Form No. 3424-723 Rev A 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) 74902TE—Serial No. 74919TE—Serial No. 74925TE—Serial No. 74942TE—Serial No. 75969TE—Serial No.
This product complies with all relevant European directives; for details, please see the separate product specific Declaration of Conformity (DOC) sheet. code or visit www.Toro.com. You may also call us at 1-888-384-9939 to request a written copy of the product warranty. 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 Sheet-Metal Guard..................... 42 Lubrication .......................................................... 42 Greasing the Machine....................................... 42 Adding Light Oil or Spray Lubrication ................ 42 Greasing the Mower Deck ................................ 43 Lubricating the Caster-Wheel Hubs .................. 44 Engine Maintenance ........................................... 45 Engine Safety ...................................................
Safety Replacing the Grass Deflector .......................... 76 Cleaning .............................................................. 77 Cleaning under the Mower Deck ....................... 77 Cleaning the Suspension System ..................... 77 Disposing of Waste........................................... 77 Storage ................................................................... 77 Storage Safety.................................................. 77 Cleaning and Storage .......................
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. decal93-7818 93-7818 decalbatterysymbols 1. Warning—read the Operator's Manual for instructions on torquing the blade bolt/nut to 115 to 149 N∙m (85 to 110 ft-lb). Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 6. Keep bystanders a safe distance away from the battery. 2.
decal106-5517 106-5517 1. Warning—do not touch the hot surface. decal109-6036 109-6036 Machines with Rear Discharge Only 1. Read the Operator’s Manual. 2. Remove the key from the key switch and read the instructions before servicing or performing maintenance. 3. Height of cut decal110-2067 110-2067 decal107-3069 107-3069 1. Warning–there is no rollover protection when the roll bar is down. 2.
decal112-9028 112-9028 1. Warning—stay away from moving parts; keep all guards in place. decal115-9625 115-9625 Machines with MyRide™ Only 1. Parking brake—disengaged decal114-4466 2. Parking brake—engaged 114-4466 1. Main (25 A) 3. Charge (25 A) 2. PTO (10 A) 4. Auxiliary (15 A) decal116-1716 116-1716 1. Fuel 2. Empty 6. Hour meter 7. PTO 3. Half 8. Parking brake 4. Full 5. Battery 9. Neutral 10. Operator-presence switch decal114-4470 114-4470 1. Read the Operator's Manual. 2.
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 a safe distance away from the machine. 2. Thrown object hazard, mower—do not operate the machine without the deflector, discharge cover, or grass collection system in place. 3. Cutting/dismemberment of hand or foot—stay away from moving parts; keep all guards and shields in place. decal117-0346 117-0346 decal120-5897 120-5897 1.
decal120-5898 120-5898 1. Choke 2. Fast 4. Slow 5. Power takeoff (PTO), blade-control switch decal127-0326 127-0326 3. Continuous-variable setting 1. Read the Operator's Manual. 3. Remove the key from the ignition and read the Operator's Manual before performing maintenance or servicing the machine. 2. Height-of-cut decal126-2055 126-2055 1. Wheel lug nut torque 95 ft-lb (129 N∙m) (4x) 2. Wheel hub nut torque 235 ft-lb (319 N∙m) 3.
decal136-5522 136-5522 Rear-Discharge Machines Only decal132-5063 1. Belt routing; read the Operator’s Manual for greasing information. 132-5063 Machines with MyRide™ Only 1. Cam lock 2. Cam unlock decal136-5508 136-5508 1.
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), and proceed off the slope slowly. 2. Warning—do not operate this machine unless you are trained. 6. Crushing/dismemberment hazard of bystanders—do not carry passengers, and look forward and down when operating the machine, look behind and down when reversing. 3.
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 those conditions on that day and at that site.
Control Panel Product Overview g008951 Figure 5 1. Blade-control switch (power takeoff) 4. Hour meter/Safety-interlock display 2. Choke control 5. Key switch 3. Throttle control 6. Fuses g029631 Figure 4 1. Side-discharge deflector 8. Rear-shock assembly (machines with MyRide™ only) 2. Height-of-cut deck lift pedal 9. Seat belt 3. Parking-brake lever 10. Fuel cap 4. Transport lock 11. Mower deck 5. Controls 6. Motion-control levers 12. Caster wheel 13.
