, static electricity can be released causing a spark which can ignite gasoline vapors. A fire or explosion from gasoline can burn you and others and cause property damage. • Always place gasoline containers on the ground away from your vehicle before filling.
Filling the Fuel Tank • Keep engine and engine area free from • • accumulation of grass, leaves, excessive grease or oil, and other debris which can accumulate in these areas. Clean up oil and fuel spills and remove fuel soaked debris. Allow the machine to cool before storing the machine in any enclosure. Do Not store near flame or any enclosed area where open pilot lights or heat appliances are present. 1. Park the machine on a level surface. 2. Engage the parking brake. 3.
Breaking in a New Machine New engines take time to develop full power. Mower decks and drive systems have higher friction when new, placing additional load on the engine. Allow 40 to 50 hours of break-in time for new machines to develop full power and best performance. 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.
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 • Be sure all drives are in neutral and parking brake During Operation Safety • General Safety • The operator must use their full attention when operating the machine. Do Not engage in any activity that causes distractions; otherwise, injury or property damage may occur. • WARNING Operating engine parts, especially the muffler, become extremely hot. Severe burns can occur on contact and debris, such as leaves, grass, brush, etc. can catch fire.
• • distance (twice the width of the machine) between the machine and any hazard. Use a walk behind machine or a hand trimmer to mow the grass in these areas. – Before clearing blockages. – Whenever you leave the mower. Do Not leave a running machine unattended. Stop engine, wait for all moving parts to stop: – Before refueling. – Before dumping the grass catcher. – Before making height adjustments. Tragic accidents can occur if the operator is not alert to the presence of children.
Rollover Protection System (ROPS) Safety Entering the Operator’s Position A Rollover Protection System (roll bar) is installed on the machine. Use the mower deck as a step to get into the operator’s position (Figure 17). WARNING There is no rollover protection when the roll bar is down. Wheels dropping over edges, ditches, steep banks, or water can cause rollovers, which may result in serious injury, death or drowning. • Do Not remove the ROPS.
Disengaging the Parking Brake Operating the Throttle You can move the throttle control between FAST and SLOW positions (Figure 22). Always use the FAST position when engaging the PTO. g027335 Figure 19 g008946 Figure 22 Operating the Mower Blade-Control Switch (PTO) The blade-control switch (PTO) starts and stops the mower blades and any powered attachments.
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.
Adjusting the Height of Cut Using the Transport Lock 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 28). g008953 Figure 27 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.
Adjusting the Height-of-Cut Pin Adjusting the Anti-Scalp Rollers 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. Machines with Side Discharge 1. Move the transport lock to the lock position. 2. Push on the deck-lift pedal with your foot, and raise the mower deck to the transport position (also the 140 mm (5-1/2 inch) cutting height position) as shown in Figure 29. 3. 4. 5.
g029957 Figure 32 1. Anti-scalp roller 4. Flange nut 2. Spacer 5. Bolt 3. Bushing g024243 Figure 34 Machines with Rear Discharge Whenever you change the height of cut, it is recommended to 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.
Adjusting the Flow Baffle Knob Adjusting the Skid(s) For Machines with Rear Discharge For Machines with Side Discharge Mount the skids in the lower position when operating in height of cuts higher than 64 mm (2-1/2 inches) and in the higher position when operating in height of cuts lower than 64 mm (2-1/2 inches). This procedure applies only to machines with the flow baffle knob. Certain models have nuts and bolts instead of the flow baffle knob that you can adjust the same way.
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.
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. • Park machine on level ground, disengage drives, set parking brake, stop engine, remove key or disconnect spark plug wire. Wait for all movement to stop and allow the machine to cool before adjusting, cleaning, repairing, or storing. Never allow untrained personnel to service machine.
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 41). 4. Back the machine up the ramp (Figure 42). g028043 Figure 42 1. Back the machine up the ramp. 2. Drive the machine forward down the ramp. 5. Shut off the engine, remove the key, and engage the parking brake. 6.
Maintenance WARNING Removal or modification of original equipment, parts and/or accessories may alter the warranty, controllability, and safety of the machine. Unauthorized modifications to the original equipment or failure to use original Toro parts could lead to serious injury or death. Unauthorized changes to the machine, engine, fuel or venting system, may violate applicable safety standards such as: ANSI, OSHA and NFPA and/or government regulations such as EPA and CARB.
