Z Master® Professional 6000 Series Riding Mower

• 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. Never use gasoline that contains more than 10% ethanol by volume, such as E15 (contains 15% ethanol), E20 (contains 20% ethanol), or E85 (contains up to 85% ethanol). Using unapproved gasoline may cause performance problems and/or engine damage which may not be covered under warranty.

• Do not use gasoline containing methanol.

• Do not store fuel either in the fuel tank or fuel containers over the winter unless you use a fuel stabilizer.

• Do not add oil to gasoline.

Use a fuel stabilizer/conditioner in the machine to provide the following benefits:

• Keeps fuel fresh during storage of 90 days or less (drain the fuel tank when storing the machine for more than 90 days)

• Cleans the engine while it runs

• Eliminates gum-like varnish buildup in the fuel system, which causes hard starting

  Important: Do not use fuel additives containing methanol or ethanol.

  Add the correct amount of fuel stabilizer/conditioner to the fuel.

  Note: A fuel stabilizer/conditioner is most effective when mixed with fresh fuel. To minimize the chance of varnish deposits in the fuel system, use fuel stabilizer at all times.

1. Park the machine on level ground.

2. Shut off the engine and engage the parking brake.

3. Clean around the fuel-tank cap.

4. Fill the fuel tank to the bottom of the filler neck (Figure 7).

   Note: Do not fill the fuel tank completely full. The empty space in the tank allows the gasoline to expand.

   

   Figure 7

Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking the Engine-Oil Level.

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.

Important: Lower the roll bar only when absolutely necessary.

Important: Ensure that the seat is secured to the machine.

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° so they are not engaged (Figure 8).

3. Lower the roll bar to the down position (Figure 8).

   

   Figure 8

   1. ROPS knob
   2. Pull the ROPS knob out and rotate 90 degrees
   3. Roll bar in the upright position
   4. Roll bar in the folded position

4. To raise the roll bar, raise the roll bar to the operate position, rotate the knobs so that they move partially into the grooves (Figure 8).

5. Raise the roll bar to the full upright position while pushing on the upper roll bar and the pins snap into position when the holes align with the pins (Figure 8).

   Important: Always use the seat belt with the roll bar in the raised position.

6. Push on the roll bar and ensure that both pins are engaged.

The seat moves forward and backward. Position the seat where you have the best control of the machine and are most comfortable.

To adjust, move the lever sideways to unlock the seat (Figure 12).

To unlatch the seat, push the seat latch forward (Figure 13).

The seat adjusts to provide a smooth and comfortable ride. Position the seat where you are most comfortable.

To adjust, turn the knob in front either direction to provide the best comfort (Figure 14).

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.

You can move the throttle control between the FAST and SLOW positions (Figure 19).

Always use the FAST position when turning on the mower deck with the blade-control switch (PTO).

Use the choke to start a cold engine.

1. If the engine is cold, use the choke to start the engine.

2. Pull up on the choke knob to engage the choke before using the ignition switch (Figure 20).

3. Push down on the choke to disengage the choke after the engine has started (Figure 20).

   

   Figure 20

   1. On position
   2. Off position

1. Turn the ignition key to the START position (Figure 21).

   Note: When the engines starts, release the key.

   Important: Do not engage starter for more than 5 seconds at a time. If the engine fails to start allow a 15 second cool-down period between attempts. Failure to follow these instructions can burn out the starter motor.

   Note: You may need multiple attempts to start the engine when you start it the first time after the fuel system has been without fuel completely.

   

   Figure 21

2. Turn the ignition key to shut off the engine.

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 sometime for you to adapt to how it moves.

The throttle control regulates the engine speed as measured in rpm (revolutions per minute). Place the throttle control in the FAST position for best performance. Always operate in the full throttle position when mowing.

To stop the machine, move the traction-control levers to neutral, and then move them to the locked position, disengage the blade-control switch (PTO), and turn the ignition key to the OFF position.

Engage the parking brake when you leave the machine; refer to Engaging the Parking Brake. Remember to remove the key from the ignition switch.

The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf.

Whenever you change the height-of-cut, it is recommended to adjust the height of the anti-scalp rollers.

1. Disengage the blade-control switch (PTO), move the motion-control levers to the NEUTRAL-LOCK position, 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. Adjust the anti-scalp rollers as shown in Figure 30, Figure 31, and Figure 32.

