Form No. 3417-811 Rev C Z Master® Professional 5000 Series Riding Mower with 60in or 72in TURBO FORCE® Side Discharge Mower Model No. 74933—Serial No. 401000000 and Up Model No. 74934—Serial No. 401000000 and Up Register at www.Toro.com.
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.
Contents This manual uses 2 words to highlight information. Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention. Safety ....................................................................... 4 Safety Alert Symbol ............................................ 4 General Safety ................................................... 5 Slope Indicator ................................................... 6 Safety and Instructional Decals ..
Safety Servicing the Electronic Fuel-Injection System.......................................................... 54 Electrical System Maintenance ........................... 54 Electrical System Safety ................................... 54 Servicing the Battery......................................... 54 Servicing the Fuses .......................................... 56 Jump-Starting the Machine............................... 56 Drive System Maintenance ..................................
General Safety This machine is capable of amputating hands and feet and of throwing objects. Toro designed and tested this lawn mower to offer reasonably safe service; however, failure to comply with safety instructions may result in injury or death. • Read, understand, and follow all instructions and warnings in the Operator’s Manual and other training material, on the machine, engine, and attachments. All operators and mechanics should be trained.
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 away from the battery. 2.
decal110-2068 110-2068 1. Read the Operator's Manual. decal112-9028 112-9028 1. Warning—stay away from moving parts; keep all guards and shields in place. decal107-3069 107-3069 1. Warning—there is no rollover protection when the roll bar is down. 2. To avoid injury or death from a rollover accident, keep the roll bar in the raised and locked position and wear the seat belt. Lower the roll bar only when absolutely necessary; do not wear the seat belt when the roll bar is down. 3.
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. decal119-6807 119-6807 1. Warning—no step decal117-0346 117-0346 1.
decal125-9383 125-9383 1. Check the hydraulic fluid every 50 operating hours. 3. Check the tire pressure every 50 operating hours. 2. Read the Operator’s Manual for information on lubricating the machine. 4. Read the Operator’s Manual before servicing or performing maintenance. 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.
decal126-3277 126-3277 1. IMPORTANT: Use only replacement tank(s) that are free of dents or damage. Match size and type required on tank specification decal. 7. Remove the empty tank(s). Check the valve and fittings for debris or damaged O-rings. 2. Stop the machine on a level surface, disengage the PTO, and engage the parking brake. 8. Install full replacement tank(s) by aligning the center hole on the tank collar over the mounting tab/index pin. 3.
decal126-4553 126-4553 g224114 126-5641 1. PTO 4. Operator-presence switch 2. Parking brake 5. See user’s guide for operating condition code decal127-0326 127-0326 1. Read the Operator's Manual. 3. Neutral 2. Height of cut decal126-7875 126-7875 1. Fuse location 4. Auxiliary (15 A) 2. Relay location 5. Start relay 3. Main (20 A) 6. Not used decal131-4036 131-4036 1. Maximum drawbar pull 36 kg (80 lb) 2. Read the Operator's Manual. 12 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.
decal136-5508 136-5508 decal132-5992 1. Belt routing 132-5992 1. Press down on the pedal to lift the deck. decal137-9208 137-9208 1. Fast 4. Engine—stop 2. Slow 5. Engine—run 3. PTO 6.
Controls Product Overview Become familiar with all the controls before you start the engine and operate the machine. Control Panel g232246 Figure 5 6. LPG fuel tank 2. Transport lock 7. Roll bar 3. Parking-brake lever 8. Motion-control levers 4. Controls 5. Seat belt 3. Hour meter/Safety-interlock display 2. Throttle control 4. Key switch Key Switch g027420 Figure 4 1. Height-of-cut deck-lift pedal 1.
Motion-Control Levers Refer to the Software Guide for more information. Use the motion-control levers to drive the machine forward, reverse, and turn either direction (Figure 4). Neutral-Lock Position Move the motion-control levers outward from the center to the NEUTRAL-LOCK position when exiting the machine (Figure 23). Always position the motion-control levers into the NEUTRAL-LOCK position when you stop the machine or leave it unattended. Parking-Brake Lever g231075 Figure 6 1.