• Keep hands and feet away from moving parts. • Use jack stands to support the machine and/or If possible, Do Not make adjustments with the engine running. If the maintenance or adjustment procedure require the engine to be running and components moving, use extreme caution. components when required. CAUTION Raising the machine for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous.
Maintenance Service Interval Every 500 hours Monthly Yearly Yearly or before storage Maintenance Procedure • • • • • • • Replace the safety air filter (more often in dirty or dusty conditions). Replace the fuel filter (more often in dusty, dirty conditions). Check the wheel lug-nut torque. Check the wheel-hub slotted-nut torque. Adjust the caster-pivot bearing. Adjust the parking brake. After the initial change—change the hydraulic-system filters and fluid when using Toro® HYPR-OIL™ 500 fluid.
4. Driving off the Z Stand Swing the stand foot out front and slide it toward machine, into the bottom of slot (Figure 44 and Figure 45). 1. Remove the chocks or blocks. 2. Raise the latch to the unlocked position (Figure 46). g001812 Figure 45 1. Z Stand (positioned in slot) 3. Latch resting on pivot tab 2. Crack in side walk or turf g001813 5. 6. 7. Figure 46 Set the foot of the stand on the ground and rest the latch on the pivot tab (Figure 45). 1. Z Stand 3.
Lubrication Removing the Sheet-Metal Guard Greasing the Machine Loosen the 2 front bolts and remove the sheet-metal guard to access the mower belts and spindles (Figure 48). After performing maintenance, install the sheet-metal guard and tighten the bolts. 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.
Greasing the Mower Deck Service Interval: Yearly—Grease the pump-belt-idler arm. 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. Grease the mower deck idler-pulley pivot until grease comes out the bottom (Figure 50 or Figure 51). g009030 Figure 52 5.
Greasing the Caster-Wheel Hubs Service Interval: Yearly g027339 Figure 54 12. 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. Raise the mower for access. 4. Remove the caster wheel from the caster forks. 5. Remove the seal guards from the wheel hub. Grease the caster-wheel bearings (Figure 54).
13. 14. 15. 16. With the open end of the wheel facing up, fill the area inside the wheel around the axle full of general-purpose grease. Insert the second bearing and new seal into the wheel. Apply a thread-locking compound to the second spacer nut, and thread it onto the axle with the wrench flats facing outward. Torque the nut to 8 to 9 N∙m (75 to 80 in-lb), loosen the nut, then torque it to 2 to 3 N∙m (20 to 25 in-lb). 17.
Servicing the Engine Oil 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). Every 200 hours—Change the engine-oil filter (more often in dirty or dusty conditions). Note: Holes in the filter appear as bright spots. Do not clean the primary filter.
3. Changing the Engine Oil To keep dirt, grass clippings, etc., out of the engine, clean the area around the oil-fill cap and dipstick before removing it (Figure 58). 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. g008804 2. Park the machine so that the drain side is slightly lower than the opposite side to ensure that the oil drains completely. 3.
6. Changing the Engine-Oil Filter 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 60). 1. Drain the oil from the engine; refer to Changing the Engine Oil (page 49). 2. Change the engine-oil filter (Figure 61). g008804 g235264 Figure 60 7. Start the engine and drive to a flat area. 8. Check the oil level again.
Servicing the Spark Plug(s) Set the gap to 0.75 mm (0.03 inch). 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 Type of Spark Plug: NGK® BPR4ES or equivalent Figure 63 Air Gap: 0.75 mm (0.
Checking the Spark Arrester Fuel System Maintenance For Machines with a Spark Arrester 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. Service Interval: Every 50 hours WARNING Refer to Fuel Safety (page 19) for a complete list of fuel related precautions. Hot exhaust-system components may ignite fuel vapors even after you shut off the engine.
6. Electrical System Maintenance Open the fuel-shutoff valve. Servicing the Fuel Tank Do not attempt to drain the fuel tank. Ensure that an Authorized Service Dealer drains the fuel tank and services any components of the fuel system. 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.
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 Servicing the Fuses Note: Position the battery in the tray with the terminal posts opposite from the hydraulic tank (Figure 68). 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 69). 1. To replace the fuses, pull out on the fuse to remove it. 2. Install a new fuse (Figure 69).