   

   Figure 30

   1. Anti-scalp roller
   2. Spacer
   3. Bushing
   4. Flange nut
   5. Bolt
   

   Figure 31

   1. Anti-scalp roller
   2. Bushing
   3. Flange nut
   4. Bolt
   

   Figure 32

   1. Anti-scalp roller
   2. Spacer
   3. Bushing
   4. Flange nut
   5. Bolt

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.

You can adjust the mower-discharge flow for different types of mowing conditions. Position the cam locks and baffle to give the best quality of cut.

1. Disengage the blade-control switch (PTO), move the motion-control levers to the NEUTRAL-LOCK position, 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. To adjust the cam locks, swing the lever up to loosen the cam lock (Figure 33).

4. Adjust the baffle and cam locks in the slots to the desired discharge flow.

5. Swing the lever back over to tighten the baffle and cam locks (Figure 33).

6. If the cam locks do not lock the baffle into place or it is too tight, loosen the lever and then rotate the cam lock.

   Note: Adjust the cam lock until the desired locking pressure is achieved.

   

   Figure 33

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.

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.

Ensure that the fuel-shutoff valve is open when starting the engine.

The drive-wheel-release valves are located in the back of each hydraulic-drive unit, under the seat.

Note: Make sure that the release valves are in the fully horizontal position when operating the machine or severe damage to the hydraulic system can occur.

1. Disengage the blade-control switch (PTO), turn the ignition key to the OFF position, move the levers to the NEUTRAL-LOCK position, engage the parking brake, and remove the key.

2. Rotate the release-valve levers vertically to push the machine (Figure 38).

   Note: This allows hydraulic fluid to bypass the pump enabling the wheels to turn.

3. Disengage the parking brake before pushing the machine.

   

   Figure 38

   1. Vertical to push the machine
   2. Horizontal to run the machine

4. Rotate the release-valve levers horizontally to run the machine (Figure 38).

Use a heavy-duty trailer or truck to transport the machine. 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, your family, pets, or bystanders avoid injury.

1. If you are using a trailer, connect it to the towing vehicle, and connect the safety chains.

2. If applicable, connect the trailer brakes.

3. Load the machine onto the trailer or truck.

4. Shut off the engine, remove the key, engage the parking brake, and close the fuel valve.

5. Use the tie-down loops on the machine to securely fasten it to the trailer or truck with straps, chains, cable, or ropes (Figure 39).

   

   Figure 39

   1. Traction unit tie-down loops

Use extreme caution when loading or unloading machines onto a trailer or a truck. Use a full-width ramp that is wider than the machine for this procedure. Back up the ramp and drive forward down the ramp (Figure 40).

Important: Do not use narrow individual ramps for each side of the machine.

The Z Stand raises the front end of the machine to allow you to clean the mower and remove the blades.

Loosen the bottom bolt of the curtain to release the mower-deck curtain and get access to the top of the mower deck (Figure 45). After performing maintenance, install the curtain and tighten the bolt.

Loosen the 2 front bolts and remove the sheet-metal guard to access the mower belts and spindles (Figure 46). After performing maintenance, install the sheet-metal guard and tighten the bolts.

Lubricate the deck-lift pivots.

1. Disengage the blade-control switch (PTO), move the motion-control levers to the NEUTRAL-LOCK position, 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 bottom bolt holding the mower-deck curtain to the mower deck. Refer to Releasing the Mower-Deck Curtain.

4. Remove the sheet-metal guard. Refer to Removing the Sheet-Metal Guard.

5. Grease the mower deck idler-pulley pivot until grease comes out the bottom (Figure 48).

   

   Figure 48

6. Grease the drive-belt idler arm (Figure 48).

   

   Figure 49

7. Remove the dust cap and adjust the caster pivots.

   Note: Keep the dust cap off until greasing is done.