Fuel-Shutoff Valve Close the fuel-shutoff valve when transporting or storing the machine; refer to Using the Fuel-Shutoff Valve (page 35). Attachments/Accessories A selection of Toro approved attachments and accessories is available for use with the machine to enhance and expand its capabilities. Contact your Authorized Service Dealer or authorized Toro distributor or go to www.Toro.com for a list of all approved attachments and accessories. g008950 Figure 6 1. Safety-interlock symbols 4.
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.
• • • • • • • Using Stabilizer/Conditioner containers on the ground, away from your vehicle before filling. Remove the equipment from the truck or trailer and refuel it while it is on the ground. If this is not possible, then refuel from a portable container rather than a fuel-dispenser nozzle. Do not operate the machine without the entire exhaust system in place and in proper working condition.
Performing Daily Maintenance Before starting the machine each day, perform the Each Use/Daily procedures listed in Maintenance (page 40). 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.
Lowering the Roll Bar Important: Lower the roll bar only when absolutely necessary. 1. To lower the roll bar, apply forward pressure to the upper part of the roll bar. 2. Pull both knobs out and rotate them 90 degrees so they are not engaged (Figure 8). 3. Lower the roll bar to the down position (Figure 8). 1. Raise the roll bar to the operating position and rotate the knobs until they move partially into the grooves (Figure 8). 2.
Testing the Safety-Interlock System Service Interval: Before each use or daily 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. 1. Sit on the seat, engage the parking brake, and move the blade-control switch (PTO) to the ON position. Try starting the engine; the engine should not start. 2.
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 MyRide™ Suspension System Adjust the rear-shock assemblies (Figure 15). 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 Adjusting the Rear-Shock Assemblies The slots for the rear-shock assemblies have detent positions for reference.
During Operation • Never run an engine in an area where exhaust During Operation Safety • • General Safety • The owner/operator can prevent and is responsible • • • • • • • • • • • • • • • for accidents that may cause personal injury or property damage. Wear appropriate clothing, including eye protection; long pants; slip-resistant, substantial footwear; and hearing protection. Tie back long hair and do not wear loose jewelry. Use your full attention while operating the machine.
injury or death. The operator is responsible for safe slope operation. Operating the machine on any slope requires extra caution. Before using the machine on a slope, do the following: – Review and understand the slope instructions in the manual and on the machine. – Use an angle indicator to determine the approximate slope angle of the area. – Never operate on slopes greater than 15 degrees. – Evaluate the site conditions of the day to determine if the slope is safe for machine operation.
Operating the Parking Brake Operating the Mower Blade-Control Switch (PTO) Always engage the parking brake when you stop the machine or leave it unattended. The blade-control switch (PTO) starts and stops the mower blades and any powered attachments. Engaging the Parking Brake Engaging the Blade-Control Switch (PTO) Park the machine on a level surface. Note: Engaging the blade-control switch (PTO) with the throttle position at half or less causes excessive wear to the drive belts.
Operating the Choke Starting the Engine Use the choke to start a cold 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. 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).
Using the Motion-Control Levers Shutting Off the Engine CAUTION Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. Always remove the key and engage the parking brake when leaving the machine unattended. g004532 Figure 27 1. Motion-control lever—NEUTRAL-LOCK position 4. Backward 2. Center, unlocked position 5. Front of machine 3. Forward Driving the Machine The drive wheels turn independently, powered by hydraulic motors on each axle.
Driving Backward WARNING The machine can spin very rapidly. You may lose control of the machine and cause personal injury or damage to the machine. 1. Move the levers to the center, unlocked position. 2. To go backward, slowly pull the motion-control levers rearward (Figure 29). • 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.
Using the Side Discharge Adjusting the Height of Cut Machines with Side Discharge Only Using the Transport Lock The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. 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).
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. 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 31. 3.
g029957 Figure 34 1. Anti-scalp roller 4. Flange nut 2. Spacer 5. Bolt 3. Bushing g024242 Figure 35 Adjusting the Anti-Scalp Rollers 1. Flange nut 3. Bushing 2. Anti-scalp roller 4. Bolt For 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.
