Form No. 3443-603 Rev A Z Master® 4000 Series Riding Mower with 48in, 52in, or 60in TURBO FORCE® Mower Model No. Model No. Model No. Model No. 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) 74000—Serial No. 400000000 and Up 74000TA—Serial No. 400000000 and Up 74002—Serial No. 400000000 and Up 74004—Serial No. 400000000 and Up 74010—Serial No. 400000000 and Up 74015—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.
Using the Motion-Control Levers....................... 27 Driving the Machine .......................................... 27 Using the Side Discharge ................................. 28 Adjusting the Height of Cut ............................... 29 Adjusting the Height of Cut ............................... 30 Adjusting the Anti-Scalp Rollers........................ 30 Operating Tips ................................................. 31 After Operation ....................................................
Adjusting the Side-to-Side Leveling and the Blade Slope .................................................. 67 Removing the Mower Deck............................... 69 Replacing the Grass Deflector .......................... 70 Cleaning .............................................................. 71 Cleaning under the Mower Deck ....................... 71 Cleaning the Suspension System ..................... 71 Disposing of Waste........................................... 71 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. decaloemmarkt Manufacturer's Mark 1. This mark indicates that the blade is identified as a part from the original machine manufacturer. decal99-8936 99-8936 decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery. 1. Explosion hazard 6. Keep bystanders away from the battery. 2.
decal115-9625 115-9625 1. Parking brake—disengaged 2. Parking brake—engaged decal107-3069 107-3069 decal116-5610 116–5610 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. Read the Operator's Manual; drive slowly and carefully. 1. Hour meter 2.
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. decal127-0326 127-0326 1. Read the Operator's Manual. 3. Cutting/dismemberment hazard of hand or foot, mower blade—stay away from moving parts; keep all guards and shields in place. 3. Remove the key and read the Operator's Manual before performing maintenance. 2.
decal144-6569 144-6569 1. Light 3. Slow 2. Fast decal144-2669 144-2669 1. Check the engine-oil level. 4. Grease the caster wheel. 2. Check the hydraulic-fluid level. 5. Read the Operator’s Manual before performing maintenance. 3. Check the tire pressure. decal144-2687 144-2687 1.
Decal 126-8383 is for machines without MyRide only. decal126-8383 126-8383 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.
Decal 132-0871 is for machines with MyRide only. 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 g332505 Figure 4 1. Height-of-cut positions 2. Controls 7. Fuel cap 8. Parking-brake lever 3. Motion-control levers 4. Electric deck lift (certain models only) 9. Mower deck 10. Caster wheel 5. Roll bar 11. Anti-scalp roller g332503 Figure 5 1. Key switch 6. Shock assembly (machines with MyRide only) 2. Blade-control switch (power takeoff) 3. Throttle control 4.
Throttle Control Electronic-Control Unit Malfunction-Indicator Light The throttle controls the engine speed, and it has a continuous-variable setting from the SLOW to FAST position (Figure 5). For Models with an EFI Engine Only The electronic-control unit (ECU) continuously monitors the operation of the EFI system. Blade-Control Switch (Power Takeoff) If a problem or fault within the system is detected, the malfunction-indicator light (MIL) illuminates.
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.
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) g004954 Figure 8 WARNING 1. Full-down position To avoid injury or death from rollover, keep the roll bar in the fully raised, locked position and use the seat belt. 2.
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.
Positioning the Seat Adjusting the Rear-Shock Assemblies The seat can move forward and backward (Figure 11). Position the seat where you have the best control of the machine and are most comfortable. 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.
During Operation During Operation Safety General Safety • The owner/operator can prevent and is responsible g030024 • • • • • • • • • • g030019 Figure 14 • • 21 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.
Disengaging the Parking Brake Entering the Operator’s Position Use the mower deck as a step to get into the operator’s position (Figure 17). g283914 Figure 19 g029797 Figure 17 1. Step here. 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.
Operating the Mower Operating the Throttle Blade-Control Switch (PTO) You can move the throttle control between FAST and SLOW positions (Figure 22). The blade-control switch (PTO) starts and stops the mower blades and any powered attachments. Always use the FAST position when engaging the PTO. Engaging the Blade-Control Switch (PTO) Note: Engaging the blade-control switch (PTO) with the throttle position at half or less causes excessive wear to the drive belts.
Starting the Engine Shutting Off the Engine Note: A warm or hot engine may not require choking. CAUTION Important: Do not engage the starter for more Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. than 5 seconds at a time. Engaging the starter motor for more than 5 seconds can damage the starter motor. If the engine fails to start, wait 10 seconds before operating the engine starter again.