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 75. 5. Service Interval: After the first 100 hours Install the dust cap (Figure 75). 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 75 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 77). B. Using needle-nose pliers, or by hand, hold the tab and remove the shim (Figure 79). Note: Do not discard the shim until the clutch is functioning properly.
Cooling System Maintenance Cleaning the Engine Screen and Engine-Oil Cooler Service Interval: Before each use or daily g010873 Figure 81 Remove any buildup of grass, dirt, or other debris from the oil cooler and the engine screen (Figure 82). 1. Feeler gauge • 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.
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 88 1. Position the belt cover. 3. Ensure that the tab is under the metal catch. 2. Slide the belt cover under the side catches. 15. Install the sheet-metal guard. Refer to Removing the Sheet-Metal Guard (page 44). 16. Tighten the bolt for the mower-deck curtain. Refer to Releasing the Mower-Deck Curtain (page 43). g024145 Figure 89 4. Idler pulley 2. Counter-rotating belt 5. Square hole in the idler arm for the ratchet 3.
9. Rotate and ensure the belt-guide tab hits against the pivot hub (Figure 91). 10. Using the ratchet in the square hole, install the belt around the spring-loaded idler pulley (Figure 91). Seat the spring ends in the anchor grooves. 11. Install the belt covers (Figure 92). g027729 Figure 90 5. Remove the counter-rotating belt; refer to Replacing the Counter-Rotating Belt (page 64). 6. Use a ratchet in the square hole in the idler arm to remove tension on the idler spring (Figure 91). 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 94). 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 6. Remove 1 dipstick from the hydraulic reservoir (Figure 99). 7. Wipe the dipstick off and thread the dipstick into the reservoir. Hydraulic System Safety 8. Remove the dipstick and look at the end (Figure 99). • 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 101). 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 A worn or damaged blade can break, and a piece of the blade could be thrown toward you or bystanders, resulting in serious personal injury or death. Trying to repair a damaged blade may result in discontinued safety certification of the product. 1. Cutting edge 3. Wear/slot forming • Inspect the blades periodically for wear or damage. 2. Curved area 4. Crack g006530 Figure 102 • Use care when checking the blades.
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 103). g014974 Figure 105 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 107). Note: If the blade is not balanced, file some metal off the end of the sail area only (Figure 108).
g298850 Figure 111 1. Top spindle nut 3. Blade bolt g027343 Figure 112 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 113 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 114 Fine-tune the adjustment nut on the front deck-lift assembly by turning it (Figure 114). Note: To increase the height, turn the adjustment nut clockwise; to decrease the height, turn the nut counterclockwise. 1. Adjustment nut 3. Rear deck adjustment 2. Jam nut 4.
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 113. 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 114).
g009038 g024146 Figure 118 Side-Discharge Machines 1. Clutch pulley 2. Mower belt 3. Spring-loaded idler pulley Figure 119 Rear-Discharge Machines 5. Square hole in the idler arm for the ratchet 6. Idler grease fitting 1. Clutch pulley 5. Belt guide 2. Mower belt 6. Spring-loaded idler pulley 7. Belt guide 3. Spring-loaded idler pulley 7. Square hole in the idler arm for the ratchet 8. Spring 4. Ratchet 4. Ensure that the belt-guide tab hits against the pivot hub. 7.
g015594 Figure 121 1. Bolt 5. Spring installed 2. Spacer 6. Grass deflector 3. Locknut 7. J-hook end of spring 4. Spring g024670 Figure 120 1. Right stabilizer 3. Place the spacer and the spring onto grass deflector. 4. Place 1 J-hook end of the spring behind the deck edge. 2. Deck strut (right side shown) 3. Remove the shoulder bolt and nut. 4. Remove the shoulder bolt and nut. 8. Raise the deck struts and secure them in the raised position. 9.
Cleaning Cleaning under the Mower Deck Service Interval: Before each use or daily 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Raise the mower deck to the TRANSPORT position.
Storage 13. Storage Safety Prepare the machine for storage when non-use occurs over 30 days. Prepare the machine for storage as follows: A. • Shut off the engine, remove the key, wait for all moving parts to stop, and allow the machine to cool before storing it. • Do not store the machine or fuel near flames or drain the fuel indoors. Add a petroleum-based stabilizer/conditioner to fuel in the tank. Follow mixing instructions from the stabilizer manufacturer.
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 Wire Diagram (Rev.