Adjusting the Flow Baffle Cam Locks 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 is applicable only to machines with the flow-baffle locks. Certain models have nuts and bolts in place of the flow-baffle locks and can be adjusted the same.
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 only recommendations for use. 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 up the baffle. Position A This is the full 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.
2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Rotate the release-valve levers vertically to push the machine (Figure 43). Note: This allows hydraulic fluid to bypass the pump, enabling the wheels to turn. 4. Disengage the parking brake before pushing the machine. g008948 Figure 42 1. ON position 2. OFF position Using the Drive-Wheel-Release Valves g015123 Figure 43 WARNING 1.
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. Using the Z StandTM 2. If applicable, connect the trailer brakes and lights. The Z Stand raises the front end of the machine to allow you to clean the mower and remove the blades. 3. Lower the ramp, ensuring that the angle between the ramp and the ground does not exceed 15 degrees (Figure 44). 4. WARNING The machine could fall onto someone and cause serious injury or death.
4. Driving off the Z Stand Swing the stand foot out front and slide it toward machine, into the bottom of slot (Figure 47 and Figure 48). 1. Remove the chocks or blocks. 2. Raise the latch to the unlocked position (Figure 49). g001812 Figure 48 1. Z Stand (positioned in slot) 3. Latch resting on pivot tab 2. Crack in side walk or turf g001813 5. 6. 7. Figure 49 Set the foot of the stand on the ground and rest the latch on the pivot tab (Figure 48). 1. Z Stand 3.
Maintenance Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 8 hours • Change the engine oil. After the first 100 hours • Check the wheel lug-nut torque. • Check the wheel-hub slotted-nut torque. • Check the parking brake adjustment. After the first 250 hours • Change the hydraulic filters and hydraulic fluid when using any type of fluid. Before each use or daily • • • • • • • • • Check the safety system. Check the engine-oil level.
CAUTION If you leave the key in the switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the switch before you perform any maintenance. Pre-Maintenance Procedures Releasing the Mower-Deck Curtain Maintenance Safety Loosen the bottom bolt of the curtain to release the mower-deck curtain and access the top of the mower deck (Figure 50). Tighten the bolt after maintenance to install the curtain.
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 51). Install the sheet-metal guard and tighten the bolts after maintenance. Grease more frequently when operating conditions are extremely dusty or sandy. 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. Yearly—Grease the front caster pivots (more often in dirty or dusty conditions). Yearly—Repack the front caster-wheel bearings (more often in dirty or dusty conditions). 1. Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3.
Lubricating the Caster-Wheel Hubs Service Interval: Yearly 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. g024207 Figure 56 Machines with Rear Discharge Only 8. Install the sheet-metal guard. Refer to Releasing the Mower-Deck Curtain (page 41). 9. Tighten the bolt for the mower-deck curtain.
Note: Make sure that the axle does not extend surface of the spacer nut to the end of the axle inside the nut. 12. Insert the assembled nut and axle into the wheel on the side of the wheel with the new seal and bearing. 13. With the open end of the wheel facing up, fill the area inside the wheel around the axle full of general-purpose grease. 14. Insert the second bearing and new seal into the wheel. 15.
Servicing the Engine Oil Note: Holes in the filter appear as bright spots. If the filter is damaged, discard it. Engine-Oil Specifications Inspecting the Filters 1. 2. Inspect the safety filter. If it is dirty, replace both the safety and primary filters. Oil Type:: Detergent oil (API service SF, SG, SH, SJ or SL) Important: Do not attempt to clean the Engine Oil Capacity: safety filter. If the safety filter is dirty, then the primary filter is damaged. • Model 74902TE, 74919TE, 75969TE: 2.
g027734 Figure 62 5. g194611 Figure 61 Changing the Engine Oil Service Interval: After the first 8 hours—Change the engine oil. Every 100 hours—Change the engine oil (more often in dirty or dusty conditions). 1. Park the machine so that the drain side is slightly lower than the opposite side to ensure that the oil drains completely. 2. Disengage the blade-control switch (PTO) and engage the parking brake. 3.