Driving the Machine Using the Motion-Control Levers The drive wheels turn independently, powered by hydraulic motors on each axle. You can turn 1 side in reverse while you turn the other forward, causing the machine to spin rather than turn. This greatly improves the machine maneuverability but may require some time for you to adapt to how it moves. The throttle control regulates the engine speed as measured in rpm (revolutions per minute).
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 For Machines with a Deck-Lift Pedal You can adjust the height of cut from 38 to 140 mm (1-1/2 to 5-1/2 inches) in 6 mm (1/4 inch) increments by relocating the clevis pin into different hole locations. 1. Push the deck-lift pedal fully forward to lock the mower deck in the TRANSPORT position (also the 140 mm/5-1/2 inches cutting height position) as shown in Figure 30. 2. To adjust, remove the pin from the height-of-cut bracket (Figure 30). 3.
Adjusting the Height of Cut Adjusting the Anti-Scalp Rollers For Machines with an Electric Deck Lift 1. Whenever you change the height-of-cut, adjust the height of the anti-scalp rollers. Push up on the deck-lift switch (Figure 31). 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.
Operating Tips Using the Fast Throttle Setting For best mowing and maximum air circulation, operate the engine at the FAST position. Air is required to thoroughly cut grass clippings, so do not set the height-of-cut so low as to totally surround the mower deck in uncut grass. Always try to have 1 side of the mower deck free from uncut grass, which allows air to be drawn into the mower deck. g029957 Cutting a Lawn for the First Time Figure 35 1. Anti-scalp roller 4. Flange nut 2. Spacer 5.
Using the Fuel-Shutoff Valve 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. Close the fuel-shutoff valve for transport, maintenance, and storage (Figure 36). Keeping the Underside of the Mower Deck Clean Ensure that the fuel-shutoff valve is open when starting the engine. Clean clippings and dirt from the underside of the mower deck after each use.
For Machines with ZT 5400 Hydros WARNING The engine and hydraulic-drive units can become very hot. Touching a hot engine or hydraulic-drive units can cause severe burns. The drive-wheel release valves are located on the left and right sides underneath the engine deck. Allow the engine and hydraulic-drive units to cool completely before accessing the drive-wheel release valves.
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 39). 4. Back the machine up the ramp (Figure 40). 2. g028043 Figure 40 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 • For Kawasaki engines—change the engine-oil filter (more often in dirty or dusty conditions). • For Kohler Engines—change the engine-oil filter (more often in dirty or dusty conditions). • For Kohler Engines—check the spark plug(s). Every 250 hours • For Kawasaki engines—replace the primary air filter (more often in dirty or dusty conditions). • For Kawasaki engines—check the safety air filter (more often in dirty or dusty conditions).
Lubricating the Mower Deck-Lift Pivots Note: Thread-locking compound has been applied to lock the spacer nuts to the axle. 7. Remove the axle (with the other spacer nut still assembled to it) from the wheel assembly. 8. Pry out seals and inspect bearings for wear or damage and replace if necessary. 9. Pack the bearings with a general-purpose grease. Service Interval: Every 100 hours Use light oil or spray lubricant to lubricate the deck-lift pivots. 10.
Engine Maintenance surfaces. Allow engine components to cool before performing maintenance. • Do not change the engine governor speed or Engine Safety overspeed the engine. • Keep your hands, feet, face, clothing, and other body parts away from the muffler and other hot Identifying the Engine Use the following graphic to identify the engine you have and proceed to the section listed below for service (Figure 44). g230252 Figure 44 1. Kawasaki engine 2.
Servicing a Kawasaki® Engine This section is only for machines with Kawasaki engines. If your engine looks like the one shown in Figure 45, you have a Kawasaki engine. Important: Refer to your engine owner’s manual for additional maintenance procedures. g001883 Figure 46 1. Air-cleaner body 4. Air-cleaner cover 2. Primary filter 5. Safety filter 3. Latch 4. Clean the inside of the air-cleaner cover with compressed air. 5. Gently slide the primary filter out of the air-cleaner body (Figure 46).
3. Carefully slide the primary filter over the safety filter (Figure 46). viscosity to accommodate atmospheric conditions. Using 20W-50 engine oil in higher ambient temperatures can reduce oil consumption. Note: Ensure that the primary filter is fully seated by pushing on the outer rim while installing it. Checking the Engine-Oil Level Important: Do not press on the soft, inside Note: Check the oil when the engine is cold. area of the filter. 4.
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 49). g008804 g008804 g311705 Figure 48 g027734 Figure 49 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 50). g008804 g194610 Figure 50 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 42). 2. Change the engine-oil filter (Figure 51).
Servicing the Spark Plug(s) 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. 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.
Servicing a Kohler® Engine This section is only for machines with Kohler engines. If your engine looks like the one shown in Figure 55, you have a Kohler engine. Important: Refer to your engine owner’s manual for additional maintenance procedures. g012996 Figure 56 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 57). 7.
