Form No. 3417-743 Rev B Z Master® Professional 5000 or 6000 Series Riding Mower with 48in, 52in, 60in, or 72in TURBO FORCE® Side or Rear Discharge 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. Register at www.Toro.com. Original Instructions (EN) 74904—Serial No. 74906—Serial No. 74918—Serial No. 74926—Serial No. 74928—Serial No. 74930—Serial No. 74943—Serial No. 74945—Serial No. 75951—Serial No. 75955—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.
Shutting Off the Engine..................................... 26 Using the Motion-Control Levers....................... 27 Driving the Machine .......................................... 27 Using the Side Discharge ................................. 28 Adjusting the Height of Cut ............................... 29 Adjusting the Anti-Scalp Rollers........................ 30 Adjusting the Anti-Scalp Rollers........................ 30 Adjusting the Skid(s).........................................
Safety Checking and Cleaning the Hydraulic-Unit Shrouds ........................................................ 57 Brake Maintenance ............................................. 58 Adjusting the Parking Brake.............................. 58 Belt Maintenance ................................................ 59 Inspecting the Belts .......................................... 59 Replacing the Mower Belt for Side-Discharge Mower Decks ................................................
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 decal116-8726 112-9028 116-8726 1. Warning—stay away from moving parts; keep all guards in place. 1. Read the Operator’s Manual for the recommended hydraulic fluid. decal115-9625 115-9625 Machines with MyRide™ Only 1. Parking brake—disengaged 2. Parking brake—engaged decal117-0346 decal116-4858 117-0346 116-4858 1. Fuel leak hazard—read the Operator's Manual; do not attempt to remove the roll bar; do not weld, drill, or modify the roll bar in any way.
decal117-3864 117-3864 decal117-3848 117-3848 1. Read the Operator’s Manual. 1. Thrown object hazard—keep bystanders a safe distance away from the machine. 2. Fill to bottom of filler neck; warning—do not overfill the tank. 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. decal119-6807 119-6807 1.
decal126-2055 126-2055 1. Wheel lug nut torque 129 N∙m (95 ft-lb) (4x) 2. Wheel hub nut torque 319 N∙m (235 ft-lb) 3. Read and understand the Operator’s Manual before performing any maintenance, check torque after first 100 hours then every 500 hours thereafter. g224114 126-5641 1. PTO 4. Operator-presence switch 2. Parking brake 5. See user’s guide for operating condition code 3. Neutral decal126-7875 126-7875 1. Fuse location 4. Auxiliary, 15A 2. Relay location 5. Start relay 3. Main, 20A 6.
decal127-6661 127-6661 Rear-Discharge Machines Only decal132-5063 132-5063 Machines with MyRide™ Only 1. Attention—read the Operator's Manual for information on removing the blade. 1. Cam lock 2. Cam unlock decal127-6663 127-6663 1. Warning—read the Operator's Manual. 2. Crushing hazard—1) Engage the parking brake, shut off the engine, and remove the key; 2) Jack the machine using a manufacturer-approved jack, and always use a jackstand. decal136-5508 136-5508 Side-Discharge Machines Only 1.
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.
decal137-9208 137-9208 1. Fast 4. Engine—stop 2. Slow 5. Engine—run 3. PTO 6. Engine—start decal136-5522 136-5522 Rear-Discharge Machines Only 1. Belt routing; read the Operator’s Manual for greasing information.
Controls Product Overview Become familiar with all the controls before you start the engine and operate the machine. Control Panel g232246 Figure 5 g029631 Figure 4 1. Grass deflector (side-discharge machines) 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. Front-shock assembly (machines with MyRide only) 1.
Fuel Gauge Fuel-Shutoff Valve When the fuel-tank level is low, the LED status light flashes a red light and the fuel-level symbol on the screen flashes. Close the fuel-shutoff valve when transporting or storing the machine; refer to Using the Fuel-Shutoff Valve (page 34). Refer to the Software Guide for more information.
Specifications Note: Specifications and design are subject to change without notice.
Operation • Do not fill containers inside a vehicle or on a truck or trailer bed with a plastic liner. Always place containers on the ground, away from your vehicle before filling. Note: Determine the left and right sides of the machine from the normal operating position. • 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.