8. Remove the hex plug.

9. Thread a grease fitting into the hole.

10. Pump grease into the fitting until it oozes out around the top bearing.

11. Remove the grease fitting in the hole.

12. Install the hex plug and dust cap (Figure 50).

    

    Figure 50

13. Grease the caster-wheel bearings (Figure 50).

14. Install the sheet-metal guard. Refer to Removing the Sheet-Metal Guard.

15. Tighten the bolt for the mower-deck curtain. Refer to Releasing the Mower-Deck Curtain.

1. Shut off the engine, wait for all moving parts to stop, remove the key, and engage the parking brake.

   

   Figure 51

   1. Seal guard
   2. Spacer nut with wrench flats

2. Raise the mower for access.

3. Remove the caster wheel from the caster forks.

4. Remove the seal guards from the wheel hub.

5. Remove a spacer nut from the axle assembly in the caster wheel.

   Note: Thread-locking adhesive has been applied to lock the spacer nuts to the axle.

6. Remove the axle (with the other spacer nut still assembled to it) from the wheel assembly.

7. Pry out seals and inspect bearings for wear or damage and replace if necessary.

8. Pack the bearings with a general-purpose grease.

9. Insert 1 bearing and 1 new seal into the wheel.

   Note: Replace the seals.

10. If the axle assembly is missing both spacer nuts, apply a thread-locking adhesive to 1 spacer nut and thread it onto the axle with the wrench flats facing outward.

    Note: Do not thread the spacer nut all of the way onto the end of the axle. Leave approximately 3 mm (1/8 inch) from the outer surface of the spacer nut to the end of the axle inside the nut.

11. Insert the assembled nut and axle into the wheel on the side of the wheel with the new seal and bearing.

12. With the open end of the wheel facing up, fill the area inside the wheel around the axle full of general-purpose grease.

13. Insert the second bearing and new seal into the wheel.

14. Apply a thread-locking adhesive to the second spacer nut, and thread it onto the axle with the wrench flats facing outward.

15. Torque the nut to 8 to 9 N∙m (75 to 80 in-lb), loosen, then torque to 2 to 3 N∙m (20 to 25 in-lb).

    Note: Make sure that the axle does not extend beyond either nut.

16. Install the seal guards over the wheel hub, and insert the wheel into the caster fork.

17. Install the caster bolt and tighten the nut fully.

Important: To prevent seal and bearing damage, check the bearing adjustment often. Spin the caster tire. The tire should not spin freely (more than 1 or 2 revolutions) or have any side play. If the wheel spins freely, adjust the torque on the spacer nut until there is a slight amount of drag. Apply another layer of thread-locking adhesive.

Note: Service the air cleaner more frequently if operating conditions are extremely dusty or sandy.

Oil Type: Detergent oil (API service SG, SH, SJ, or higher)

Oil Capacity:

• Model 74919TE: with a filter change, 2.1L (71 oz); with no filter change, 1.8L (61 oz)

• Model 74925TE: with a filter change, 2.3 L (77 oz); with no filter change, 2.1L (70 oz)

Viscosity: See the table below.

Note: Use of multi-grade oils (5W-20, 10W-30, or 10W-40) increase oil consumption. Check the oil level more frequently when using them.

Make sure 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(s) and a gapping tool/feeler gauge to check and adjust the air gap. Install a new spark plug(s) if necessary.

Type : NGK^® BPR4ES or equivalent

Air Gap: 0.76 mm (0.03 inch)

For Models with a Spark Arrester

1. Shut off the engine, wait for all moving parts to stop, remove the key, and engage the parking brake.

2. Wait for the muffler to cool.

3. If there are any breaks in the screen or welds are observed, replace the arrester.

4. If the screen is plugged, remove the arrester and shake loose particles out of the arrester, and clean the screen with a wire brush (soak in solvent if necessary).

5. Install the arrester on the exhaust outlet.

The fuel filter is located near the engine on the front or rear side of the engine.

1. Disengage the blade-control switch (PTO), move the motion-control levers to the NEUTRAL-LOCK position, 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. Allow the machine to cool down.

4. Close the fuel-shutoff valve under the seat (Figure 62).

   

   Figure 62

   1. Fuel filter
   2. Hose clamp
   3. Fuel-shutoff valve

5. Squeeze the ends of the hose clamps together and slide them away from the filter (Figure 62).

6. Remove the filter from the fuel lines.

7. Install a new filter and move the hose clamps close to the filter (Figure 62).

8. Open the fuel-shutoff valve.

Important: Install the fuel line hoses and secure with plastic ties the same as they were originally installed at the factory to keep the fuel line away from components that can cause fuel line damage.