Specifications also result in permanent fuel-system damage and the release of highly-flammable-propane liquid or vapor. Note: Specifications and design are subject to change without notice. Width 60-inch Deck 72-inch Deck Without Deck 134.6 cm (53.0 inches) 150.1 cm (59.1 inches) Deflector Up 156.8 cm (61.7 inches) 187 cm (73.6 inches) Deflector Down 192.2 cm (75.7 inches) 222.4 cm (87.6 inches) 60-inch Deck 72-inch Deck Roll Bar - Up 211.1 cm (83.1 inches) 218.7 cm (86.
Operation • Do Not operate the mower when people, especially Before Operation • Do Not operate the machine without the entire children, or pets are in the area. Stop the machine and attachment(s) if anyone enters the area. grass collection system, discharge deflector, or other safety devices in place and in proper working condition. Grass catcher components are subject to wear, damage and deterioration, which could expose moving parts or allow objects to be thrown.
DANGER DANGER LPG fuel is extremely flammable and vapors are explosive. LPG fuel is extremely flammable and vapors are explosive. A fire or explosion from LPG fuel can burn you, others, and cause property damage. • In case of fire take the following steps: 1. If you can safely do so, stop the flow of gas as quickly as possible. Never put out flame unless gas can be shut off. • Never smoke around tank(s) and stay away from an open flame or where fumes may be ignited by a spark.
WARNING Fuel system components are under high pressure. The use of improper components can result in system failure, fuel leakage and possible explosion. • Use only approved fuel lines and fuel filters for high pressure systems. To help prevent fires: • Keep engine and engine area free from accumulation of grass, leaves, excessive grease or oil, and other debris which can accumulate in these areas. • Clean up oil and fuel spills and remove fuel soaked debris.
Adding Fuel DANGER LPG fuel is extremely flammable and vapors are explosive. LPG (liquefied-petroleum gas) is more commonly called propane. LPG is a liquid fuel that is stored in a tank under pressure. Before the liquid leaves the tank, it is converted into a vapor. Since LPG is stored as both liquid and gas, it may leak from joints or connections that are not sealed properly. LPG becomes flammable when it is mixed with air. • In case of fire, take the following steps: 1.
g021393 Figure 8 1. Cylinder brackets g021497 2. Mounting pin Figure 7 1. LPG fuel hose connection fitting 3. Fuel gauge 2. Tank valve 4. Safety pressure-relief valve 7. 3. Center hole Important: The valves and gauges may not function properly if the LPG tank is not installed correctly. Unlatch the cylinder brackets and remove the tank. WARNING Fuel system components are under high pressure.
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.
Positioning the Seat Changing the Seat Suspension The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable (Figure 11). The seat is adjustable to provide a smooth and comfortable ride. Position the seat where you are most comfortable. To adjust it, turn the knob in front either direction to provide the best comfort (Figure 13). g019754 Figure 11 Unlatching the Seat To unlatch the seat, push the seat latch forward (Figure 12).
WARNING WARNING Engine exhaust contains carbon monoxide, which is an odorless deadly poison that can kill you. Hands, feet, hair, clothing, or accessories can become entangled in rotating parts. Contact with the rotating parts can cause traumatic amputation or severe lacerations. – Do Not operate the machine without guards, shields, and safety devices in place and working properly. – Keep hands, feet, hair, jewelry, or clothing away from rotating parts.
– Before and while backing or changing direction, look behind, down, and side-to-side for small children. – Never allow children to operate the machine. – Do Not carry children, even with the blades shut off. Children could fall off and be seriously injured or interfere with the safe operation of the machine. Children that have been given rides in the past could suddenly appear in the working area for another ride and be run over or backed over by the machine.