Adding Fuel Recommended Fuel • For best results, use only clean, fresh (less than 30 days old), unleaded gasoline with an octane rating of 87 or higher ((R+M)/2 rating method). • Ethanol: Gasoline with up to 10% ethanol (gasohol) or 15% MTBE (methyl tertiary butyl ether) by volume is acceptable. Ethanol and MTBE are not the same. Gasoline with 15% ethanol (E15) by volume is not approved for use.
Using the Rollover-Protection System (ROPS) WARNING To avoid injury or death from rollover, keep the roll bar in the fully raised, locked position and use the seat belt. Ensure that the seat is secured to the machine. WARNING There is no rollover protection when the roll bar is in the down position. • Lower the roll bar only when absolutely necessary. • Do not wear the seat belt when the roll bar is in the down position. • Drive slowly and carefully. • Raise the roll bar as soon as clearance permits.
Testing the Safety-Interlock System Using the Safety-Interlock System Service Interval: Before each use or daily WARNING 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. If the safety-interlock switches are disconnected or damaged, the machine could operate unexpectedly, causing personal injury. 1.
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.
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.
Driving Backward Using the Side Discharge 1. Move the levers to the center, unlocked position. 2. To go backward, slowly pull the motion-control levers rearward (Figure 28). Machines with Side Discharge Only The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. DANGER Without a grass deflector, discharge cover, or a complete grass-catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris.
Adjusting the Height of Cut Adjusting the Height-of-Cut Pin Using the Transport Lock The height-of-cut is adjusted from 25 to 140 mm (1 to 5-1/2 inches) in 6 mm (1/4 inch) increments by relocating the clevis pin into different hole locations. The transport lock has 2 positions, and is used with the deck-lift pedal. There is a LOCK position and an UNLOCK position for the transport position of the mower deck (Figure 29). 1. Move the transport lock to the lock position. 2.
Adjusting the Anti-Scalp Rollers For Machines with Side Discharge Whenever you change the height-of-cut, adjust the height of the anti-scalp rollers. 1. Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. g029957 Figure 33 Adjust the anti-scalp rollers as shown in Figure 31, Figure 32, and Figure 33. 1. Anti-scalp roller 4.
Adjusting the Skid(s) For Machines with Rear 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). Note: When the skids become worn, switch the skid to the opposite sides of the mower, flipping them over. This allows you to use the skids longer before replacing them. g024242 1.
Adjusting the Flow Baffle Cam Locks Positioning the Flow Baffle For Machines with Side Discharge For Machines with Side Discharge The following figures are only recommendations for use. Adjustments vary by grass type, moisture content, and the height of the grass. 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.
Position B Operating Tips Use this position when bagging. Always align it with the blower opening. 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.
Stopping the Machine Using the Fuel-Shutoff Valve If you must stop the forward motion of the machine while mowing, a clump of grass clippings may drop onto your lawn. To avoid this, move onto a previously cut area with the blades engaged or you can disengage the mower deck while moving forward. The fuel-shutoff valve is located under the seat. Move the seat forward to access it. Close the fuel-shutoff valve for transport, maintenance, and storage.
Transporting the Machine The drive-wheel-release valves are located in the back of each hydraulic-drive unit, under the seat. Use a heavy-duty trailer or truck to transport the machine. Use a full-width ramp. Ensure that the trailer or truck has all the necessary brakes, lighting, and marking as required by law. Please carefully read all the safety instructions. Knowing this information could help you or bystanders avoid injury. Refer to your local ordinances for trailer and tie-down requirements.
1. If using a trailer, connect it to the towing vehicle and connect the safety chains. 2. If applicable, connect the trailer brakes and lights. 3. Lower the ramp, ensuring that the angle between the ramp and the ground does not exceed 15 degrees (Figure 43). 4. Back the machine up the ramp (Figure 44). g028043 Figure 44 1. Back the machine up the ramp. 2. Drive the machine forward down the ramp. 5. Shut off the engine, remove the key, and engage the parking brake. 6.
Maintenance Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure 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. Check the seat belt. Check the roll bar knobs.