Do not attempt to drain the fuel tank. Ensure that an Authorized Service Dealer drains the fuel tank and services any components of the fuel system.

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.

1. The fuses are located on the console to the right of the seat (Figure 66).

2. To replace the fuses, pull out on the fuse to remove it.

3. Install a new fuse (Figure 66).

   

   Figure 66

   1. Optional accessory (15 A)
   2. Charge (25 A)
   3. PTO (10 A)
   4. Main (25 A)
   5. Console

Visually inspect seat belt for wear, cuts, and proper operation of retractor and buckle. Replace before operating if damaged.

Check that both the mounting hardware and the knobs are in good working condition. Make sure that the knobs are fully engaged with the roll bar in the raised position. The upper hoop of the roll bar may need to be pushed forward or pulled rearward to get both knobs fully engaged (Figure 67).

1. Disengage the blade-control switch (PTO).

2. Drive to an open, flat area, and move the motion-control levers to the NEUTRAL-LOCK position.

3. Move the throttle midway between FAST and SLOW.

4. Move both motion-control levers forward until they both hit the stops in the T-slot.

5. Check which way the machine tracks.

6. If it tracks to the right, loosen the bolts and adjust the left stop plate rearward on the left T-slot until the machine tracks straight (Figure 68).

7. If it tracks to the left, loosen the bolts and adjust the right stop plate rearward on the right T-slot until the machine tracks straight (Figure 68).

8. Tighten the stop plate (Figure 68).

   

   Figure 68

   Left control lever shown

   1. Control lever
   2. Bolt
   3. Stop plate

Maintain the air pressure in the rear tires at 90 kPa (13 psi). Uneven tire pressure can cause uneven cut. Check the tires when they are cold to get the most accurate pressure reading.

Note: The front tires are semi-pneumatic tires and do not require air pressure maintenance.

Check and torque the wheel lug nuts to 122 to 129 N∙m (90 to 95 ft-lb).

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.

1. Disengage the blade-control switch (PTO), move the motion-control levers to the NEUTRAL-LOCK position, 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 dust cap from caster and tighten the locknut (Figure 71).

4. Tighten the locknut until the spring washers are flat, and then back off a 1/4turn to properly set the preload on the bearings (Figure 71).

   Important: Make sure that the spring washers are installed correctly as shown in Figure 71.

5. Install the dust cap (Figure 71).

   

   Figure 71

   1. Spring washers
   2. Lock nut
   3. Dust cap

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, the shim can be removed to extend the clutch life.

Remove any buildup of grass, dirt, or other debris from the oil cooler (Figure 78).

Before each use, remove any buildup of grass, dirt, or other debris from the engine screen. This helps ensure adequate cooling, correct the engine speed, and reduces the possibility of overheating and mechanical damage to the engine (Figure 79).

1. 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 79).

4. Clean the debris and grass from the engine parts.

5. Install the air-intake screen, the recoil starter, and the fan housing (Figure 79).

   

   Figure 79

   1. Engine guard
   2. Engine air-intake screen
   3. Bolt
   4. Fan housing
   5. Screw

Important: The fasteners on the covers of this machine are designed to remain on the cover after removal. Loosen all of the fasteners on each cover a few turns so that the cover is loose but still attached, then go back and loosen them until the cover comes free. This prevents you from accidentally stripping the bolts free of the retainers.

1. 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. Move the seat forward.

4. Wait for the engine and hydraulic system to cool.

5. Clean the debris and grass from the hydraulic unit shrouds (Figure 80).

   

   Figure 80

   1. Hydraulic unit shrouds

6. Over each dipstick, remove the cover and the bolt attached to the cover . Clean around each dipstick and hydraulic unit (Figure 81).

   

   Figure 81

   1. Cover
   2. Bolt

7. Position the seat.

Note: This procedure must be followed after the first 100 hours or when a brake component has been removed or replaced.

1. Drive the machine onto a level surface.

2. Disengage the blade-control switch (PTO), move the motion control levers to the NEUTRAL-LOCK position, and engage the parking brake.

3. Shut off the engine, wait for all moving parts to stop, and remove the key.

4. Raise the back of the machine and support the machine with jack stands.

   Danger

   Mechanical or hydraulic jacks may fail to support machine and cause a serious injury.

   • Use jack stands when supporting machine.

   • Do not use hydraulic jacks.