Rollover Protection System (ROPS) Safety A Rollover Protection System (roll bar) is installed on the machine. WARNING There is no rollover protection when the roll bar is down. Wheels dropping over edges, ditches, steep banks, or water can cause rollovers, which may result in serious injury, death or drowning. • Do Not remove the ROPS. g029797 Figure 15 • Keep the roll bar in the raised and locked position and use seat belt. • Lower the roll bar only when absolutely necessary.
Operating the Mower Starting the Engine Raise the roll bar up and lock it into place, sit on Blade-Control Switch (PTO) 1. the seat, and fasten the seat belt (Figure 21). The blade-control switch (PTO) starts and stops the mower blades and any powered attachments. 2. Engaging the Blade-Control Switch (PTO) Slowly open the fuel valve to equalize the pressure in the tank (Figure 21). Note: The fuel valve is located on the top end of the LPG tank.
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. g027421 g008947 Figure 21 g027337 Figure 22 Important: Make sure that the fuel-shutoff valve is closed before transporting or storing the machine, as fuel leakage may occur. Engage the parking brake before transporting.
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).
Driving Backward 1. Move the levers to the center, unlocked position. 2. To go backward, slowly pull the motion-control levers rearward (Figure 25).
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 Anti-Scalp Rollers (also the 140 mm (5-1/2 inch) cutting height position) as shown in Figure 27. 3. To adjust, rotate the pin 90 degrees and remove the pin from the height-of-cut bracket (Figure 27). Whenever you change the height-of-cut, adjust the height of the anti-scalp rollers. 4. Select a hole in the height-of-cut bracket corresponding to the height-of-cut desired, and insert the pin (Figure 27). 1.
g027727 g029957 Figure 31 Figure 30 1. Anti-scalp roller 4. Flange nut 2. Spacer 5. Bolt Positioning the Flow Baffle 3. Bushing The following figures are only recommendations for use. Adjustments vary by grass type, moisture content, and the height of the grass. Adjusting the Flow Baffle Cam Locks Note: If the engine power draws down and the mower ground speed is the same, open up the baffle. This procedure is applicable only to machines with the flow-baffle locks.
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.
After Operation 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. After Operation Keeping the Underside of the Mower Deck Clean General Safety • Park machine on level ground, disengage drives, Clean clippings and dirt from the underside of the mower deck after each use. If grass and dirt build up inside the mower deck, cutting quality will eventually become unsatisfactory.
On flat ground, this requires a ramp to be at least four times (4X) as long as the height of the trailer or truck bed to the ground. A steeper angle may cause mower components to get caught as the unit moves from the ramp to the trailer or truck. Steeper angles may also cause the machine to tip or lose control. If loading on or near a slope, position the trailer or truck so that it is on the down side of the slope and the ramp extends up the slope. This will minimize the ramp angle.
above 120°F (49°C). If the temperature exceeds approximately 160°F (71°C), the tank will release highly flammable propane vapor. See Preparation in the Safety Section. • Do Not transport LPG tank(s) in the passenger space of a vehicle. • Do Not transport leaking fuel tanks. • Trailers must have appropriate markings to transport LPG. • Follow NFPA 58 and state and local regulations for transporting LPG. Towing the Machine • Do not attach towed equipment except at the hitch point.
Using the Drive-Wheel-Release Valves WARNING Hands may become entangled in the rotating drive components below the engine deck, which could result in serious injury. Shut off the engine, remove the key, and allow all moving parts to stop before accessing the drive-wheel-release valves. g024246 Figure 38 1. Vertical to push the machine WARNING The engine and hydraulic-drive units can become very hot. Touching a hot engine or hydraulic-drive units can cause severe burns. 5.
Maintenance WARNING Removal or modification of original equipment, parts and/or accessories may alter the warranty, controllability, and safety of the machine. Unauthorized modifications to the original equipment or failure to use original Toro parts could lead to serious injury or death. Unauthorized changes to the machine, engine, fuel or venting system, may violate applicable safety standards such as: ANSI, OSHA and NFPA and/or government regulations such as EPA and CARB.