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 Lubrication Maintenance Safety Grease more frequently when operating conditions are extremely dusty or sandy. Greasing the Machine • Before repairing the machine do the following: Grease Type: No. 2 lithium or molybdenum grease – Disengage the drives.
Adding Light Oil or Spray Lubrication Greasing the Mower Deck Service Interval: Yearly—Grease the pump-belt-idler arm. Service Interval: Every 100 hours Yearly—Grease the front caster pivots (more often in dirty or dusty conditions). Lubricate the deck-lift pivots. 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.
g024207 Figure 51 Machines with Rear Discharge Only g192516 Figure 49 Machine with Rear Discharge Shown 4. 6. Remove the dust cap and adjust the caster pivots. Note: Keep the dust cap off until greasing is Grease the drive-belt idler arms (Figure 50). done. 7. Remove the hex plug. 8. Thread a grease fitting into the hole. 9. Pump grease into the fitting until it oozes out around the top bearing. 10. Remove the grease fitting in the hole. 11. Install the hex plug and dust cap (Figure 52).
Lubricating the Caster-Wheel Hubs 12. Insert the assembled nut and axle into the wheel on the side of the wheel with the new seal and bearing. Service Interval: Yearly 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. Apply a thread-locking adhesive to the second spacer nut, and thread it onto the axle with the wrench flats facing outward. 16.
Engine Maintenance Engine Safety 6. Release the latches on the air cleaner and pull the air-cleaner cover off the air-cleaner body (Figure 55). 7. Clean the inside of the air-cleaner cover with compressed air. 8. Gently slide the primary filter out of the air-cleaner body (Figure 55). • Shut off the engine before checking the oil or adding oil to the crankcase. Keep your hands, feet, face, clothing, and other body parts away the muffler and other hot surfaces.
2. Checking the Engine-Oil Level Inspect the primary filter for damage by looking into the filter while shining a bright light on the outside of the filter. If the primary filter is dirty, bent, or damaged, replace it. Service Interval: Before each use or daily Note: Check the oil when the engine is cold. Note: Holes in the filter appear as bright spots. Do not clean the primary filter. Important: If you overfill or underfill the engine crankcase with oil and run the engine, you may damage the engine.
Changing the Engine Oil 6. Service Interval: Every 100 hours (more often in dirty or dusty conditions). Slowly pour approximately 80% of the specified oil into the filler tube and slowly add the additional oil to bring it to the Full mark (Figure 59). 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.
Changing the Engine-Oil Filter Servicing the Spark Plug Service Interval: Every 200 hours—Change the engine-oil filter (more often in dirty or dusty conditions). Service Interval: Every 500 hours—Check, clean and regap the spark plug. 1. Drain the oil from the engine; refer to Changing the Engine Oil (page 44). 2. Change the engine-oil filter (Figure 60). Ensure that the air gap between the center and side electrodes is correct before installing the spark plug.
5. Install the left hydraulic-unit shroud (Figure 61). Checking the Spark Plug Important: Replace the spark plug(s) when it has: a black coating, worn electrodes, an oily film, cracks or reuse is questionable. g009922 If you see light brown or gray on the insulator, the engine is operating properly. A black coating on the insulator usually means that the air cleaner is dirty. Set the gap to 0.76 mm (0.030 inches). g027479 Figure 63 Installing the Spark Plug Tighten the spark plug(s) to 24.4 to 29.
Checking the Spark Arrester Fuel System Maintenance For Machines with a Spark Arrester WARNING Fuel-system components are under high pressure. The use of improper components can result in system failure, fuel leakage, and possible explosion. Service Interval: Every 50 hours WARNING Hot exhaust-system components may ignite fuel vapors even after you shut off the engine. Hot particles exhausted during engine operation may ignite flammable materials, resulting in personal injury or property damage.
Electrical System Maintenance Electrical System Safety • Disconnect the battery before repairing the machine. Disconnect the negative terminal first and the positive last. Connect the positive terminal first and the negative last. • Charge the battery in an open, well-ventilated area, away from sparks and flames. Unplug the charger before connecting or disconnecting the battery. Wear protective clothing and use insulated tools. g008963 Figure 65 1. Fuel filter 2. Hose clamp Servicing the Battery 3.