Note: Ensure that the primary filter is fully seated by pushing on the outer rim while installing it. 4. Important: Do not press on the soft, inside area of the filter. Install the air-cleaner cover and secure the latches (Figure 57). Servicing the Engine Oil Service Interval: Before each use or daily—For Kohler Engines—check the engine-oil level. Every 100 hours—For Kohler Engines—change the engine oil (more often in dirty or dusty conditions).
Note: This warms the oil so that it drains better. Note: Ensure that the engine is cool so that the oil has had time to drain into the sump. 3. To keep dirt, grass clippings, etc., out of the engine, clean the area around the oil-fill cap and dipstick before removing it (Figure 59). 2. Park the machine so that the drain side is slightly lower than the opposite side to ensure that the oil drains completely. 3. Disengage the blade-control switch (PTO) and engage the parking brake. 4.
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 61). g008804 g194610 Figure 61 7. Start the engine and drive to a flat area. 8. Check the oil level again. g027477 Figure 62 Changing the Engine-Oil Filter 1. 2. Drain the oil from the engine; refer to Changing the Engine Oil (page 47). Note: Ensure that the oil-filter gasket touches Change the engine-oil filter (Figure 62).
Removing the Spark Plug Installing the Spark Plug 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Clean the area around the base of the plug(s) to keep dirt and debris out of the engine. 4. Locate and remove the spark plug(s) as shown in Figure 63.
Cleaning the Engine Screen Fuel System Maintenance Service Interval: Before each use or daily—Clean the engine screen, engine-oil cooler, and the area around the engine. DANGER Before each use or daily—Clean around the engine-exhaust system. 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.
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.
2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove the battery as shown in Figure 67. 4. Install the battery in the machine and connect the battery cables; refer to Installing the Battery (page 53). Note: Do not run the machine with the battery disconnected; electrical damage may occur. g036853 g000960 Figure 68 g036855 Figure 67 Charging the Battery WARNING Charging the battery produces gasses that can explode.
Installing the Battery Servicing the Fuses 1. Position the battery in the tray with the terminal posts opposite from the hydraulic tank (Figure 67). 2. Install the positive (red) battery cable to the positive (+) battery terminal. 3. Install the negative (black) battery cable and ground wire to the negative (-) battery terminal. The electrical system is protected by fuses. It requires no maintenance; however, if a fuse blows check the component and circuit for a malfunction or short.
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. Adjusting the Tracking 1. Disengage the blade-control switch (PTO). 2. Drive to an open, flat area and move the motion-control levers to the NEUTRAL-LOCK position. 3. Move the throttle midway between the FAST and SLOW positions. 4.
Brake Maintenance Checking the Tire Pressure For Machines with Pneumatic Tires Only Adjusting the Parking Brake Service Interval: Every 50 hours/Monthly (whichever comes first) For machines with pneumatic tires only. If you need to adjust the parking brake, contact an Authorized Service Dealer. 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.
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 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2.
g027730 Figure 75 Replacing the Hydraulic Pump-Drive Belt 1. 2. g334847 Figure 76 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. 3. Remove the mower belt; refer to Replacing the Mower Belt (page 56). 4. Raise the machine and support it with jack stands. 5.
Adjusting the Tilt Controls System Maintenance Adjusting the Control-Handle Position If the ends of the levers hit against each other, refer to Adjusting the Motion-Control Linkage (page 59). 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 upper bolt holding the control lever to the control arm shaft. 4.
Adjusting the Motion-Control Linkage 11. Located on either side of the machine, below the seat, are the pump-control linkages. Rotating the end nut with a 1/2-inch deep socket wrench allows fine tuning adjustments so that the machine does not move in neutral. Any adjustments should be made for neutral positioning only. Adjust the pump-control-rod lengths by rotating the nut in the appropriate direction until the wheels slightly creep in reverse (Figure 79 and Figure 80).
Hydraulic System Maintenance Note: The wheels should stop turning or slightly creep in reverse. Note: You may need to remove the motion-control cover to gain access. 13. Shut off the machine. Hydraulic System Safety 14. Remove the jumper wire from the wire harness and plug the connector into the seat switch. • Seek immediate medical attention if fluid is injected 15. Remove the jack stands. 16. Raise the mower deck and install the height-of-cut pin. 17. into skin.
Checking the Hydraulic-Fluid Level Changing the Hydraulic Fluid and Filters Service Interval: Before each use or daily Service Interval: After the first 100 hours—Change the hydraulic-system filters and fluid. 1. Allow the hydraulic fluid to cool down. Check the oil level when the fluid is cold. 2. Check expansion reservoir and if necessary add Toro® HYPR-OIL™ 500 hydraulic fluid to the FULL COLD line (Figure 81).