5. Remove the rear tires from the machine.

6. Remove any debris from the brake area.

7. Rotate the drive-wheel release handle to the released position; refer to Using the Drive-Wheel-Release Valves.

8. Check to see if there is a visible gap between the L-bracket and the linkage stop (Figure 82).

   

   Figure 82

   Left Side Shown

   1. L-bracket
   2. Linkage stop
   3. Gap
   4. Rear linkage assembly
   5. Caliper
   6. Wheel hub

9. Disengage the parking brake, the lever should be in the down position.

10. Turn the wheel hub by hand in both directions relative to the caliper; the wheel hub should move freely between the caliper.

11. If a gap is needed or the wheel hub does not move freely:

    1. Disengage the parking brake.

    2. Disconnect and fine-tune the rear linkage assembly:

       • Shorten the link to create a gap.

       • Lengthen the link to allow wheel hub movement.

    3. Connect the rear linkage assembly.

12. Engage the parking brake and check the gap.

13. Repeat steps 9 through 13 until a visible gap is achieved and the wheel hub rotates freely.

14. Repeat this procedure for the brake on the opposite side.

15. Rotate the drive-wheel release handle to the operating position; refer to Using the Drive-Wheel-Release Valves.

16. Install the rear tires and torque the lug nuts; refer to Checking the Wheel-Lug Nuts.

17. Remove the jack stands.

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.

1. Disengage the blade-control switch (PTO), move the motion-control levers to the NEUTRAL-LOCK position, 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 inch) height-of-cut.

4. Loosen the bottom bolt holding the mower-deck curtain to the mower deck. Refer to Releasing the Mower-Deck Curtain.

5. Remove the sheet-metal guard. Refer to Removing the Sheet-Metal Guard

6. Remove the belt covers (Figure 83).

   

   Figure 83

   1. Push the tab down
   2. Remove the belt cover

7. Use a ratchet in the square hole in the idler arm to remove tension on the idler spring (Figure 84).

8. Remove the belt from the mower-deck pulleys.

9. Remove the belt guide on the spring-loaded idler arm (Figure 84).

10. Remove the existing belt.

11. Install the new belt around the mower pulleys and the clutch pulley under the engine (Figure 84).

    

    Figure 84

    1. Clutch pulley
    2. Mower belt
    3. Spring-loaded idler pulley
    4. Ratchet
    5. Square hole in the idler arm for the ratchet
    6. Idler-grease fitting
    7. Belt guide

12. Install the belt guide on the idler arm (Figure 84).

13. Using the ratchet in the square hole, install the idler spring (Figure 84).

    Note: Make sure that the spring ends are seated in the anchor grooves.

14. Install the belt covers (Figure 85).

    

    Figure 85

    1. Position the belt cover
    2. Slide the belt cover under the side catches
    3. Ensure that the tab is under the metal catch

15. Install the sheet-metal guard. Refer to Removing the Sheet-Metal Guard.

16. Tighten the bolt for the mower-deck curtain. Refer to Releasing the Mower-Deck Curtain.

1. 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 mower belt; refer to Replacing the Mower Belt.

4. Raise the machine and support it with jack stands (Figure 86).

   

   Figure 86

   1. Idler pulley
   2. Clutch pulley
   3. Pump-drive belt
   4. Right hydraulic-pump pulley
   5. Left hydraulic-pump pulley
   6. Square hole in the idler arm
   7. Idler spring

5. Use a ratchet in the square hole in the idler arm to remove the idler spring (Figure 86).

6. Unhook the idler spring from the frame (Figure 86).

7. Remove the belt from the hydraulic-unit-drive pulleys and the engine pulley.

8. Install the new belt around engine pulley and the 2 drive pulleys.

9. Using a ratchet in the square hole in the idler arm, install the idler spring to the frame (Figure 86).

10. Install the mower belt; refer to Replacing the Mower Belt.

There are 2 height positions for the control levers—high and low. Remove the bolts to adjust the height for the operator.

1. Disengage the blade-control switch (PTO), move the motion-control levers to the NEUTRAL-LOCK position, 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 87).

4. Align the levers in the front-to-rear position by bringing the levers together to the NEUTRAL position, and slide them until they are aligned, then tighten the bolts (Figure 88).