2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Charging the Battery 3. Remove the battery as shown in Figure 66. Charging the battery produces gasses that can explode. WARNING Never smoke near the battery and keep sparks and flames away from the battery. Important: Always keep the battery fully charged (1.265 specific gravity). This is especially important to prevent battery damage when the temperature is below 0°C (32°F). 1.
Installing the Battery Jump-Starting the Machine Note: Position the battery in the tray with the terminal posts opposite from the hydraulic tank (Figure 66). 1. Check and clean corrosion from the battery terminals before jump-starting. Ensure that the connections are tight. CAUTION Corrosion or loose connections can cause unwanted electrical voltage spikes at any time during the jump-starting procedure.
machines do not touch and that both electrical systems are off and at the same rated system voltage. These instructions are for negative ground systems only. 3. Connect the positive (+) cable to the positive (+) terminal of the discharged battery that is wired to the starter or solenoid as shown in Figure 70. g024213 g013117 g012785 Figure 71 Figure 70 1. Positive (+) cable on discharged battery 5. Booster battery 2. Positive (+) cable on booster battery 6. Discharged battery 3.
Drive System Maintenance Checking the Seat Belt Service Interval: Before each use or daily Inspect the seat belt for wear, cuts, and proper operation of the retractor and buckle. Replace the seat belt if it is damaged. Checking the Roll-Bar Knobs Service Interval: Before each use or daily WARNING To avoid injury or death from rollover, keep the roll bar in the fully raised, locked position and use the seat belt. Ensure that the seat is secured to the machine.
Adjusting the Tracking 1. Disengage the blade-control switch (PTO). 2. Drive to an open flat area, move the motion-control levers to the NEUTRAL-LOCK position. Checking the Tire Pressure Service Interval: Every 50 hours/Monthly (whichever comes first) 3. Move the throttle midway between 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 77 1. Spring washers 3. Dust cap 2. Locknut g024121 Figure 76 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 79). Note: Do not discard the shim until the clutch is functioning properly. g010871 Figure 81 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 83 Remove any buildup of grass, dirt, or other debris from the oil cooler and the engine screen (Figure 84). 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 54). • 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 87 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.
g027730 Figure 90 1. Position the belt cover 3. Ensure that the tab is under the metal catch 2. Slide the belt cover under the side catches g024145 Figure 91 Replacing the Mower Belt for Rear-Discharge Mower Decks Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Lower the mower to the 76 mm (3 inches) height of cut. 4.
9. Rotate and ensure the belt-guide tab hits against the pivot hub (Figure 93). 10. Using the ratchet in the square hole, install the belt around the spring-loaded idler pulley (Figure 93). Seat the spring ends in the anchor grooves. 11. Install the belt covers (Figure 94). g027729 Figure 92 5. Remove the counter-rotating belt; refer to Replacing the Counter-Rotating Belt (page 60). 6. Use a ratchet in the square hole in the idler arm to remove tension on the idler spring (Figure 93). 7.
Controls System Maintenance Adjusting the Control-Handle Position There are 2 height positions for the control levers—high and low. Remove the bolts to adjust the height for the operator. 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Loosen the bolts and flange nuts installed in the levers (Figure 96). 4.
4. Lower deck to the ground. 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.
g008620 Figure 99 Right Motion Control Shown 1. Torque the locknut to 23 N∙m (17 ft-lb). The bolt must protrude past the end of the locknut after torquing. 2. Most resistance (firmest feel) 3. Damper 4. Medium resistance (medium feel) 5. Least resistance (softest feel) g027409 Figure 98 1. Double nuts 12.
Hydraulic System Maintenance Hydraulic System Safety 6. Remove 1 dipstick from the hydraulic reservoir (Figure 101). 7. Wipe the dipstick off and thread the dipstick into the reservoir. 8. Remove the dipstick and look at the end (Figure 101). • Seek immediate medical attention if fluid is injected Important: Do not overfill the hydraulic into skin. Injected fluid must be surgically removed within a few hours by a doctor. units with fluid, as damage may occur.