• Use care when checking blades. Wrap the • WARNING blade(s) or wear gloves, and use caution when servicing them. Only replace damaged blades. Never straighten or weld them. Use jack stands to support the machine and/or components when required. If the engine must be running so an adjustment can be performed, contact with moving parts or hot surfaces may cause personal injury. Keep fingers, hands, and clothing clear of rotating components and hot surfaces.
Maintenance Service Interval Maintenance Procedure Every 200 hours • Change the engine-oil filter (more often in dirty or dusty conditions). • Check the spark plug(s). Every 250 hours • Service or replace the air-cleaner foam element (more often under dusty, dirty conditions). • After the initial change—change the hydraulic-system filters and fluid when using Mobil 1 15W50 fluid.
Greasing the Mower Deck Service Interval: Yearly—Grease the pump-belt-idler arm. 1. Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Grease the mower deck idler-pulley pivot until grease comes out the bottom (Figure 40). g021419 Figure 39 g185957 Figure 40 4. Grease the drive-belt-idler arm (Figure 41).
6. Remove the hex plug. Greasing the Caster-Wheel Hubs 7. Thread a grease fitting into the hole. Service Interval: Yearly 8. Pump grease into the fitting until it oozes out around the top bearing. 9. Remove the grease fitting in the hole. Note: Keep the dust cap off until greasing is done. 10. Install the hex plug and dust cap (Figure 42). 1. Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake. 2.
12. Insert the assembled nut and axle into the wheel on the side with the new seal and bearing. Engine Maintenance 13. With the open end of the wheel facing up, fill the area inside the wheel around the axle full of general-purpose grease. Engine Safety 14. Insert the second bearing and new seal into the wheel. 15. Apply a thread-locking compound to the second spacer nut, and thread it onto the axle with the wrench flats facing outward. 16.
10. Inspect the primary filter for damage by looking into the filter, while shining a bright light on the outside of the filter. Note: Holes in the filter will appear as bright spots. If the filter is damaged, discard it. Servicing the Foam Element 1. Wash the foam element in liquid soap and warm water. When the element is clean, rinse it thoroughly. 2. Dry the element by squeezing it in a clean cloth. Important: Replace the foam element if it is torn or worn. g028105 Figure 44 1.
Installing the Filters Servicing the Engine Oil Important: To prevent engine damage, always Service Interval: Before each use or daily operate the engine with both air filters and the cover installed. 1. Every 100 hours (more often in dirty or dusty conditions). If you are installing new filters, check each filter for shipping damage. Every 200 hours—Change the engine-oil filter (more often in dirty or dusty conditions). Note: Do not use a damaged filter. 2.
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 48). g021395 g021395 g194611 Figure 47 g027734 Figure 48 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 49). g021395 g194610 Figure 49 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 49). 2. Change the engine-oil filter (Figure 50).
Servicing the Spark Plug(s) 4. Remove the spark plug. Service Interval: Every 200 hours—Check the spark plug(s). Every 500 hours—Replace the spark plug(s). Type: Champion XC12YC Air Gap: 0.76 mm (0.03 inch) g021396 Removing the Spark Plug(s) 1. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 2. Disengage the PTO, move the motion-control levers to the NEUTRAL-LOCK position, and engage the parking brake. 3.
Checking the Spark Arrester For Machines with a Spark Arrester Service Interval: Every 50 hours WARNING Hot exhaust-system components may ignite fuel vapors even after you shut off the engine. Hot particles exhausted during engine operation may ignite flammable materials, resulting in personal injury or property damage. g028109 Figure 54 Do not refuel or run the engine unless the spark arrester is installed. 52 1. Park the machine on a level surface, disengage the PTO, and engage the parking brake.
Fuel System Maintenance 2. Look for deterioration and worn or missing O-rings on the tank connection fitting. 3. Inspect the LPG tank and the fuel-connection joint for leaks. Use the following procedure below to detect leaks: Inspecting the LPG System A. Service Interval: Before each use or daily—Check the LPG tank and components. Every 40 hours—Check the LPG hoses, regulator, and connections.