   

   Figure 87

   1. Bolt
   2. Handle
   3. Control lever
   4. Nut
   

   Figure 88

5. If the ends of the levers hit against each other, refer to Adjusting the Control-Handle Position.

6. Repeat to adjust the control levers.

Located on either side of the fuel tank, below the seat are the pump-control linkages. Rotating the pump linkage with a wrench (1/2 inch) allows fine tuning adjustments so that the machine does not move in neutral. Any adjustments should be made for neutral positioning only.

1. Prior to starting the engine, push the deck-lift pedal, and remove the height-of-cut pin.

2. Lower deck to the ground.

3. 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.

4. 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.

5. Temporarily install a jumper wire across the terminals in the connector of the main wire harness.

6. Start the engine and run it at full throttle and disengage the brake.

   Note: The brake must be engaged and the motion-control levers must be out to start the engine. The operator does not have to be in the seat, because of the jumper wire being used.

7. Run the unit for at least 5 minutes with the drive levers at full forward speed to bring the hydraulic fluid up to the operating temperature.

   Note: The motion-control levers needs to be in neutral while making any necessary adjustments.

8. Bring the motion-control levers into the NEUTRAL position.

9. Adjust the pump control rod lengths by rotating the double nuts on the rod in the appropriate direction until the wheels slightly creep in reverse (Figure 89).

   

   Figure 89

   1. Double nuts

10. 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 must stop turning or slightly creep in reverse.

11. Shut off the unit, remove the jumper wire from the wire harness, and plug the connector into the seat switch.

12. Remove the jack stands.

13. Raise the deck and install the height-of-cut pin.

14. Check that the machine does not creep in neutral with the park brakes disengaged.

The top damper mounting bolt can be adjusted to obtain a more desired motion-control lever resistance. See Figure 90 for mounting options.

The flanged nut can be adjusted to obtain a more desired motion-control lever resistance when moving it to the NEUTRAL-LOCK position. See Figure 91 for adjustment options.

1. Loosen the jam nut.

2. Tighten or loosen the flanged nut to the desired feel.

   Note: For more resistance, tighten the flanged nut.

   Note: For less resistance, loosen the flanged nut

3. Tighten the jam nut.

   

   Figure 91

   1. Flanged nut
   2. Jam nut

Hydraulic-Fluid Type: Toro^® HYPR-OIL ^™ 500 hydraulic fluid or Mobil^® 1 15W-50.

Important: Use the specified fluid. Other fluids could damage the hydraulic system.

Each Hydraulic System Fluid Capacity: 1.5 L (52 oz) per side with filter change

Note: Ensure that the mower deck is level before matching the height of cut (HOC).

1. Position the mower on a flat surface.

2. Disengage the blade-control switch (PTO), move the motion-control levers to the NEUTRAL-LOCK position, and engage the parking brake.

3. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

4. Check tire pressure of the drive tires.

5. If needed, adjust to 90 kPa (13 psi).

6. Position the mower to the 76 mm (3 inches) height-of-cut position.

1. Position the mower on a flat surface.

2. Stop engine, wait for all moving parts to stop, remove the key, and engage the parking brake.

3. Check the tire pressure in the drive tires.

   Note: Proper inflation pressure for the tires is 90 kPa (13 psi).

4. Position the transport lock in the latching position.

5. Push the deck-lift pedal all the way forward and the deck latches at the 14 cm (5-1/2 inches) transport position (Figure 95).

   

   Figure 95

   1. Deck-lift pedal
   2. Height-of-cut pin
   3. Transport lock

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. On both sides of the deck, measure from the level surface to the front tip of the blade (Postion A) as shown in Figure 96.

   Note: The measurement should read 7.6 mm (3 inches)

   

   Figure 96

   1. 7.6 cm (3 inch) at position A is correct
   2. 8.3 cm (3-1/4 inch) at position B is correct
   3. Measure here from the blade tip to the hard surface
   4. Measure at position A and B on both sides

10. Fine-tune the adjustment nut on the front deck lift assembly by turning it (Figure 97).

    Note: To increase the height, turn the adjustment nut clockwise; to decrease, turn counterclockwise.

    Note: If the front deck links do not have enough adjustment to achieve accurate cut height, the single-point adjustment can be utilized to gain more adjustment.