Replacing the Hydraulic Fluid and Filters 5. Place a drain pan under the filter, remove the old filter, and wipe the surface clean (Figure 103). Service Interval: After the first 250 hours—Change the hydraulic filters and hydraulic fluid when using any type of fluid. Every 250 hours—Change the hydraulic filters and hydraulic fluid when using Mobil® 1 fluid (more often in dirty or dusty conditions).
Mower Deck Maintenance 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 105. Note: The measurement should read 7.6 mm (3 inches) 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.
holes for further adjustment when leveling the mower deck. g010251 Figure 106 5000 Series Machines 1. Adjustment nut 3. Rear deck adjustment 2. Jam nut 4. Front deck adjustment g027345 Figure 108 1. Bolts at the bottom of the height-of-cut plate g025558 Figure 109 Rear-Discharge Machines Only g027344 Figure 107 6000 Series Machines 1. Adjustment nut 3. Rear deck adjustment 2. Jam nut 4. Front deck adjustment 11. 1. Mower deck 2. Front hole 12.
Servicing the Cutting Blades This regains some up and down adjustment on each of the 4 deck links. 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 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.
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. g006530 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 113). Figure 111 1. Cutting edge 3. Wear/slot forming 2. Curved area 4. Crack Checking for Bent Blades 1. Rotate the blades until the ends face forward and backward. 2.
Sharpening the Blades 1. Use a file to sharpen the cutting edge at both ends of the blade (Figure 116). Note: Maintain the original angle. Note: The blade retains its balance if the same amount of material is removed from both cutting edges. g000552 Figure 116 1. Sharpen at original angle. g004536 Figure 114 Left and Center Spindle Shown 1. Sail area of the blade 2. Blade 2. 3. Curved washer 4. Blade bolt Check the balance of the blade by putting it on a blade balancer (Figure 117).
Rear-Discharge Machines and remove the mower belt (Figure 118 or Figure 119). Important: The right blade on this mower deck is counter-rotating and uses a left-threaded blade bolt. Use Figure 115 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 114 and Figure 115). Important: The curved part of the blade must point upward toward the inside of the mower to ensure proper cutting.
g010252 Figure 120 1. Right stabilizer 2. Deck strut (right side shown) 3. Remove the shoulder bolt and nut. 4. Remove the shoulder bolt and nut. g024146 Figure 119 Rear-Discharge Machines 1. Clutch pulley 5. Belt guide 2. Mower belt 6. Spring-loaded idler pulley 3. Spring-loaded idler pulley 7. Square hole in the idler arm for the ratchet 8. Spring 4. Ensure that the belt-guide tab hits against the pivot hub. 7. 8. Raise the deck struts and secure them in the raised position. 9.
Cleaning Cleaning under the Mower Deck Service Interval: 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. g015594 Figure 121 1. Bolt 5. Spring installed 2. Spacer 6. Grass deflector 3. Locknut 7.
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 malfunction-indicator light (MIL) comes on. Possible Cause 1. The engine is too hot. 1. Shut off the engine and let it cool. 2. There is old fuel in the fuel tank. 3. The fuel-shutoff valve is not open completely. 4. The air cleaner is dirty. 2. Use new fuel. 3. Open the fuel-shutoff valve. 5. The battery is not charged. 6. Incorrect fuel filters are being used or the fuel filters are dirty. 7.
Problem The engine loses power. The engine overheats. Possible Cause 1. The engine load is excessive. 1. Reduce the ground speed. 2. The air cleaner is dirty. 3. The oil level in the crankcase is low. 4. The cooling fins and the air passages above the engine are plugged. 5. The vent hole in the fuel cap is plugged. 6. There is dirt in the fuel filter. 7. There is dirt, water, or stale fuel in the fuel system. 2. Clean the air-cleaner element. 3. Add oil to the crankcase. 4.
Problem The blades do not rotate. Possible Cause 1. The mower deck belt is damaged, worn, loose, or broken. 1. Install a new deck belt. 2. The mower deck belt is off the pulley. 2. Install the mower belt on the deck pulley and check the idler pulley, idler arm, and spring for correct position and function. 3. Check the belt tension or install a new belt. 4. Replace the spring. 3. The pump drive belt is worn, loose, or broken. 4. The idler spring is broken or missing. The clutch does not engage.
Electrical Schematic (Rev.