Servicing the Electronic Fuel-Injection System Electrical System Maintenance This machine contains an electronic fuel-injection system. It controls the fuel flow under different operating conditions. Electrical System Safety • Disconnect the battery before repairing the The electronic-control unit (ECU) continuously monitors the operation of the EFI system. machine. Disconnect the negative terminal first and the positive last. Connect the positive terminal first and the negative last.
2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Charging the Battery 3. Remove the battery as shown in Figure 55. 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 55). 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 59. g021395 g012785 g013117 Figure 59 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 Rollover Protection System (ROPS) 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.
6. Checking the Wheel Lug Nuts Tighten the stop plate (Figure 62). Check and torque the wheel lug nuts to 122 to 129 N∙m (90 to 95 ft-lb). Checking the Wheel-Hub Slotted Nut Service Interval: After the first 100 hours Every 500 hours Check and ensure that the torque of the slotted nut is 286 to 352 N∙m (211 to 260 ft-lb). Note: Do not use anti-seize compound on wheel hub. g027424 Figure 62 Left control lever shown 1. Control lever 3. Stop plate 2.
Adjusting the Caster-Pivot Bearing Removing 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. Service Interval: Every 500 hours/Yearly (whichever comes first) 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2.
5. Verify that 12 V is present at the clutch connector when the blade-control switch (PTO) switch is engaged. the rotor and the armature face on both sides of the brake pole as shown in Figure 70 and Figure 71. 6. Measure the gap between the rotor and armature. If the gap is greater than 1 mm (0.04 inch), do the following steps: Note: Due to the way the rotor and the A. armature faces wear (peaks and valleys) it is sometimes difficult to measure the gap accurately.
Cleaning the Engine-Cooling Fins and Shrouds Cooling System Maintenance Cleaning the Engine Screen and Engine-Oil Cooler 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. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove the air-intake screen, the recoil starter, and the fan housing (Figure 73). 4.
Brake Maintenance Checking and Cleaning the Hydraulic-Unit Shrouds Adjusting the Parking Brake Service Interval: Before each use or daily 1. 2. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. Service Interval: After the first 100 hours Every 500 hours thereafter Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Move the seat forward. 4.
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 g026961 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2.
g027730 Figure 78 1. Position the belt cover. 2. Slide the belt cover under the side catches. g009038 Figure 77 1. Clutch pulley 2. Mower belt 5. Square hole in the idler arm for the ratchet 6. Idler-grease fitting 3. Spring-loaded idler pulley 7. Belt guide 4. Ratchet 10. Install the belt guide on the idler arm (Figure 77). 11. Using the ratchet in the square hole, install the idler spring (Figure 77). Note: Make sure that the spring ends are seated in the anchor grooves. 12.
Replacing the Hydraulic Pump-Drive Belt 1. 2. Controls System Maintenance Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. Adjusting the Control-Handle Position 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 64). 4. Raise the machine and support it with jack stands (Figure 79).
4. Raise the rear of the machine up and support it with jack stands (or equivalent support) just high enough to allow the drive wheels to turn freely. 5. Remove the electrical connection from the seat safety switch, located under the bottom cushion of the seat. Note: The switch is a part of the seat assembly. 6. Temporarily install a jumper wire across the terminals in the connector of the main wire harness. 7. Start the engine, run it at full throttle, and disengage the parking brake.
11. Adjusting the Motion-Control Neutral-Lock Pivot Move the motion-control levers to the REVERSE position and while applying slight pressure to the lever, allow the reverse-indicator springs to bring the levers back to neutral. Note: The wheels should stop turning or slightly creep in reverse. 12. Shut off the machine. 13. Remove the jumper wire from the wire harness and plug the connector into the seat switch. 14. Remove the jack stands. 15.