    

    Figure 97

    1. Adjustment nut
    2. Jam nut
    3. Rear deck adjustment
    4. Front deck adjustment

11. To adjust the single-point system, loosen the 2 bolts at the bottom of the height-of-cut plate (Figure 98).

    

    Figure 98

    1. Bolts at the bottom of the height-of-cut plate

12. If the deck is too low, tighten the single-point-adjustment bolt by rotating it clockwise. If the deck is too high, loosen the single-point-adjustment bolt by rotating it counterclockwise (Figure 99).

    Note: Loosen or tighten the single-point adjustment bolt enough to move the height-of-cut plate mounting bolts at least 1/3 the length of the available travel in their slots. This regains some up and down adjustment on each of the 4 deck links.

    

    Figure 99

    1. Single-point adjustment bolt

13. Tighten the 2 bolts at the bottom of the height-of-cut plate (Figure 98).

    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 96.

    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 97).

    To increase the height, turn the adjustment nut clockwise; to decrease, turn counterclockwise.

17. Measure until all 4 sides are the correct height.

18. Tighten all of the nuts on the deck-lift-arm assemblies.

19. Lower the discharge chute.

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 disconnect the spark-plug wires from the spark plugs.

1. Inspect the cutting edges (Figure 100).

2. If the edges are not sharp or have nicks, remove and sharpen the blade; refer to Sharpening the Blades.

3. Inspect the blades, especially in the curved area.

4. If you notice any cracks, wear, or a slot forming in this area, immediately install a new blade (Figure 100).

   

   Figure 100

   1. Cutting edge
   2. Curved area
   3. Wear/slot forming
   4. Crack

1. Disengage the blade-control switch (PTO), move the motion-control levers to the NEUTRAL-LOCK position, 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. Rotate the blades until the ends face forward and backward.

4. Measure from a level surface to the cutting edge, position A, of the blades (Figure 101).

   

   Figure 101

   1. Measure here from blade to hard surface
   2. Position A

5. Rotate the opposite ends of the blades forward.

6. Measure from a level surface to the cutting edge of the blades at the same position as in step4 above.

   Note: The difference between the dimensions obtained in steps 4 and 6 must not exceed 3 mm (1/8 inch).

   Note: If this dimension exceeds 3 mm (1/8 inch), the blade is bent and must be replaced.

   Warning

   A blade that is bent or damaged could break apart and could seriously injure or kill you or bystanders.

   • Always replace a bent or damaged blade with a new blade.

   • Do not file or create sharp notches in the edges or surfaces of the blade.

Blades must be replaced if a solid object is hit, if the blade is out of balance, or if the blade is bent. To ensure optimum performance and continued safety conformance of the machine, use genuine Toro replacement blades. Replacement blades made by other manufacturers may result in nonconformance with safety standards.

1. Hold the blade end using a rag or a thickly-padded glove.

2. Remove the blade bolt, the curved washer, and the blade from the spindle shaft (Figure 102).

   

   Figure 102

   1. Sail area of the blade
   2. Blade
   3. Curved washer
   4. Blade bolt

1. Use a file to sharpen the cutting edge at both ends of the blade (Figure 103).

   Note: Maintain the original angle.

   Note: The blade retains its balance if the same amount of material is removed from both cutting edges.

   

   Figure 103

   1. Sharpen at original angle.

2. Check the balance of the blade by putting it on a blade balancer (Figure 104).

   Note: If the blade stays in a horizontal position, the blade is balanced and can be used.

   Note: If the blade is not balanced, file some metal off the end of the sail area only (Figure 103).

   

   Figure 104

   1. Blade
   2. Balancer

3. Repeat this procedure until the blade is balanced.

1. Install the blade onto the spindle shaft (Figure 105).

   Important: The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting.

2. Install the spring disk and blade bolt (Figure 105).

   Note: The spring-disk cone must be installed toward the bolt head (Figure 105).

3. Torque the blade bolt to 115 to 150 N∙m (85 to 110 ft-lb).

   

   Figure 105

   1. Sail area of the blade
   2. Blade
   3. Spring disk
   4. Blade bolt

1. Disengage the blade-control switch (PTO), move the motion-control levers to the NEUTRAL-LOCK position, 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 to the transport position.

Engine oil, batteries, hydraulic fluid, and engine coolant are pollutants to the environment. Dispose of these according to your state and local regulations.