Changing the Engine-Oil Filter Service Interval: Every 200 hours—For Kawasaki engines—change the engine-oil filter (more often in dirty or dusty conditions). 1. Drain the oil from the engine; refer to Changing the Engine Oil (page 47). 2. Change the engine-oil filter (Figure 64). g008804 g027660 Figure 63 6. Dispose of the used oil at a recycling center. g027477 Figure 64 Note: Ensure that the oil-filter gasket touches the engine, and then turn the oil filter an extra 3/4 turn. 3.
Servicing the Spark Plug 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. g009922 Type of Spark Plug: NGK® BPR4ES or equivalent Air Gap: 0.75 mm (0.03 inch) Removing the Spark Plug 1.
5. Checking the Spark Arrester Install the left hydraulic-unit shroud (Figure 65). Checking the Spark Plug For Machines with a Spark Arrester Important: Do not clean the spark plug(s). Always replace the spark plug(s) when it has a black coating, worn electrodes, an oily film, or cracks. Service Interval: Every 50 hours 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.
Fuel System Maintenance Electrical System Maintenance Replacing the Fuel Filter Electrical System Safety Service Interval: Every 200 hours (more often in dusty, dirty conditions). • 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. Every 500 hours/Yearly (whichever comes first) (more often in dusty, dirty conditions).
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 70. 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 70). 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 73). 1. To replace the fuses, pull out on the fuse to remove it. 2. Install a new fuse (Figure 73).
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 fast and slow. 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.
g001297 Figure 79 1. Spring washers 3. Dust cap 2. Locknut g024121 Figure 78 1. Slotted nut Using the Clutch Shim Some later model year units have been built with clutches that contain a brake shim. When the clutch brake has worn to the point where the clutch no longer engages consistently, you can remove the shim to extend the clutch life. Adjusting the Caster-Pivot Bearing Service Interval: Every 500 hours/Yearly (whichever comes first) 1.
2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Using an air compressor, blow out any debris from under the brake pole and around the brake spacers (Figure 81). Note: Do not discard the shim until the clutch is functioning properly. g010871 Figure 83 1. Shim C. Using a pneumatic line, blow out any debris from under the brake pole and around the brake spacers. D. Torque each bolt (M6 x 1) to 12.3 to 13.7 N∙m (9.5 to 10.
Cooling System Maintenance Cleaning the Engine Screen and Engine-Oil Cooler Service Interval: Before each use or daily g010873 Figure 85 Remove any buildup of grass, dirt, or other debris from the oil cooler and the engine screen (Figure 86). 1. Feeler gauge • If the gap is less than 0.25 mm (0.01 inch), then install the shim; refer to Using the Clutch Shim (page 56). • If the gap is sufficient, proceed to the safety check in step F. F. g008804 Perform the following safety check: i.
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 Adjusting the Parking Brake Service Interval: After the first 100 hours Every 500 hours thereafter Note: Perform this procedure at the recommended service interval or when a brake component has been removed or replaced. 1. 2. 3. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. g026961 Figure 89 Left Side Shown Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
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.
8. Remove the 3 bolts holding the metal belt cover in place and remove the metal belt cover. g027730 Figure 92 1. Position the belt cover 3. Ensure that the tab is under the metal catch 2. Slide the belt cover under the side catches g024145 15. Install the sheet-metal guard. Refer to Removing the Sheet-Metal Guard (page 42). 16. Tighten the bolt for the mower-deck curtain. Refer to Releasing the Mower-Deck Curtain (page 41). Figure 93 2.
5. Remove the sheet-metal guard. Refer to Removing the Sheet-Metal Guard (page 42). 6. Remove the belt covers (Figure 94). g027729 Figure 94 7. Remove the counter-rotating belt; refer to Replacing the Counter-Rotating Belt (page 62). 8. Use a ratchet in the square hole in the idler arm to remove tension on the idler spring (Figure 95). 9. Remove the belt from the mower-deck pulleys and the clutch pulley. 10.
g027730 Figure 96 g009039 Figure 97 14. 15. Install the sheet-metal guard. Refer to Removing the Sheet-Metal Guard (page 42). 1. Idler pulley 5. Left hydraulic-pump pulley 2. Clutch pulley Tighten the bolt for the mower-deck curtain. Refer to Releasing the Mower-Deck Curtain (page 41). 3. Pump-drive belt 6. Square hole in the idler arm 7. Idler spring 4. Right hydraulic-pump pulley Replacing the Hydraulic Pump-Drive Belt 1.