Hydraulic System Maintenance 6. Remove 1 dipstick from the hydraulic reservoir (Figure 85). 7. Wipe the dipstick off and thread the dipstick into the reservoir. Hydraulic System Safety 8. Remove the dipstick and look at the end (Figure 85). • Seek immediate medical attention if fluid is injected Important: Do not overfill the hydraulic into skin. Injected fluid must be surgically removed within a few hours by a doctor. units with fluid, as damage may occur.
Changing the Hydraulic Fluid and Filters 5. Place a drain pan under the filter, remove the old filter, and wipe the surface clean (Figure 87). Service Interval: After the first 250 hours—Change the hydraulic filters and hydraulic fluid. Every 250 hours—After the initial change—change the hydraulic-system filters and fluid when using Mobil 1 15W50 fluid.
Blade Maintenance 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. g006530 Figure 88 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.
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 89). g014974 Figure 91 1. Blade (side previously measured) 2. Measurement (position used previously) 3.
Removing the Blades 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 93). g000553 Figure 95 1. Blade 3. 2. Balancer Repeat this procedure until the blade is balanced. Installing the Blades 1. Install the blade onto the spindle shaft (Figure 93).
g009196 Figure 97 1. 7.6 cm (3 inch) at position A is correct 2. 8.3 cm (3-1/4 inch) at position B is correct g027343 Figure 96 1. Deck-lift pedal 3. Transport lock 10. 2. Height-of-cut pin 6. Insert the height-adjustment pin into the 7.6 cm (3 inches) cutting-height location. 7. Release the transport lock and allow the deck to lower to the cutting height. 8. Raise the discharge chute. 9.
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 97. 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 98). To increase the height, turn the adjustment nut clockwise; to decrease, turn counterclockwise. g027345 Figure 99 1. Bolts at the bottom of the height-of-cut plate 12.
Removing the Mower Deck Lock out the spring-loaded deck arms before servicing or removing the mower deck. WARNING Deck-lift arm assemblies have stored energy. Removing the deck with out releasing the stored energy can cause serious injury or death. Do not attempt to disassemble the deck from the front frame without locking out the stored energy. 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2.
8. Raise the deck struts and secure them in the raised position. 9. Slide the deck out to the right side of the machine. 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.
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. Disposing of Waste Engine oil, batteries, hydraulic fluid, and engine coolant are pollutants to the environment.
Storage 11. Check the condition of the blades; refer to Inspecting the Blades (page 71). Storage Safety 12. Check and tighten all bolts, nuts, and screws. Repair or replace any part that is damaged. • Shut off the engine, remove the key, wait for all 13. Paint all scratched or bare metal surfaces. Paint is available from your Authorized Service Dealer. 14. Store the machine in a clean, dry garage or storage area. 15.
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 a faulty valve in the fuel tank. 3. The air cleaner is dirty. 2. Contact an Authorized Service Dealer. 3. Make sure that the air cleaner and precleaner are clean. Replace if necessary. 4. Charge or replace the battery. 5. Contact an Authorized Service Dealer. 4. The battery is not charged. 5.
Problem The engine overheats. The machine pulls to the left or right (with the motion-control levers fully forward). The machine does not drive. The machine vibrates abnormally. The cutting height is uneven. Possible Cause 1. The engine load is excessive. 1. Reduce the ground speed. 2. The oil level in the crankcase is low. 3. The cooling fins and the air passages above the engine are plugged. 4. The air cleaner is dirty. 2. Add oil to the crankcase. 3.
Problem The clutch does not engage. Possible Cause Corrective Action 1. The fuse is blown. 1. Replace the fuse. Check the coil resistance, battery charge, charging system, and wiring connections, and replace components if necessary. 2. There is low voltage supply at the clutch. 2. Check the coil resistance, battery charge, charging system, and wiring connections and replace parts if necessary. 3. Replace the clutch. 4. Repair or replace the clutch lead wire or electrical system.
Schematics g287722 Electrical Schematic (Rev.
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.