6. Place a drain pan below the filter to catch the fluid that drains when the filter and vent plugs are removed. 7. Remove the hydraulic-fluid filter cover from the transaxle to drain the fluid (Figure 84). g336998 Figure 82 1. Access holes for the vent plugs • For ZT 5400 Hydros, use a 7/16-inch wrench to access the vent plug from underneath the machine (Figure 83). g334915 Figure 84 1. Hydraulic-filter housing 2. Cover 8. Remove the O-ring from the filter cover and discard the O-ring. 9.
Important: Failure to perform the Bleeding 4. the Hydraulic System procedure after changing hydraulic filters and fluid can result in irreparable damage to the transaxle drive system. Bleeding the Hydraulic System 1. Raise the rear of machine and support it with jack stands (or equivalent support) just high enough to allow the drive wheels to turn freely. g017625 Figure 85 1. Jacking points 2. 3.
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 86 • 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 87). g014974 Figure 89 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 91). Note: If the blade is not balanced, file some metal off the end of the sail area only (Figure 92).
3. Check the tire pressure in the drive tires; refer to Checking the Tire Pressure (page 55). 4. Position the mower deck in the transport-lock position. 5. Carefully rotate the blades from side to side. 6. Measure between the blade tip and the flat surface (Figure 96). If both measurements are not within 5 mm (3/16 inch), adjust the leveling; continue with this procedure. g298850 Figure 95 1. Top spindle nut 3. Blade bolt 2. Flat of the spindle shaft 3. 4.
9. For 60-inch mower decks only: A. Raise the deck to the transport position (140 mm or 5-1/2 inches). B. Slowly loosen the adjusting screw on the lift-assist spring until you can remove the screw (Figure 98). Note: Save the screw for installation. g038090 Figure 99 Bottom view 1. Block—73 mm (2-7/8 inches) 2. Welds Block Height and Rake Table Deck Size Front Block Height Rake All mower decks 73 mm (2-7/8 inches) 4.8 to 6.4 mm (3/16 to 1/4 inch) 13. 14. g334850 Figure 98 1.
17. Ensure that the blocks fit snugly under the deck skirt and that all attachment bolts are tight 18. Continue leveling the deck by checking the front-to-rear blade slope. 19. Check the blades for levelness and repeat deck leveling procedure if necessary. 20. For 60-inch mower decks only: Removing the Mower Deck Before servicing or removing the mower deck, lock out the spring-loaded deck arms. 1.
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. Never operate the machine unless you install a mulch plate, discharge deflector, or grass collection system. 1. Remove the locknut, bolt, spring, and spacer holding the deflector to the pivot brackets (Figure 102). 2. Remove the damaged or worn grass deflector (Figure 102). g015594 Figure 102 1.
Cleaning Cleaning under the Mower Deck Service Interval: After each use 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Raise the mower deck to the TRANSPORT position.
Storage 12. Check the condition of the blades; refer to Servicing the Cutting Blades (page 64). 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 engine overheats. Possible Cause 1. The engine load is excessive. 1. Reduce the ground speed. 2. The oil level in the crankcase is low. 3. The cooling fins and air passages under the engine-blower housing are plugged. 4. The air cleaner is dirty. 2. Add oil to the crankcase. 3. Remove the obstruction from the cooling fins and air passages. 5. Dirt, water, or stale fuel is in the fuel system. The malfunction-indicator light (MIL) comes on. 4.
Problem The engine does not start, starts hard, or fails to keep running. Possible Cause 1. The fuel tank is empty. 1. Fill the fuel tank. 2. The fuel-shutoff valve is closed. 3. The oil level in the crankcase is low. 4. The throttle is not in the correct position. 2. Open the fuel-shutoff valve. 3. Add oil to the crankcase. 4. Be sure that the throttle control is midway between the SLOW and FAST positions. 5. Replace the fuel filter. 6. Contact an Authorized Service Dealer. 5.
Problem The cutting height is uneven. The blades do not rotate. Possible Cause 1. The blade(s) is not sharp. 1. Sharpen the blade(s). 2. A cutting blade(s) is/are bent. 3. The mower is not level. 2. Install a new cutting blade(s). 3. Level the mower from side-to-side and front-to-rear. 4. Adjust the anti-scalp wheel height. 4. An anti-scalp roller (if applicable) is not set correctly. 5. The underside of the mower deck is dirty. 6. The tire pressure is incorrect. 7. A blade spindle is bent. 5.
Schematics g338323 Kawasaki Engines Electrical Schematic—Page 1 (Rev.
g338324 Kawasaki Engines Electrical Schematic—Page 2 (Rev.
g341124 Kohler Engines Electrical Schematic (Rev.
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.