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 98). 4.
5. Raise the rear of machine up and support it with jack stands (or equivalent support). Note: Raise the machine just high enough to allow the drive wheels to turn freely. 6. 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. 7. Temporarily install a jumper wire across the terminals in the connector of the main wire harness. 8. Start the engine and run it at full throttle and disengage the brake.
Hydraulic System Maintenance Hydraulic System Safety • Seek immediate medical attention if fluid is injected into skin. Injected fluid must be surgically removed within a few hours by a doctor. Ensure that all hydraulic-fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to the hydraulic system. Keep your body and hands away from pinhole leaks or nozzles that eject high-pressure hydraulic fluid.
7. Wipe the dipstick off and thread the dipstick into the reservoir. 8. Remove the dipstick and look at the end (Figure 103). Replacing the Hydraulic Fluid and Filters Service Interval: After the first 250 hours—Change the hydraulic filters and hydraulic fluid when using any type of fluid. Important: Do not overfill the hydraulic units with fluid, as damage may occur. Do not run the machine with fluid below the add mark. 9.
5. Mower Deck Maintenance Place a drain pan under the filter, remove the old filter, and wipe the surface clean (Figure 105). Leveling the Mower Deck Leveling the Deck 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. Check the tire pressure in the drive tires; refer to Checking the Tire Pressure (page 55). 4.
9. On both sides of the deck, measure from the level surface to the front tip of the blade (Postion A) as shown in Figure 107. Note: The measurement should read 7.6 mm (3 inches) g009196 g027344 Figure 107 1. 7.6 cm (3 inch) at position A is correct 2. 8.3 cm (3-1/4 inch) at position B is correct Figure 108 3. Measure here from the blade tip to the hard surface 4. Measure at position A and B on both sides 1. Adjustment nut 3. Rear deck adjustment 2. Jam nut 4. Front deck adjustment 11. 10.
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 107. 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 108).
Servicing the Cutting Blades To ensure a superior quality of cut, keep the blades sharp. For convenient sharpening and replacement, you may want to keep extra blades on hand. Blade Safety g006530 Figure 112 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. • Inspect the blades periodically for wear or damage.
Removing the Blades Side-Discharge Machines Replace the blades if they hit a solid object, or if the blade is out of balance or bent. 1. Hold the blade end using a rag or thickly padded glove. 2. Remove the blade bolt, curved washer, and blade from the spindle shaft (Figure 114). g004536 Figure 115 Left and Center Spindle Shown 1. Sail area of the blade 2. Blade 3. Curved washer 4. Blade bolt g004536 Figure 114 1. Sail area of the blade 2. Blade 3. Curved washer 4.
Sharpening the Blades 1. Rear-Discharge Machines Important: The right blade on this mower deck is counter-rotating and uses a left-threaded blade bolt. Use Figure 116 for the correct placement of the mower blades. 1. Install the left and center blades, curved washers, and blade bolts to the spindle shafts (Figure 115 and Figure 116). Use a file to sharpen the cutting edge at both ends of the blade (Figure 117). Note: Maintain the original angle.
g009038 g024146 Figure 119 Side-Discharge Machines 1. Clutch pulley 2. Mower belt 3. Spring-loaded idler pulley Figure 120 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 122 1. Bolt 5. Spring installed 2. Spacer 6. Grass deflector 3. Locknut 7. J-hook end of spring 4. Spring g024670 Figure 121 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 Storage Cleaning under the Mower Deck Storage Safety • Shut off the engine, remove the key, wait for all moving parts to stop, and allow the machine to cool before storing it. Service Interval: Before each use or daily 1. • Do not store the machine or fuel near flames or Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2.
13. Prepare the machine for storage when non-use occurs over 30 days. Prepare the machine for storage as follows: A. Add a petroleum-based stabilizer/conditioner to fuel in the tank. Follow mixing instructions from the stabilizer manufacturer. Do not use an alcohol-based stabilizer (ethanol or methanol). Note: A fuel stabilizer/conditioner is most effective when mixed with fresh fuel and used at all times. B. Run the engine to distribute conditioned fuel through the fuel system for 5 minutes. C.
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 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. The pump belt is off a pulley. 4.
Schematics g009180 Wire Diagram (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.
