Z Master® Professional 6000 Series Riding Mower

Before starting the machine each day, perform the Each Use/Daily procedures listed in .

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.

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).

Figure 10

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).

Figure 13

1. Seat-suspension knob

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.

Adjusting the Rear-Shock Assemblies

The slots for the rear-shock assemblies have detent positions for reference. You can position the rear-shock assemblies anywhere in the slot, not just in the detent positions.

The following graphic shows the position for a soft or firm ride and the different detent positions (Figure 14).

Figure 14

1. Firmest position
2. Softest position
3. Detents in the slots

Note: Ensure that the left and right rear-shock assemblies are always adjusted to the same positions.

Adjust the rear-shock assemblies (Figure 15).

Figure 15

Use the mower deck as a step to get into the operator’s position (Figure 18).

Figure 18

Always engage the parking brake when you stop the machine or leave it unattended.

Engaging the Parking Brake

Park the machine on a level surface.

Figure 19

Disengaging the Parking Brake

Figure 20

The blade-control switch (PTO) starts and stops the mower blades and any powered attachments.

Engaging the Blade-Control Switch (PTO)

Note: Engaging the blade-control switch (PTO) with the throttle position at half or less causes excessive wear to the drive belts.

Figure 21

Disengaging the Blade-Control Switch (PTO)

Figure 22

You can move the throttle control between FAST and SLOW positions (Figure 23).

Always use the FAST position when engaging the PTO.

Figure 23

Use the choke to start a cold engine.

1. Pull up the choke knob to engage the choke before using the key switch (Figure 24).

2. Push down the choke knob to disengage the choke after the engine has started (Figure 24).

   

   Figure 24

   1. ON position
   2. OFF position

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.

Note: You may need multiple attempts to start the engine the first time after adding fuel to an empty fuel system.

Figure 25

Figure 26

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. Make sure that you remove the key as the fuel pump may run and cause the battery to lose charge.

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). Place the throttle control in the FAST position for best performance. Always operate in the full throttle position when mowing.

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, 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. Adjust the anti-scalp rollers as shown in Figure 32, Figure 33, and Figure 34.

   

   Figure 32

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

   Figure 33

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

   Figure 34

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

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

1. Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake.

2. 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 35 and Figure 36.

   

   Figure 35

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

   Figure 36

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

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.

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. Remove the carriage bolts and nuts from each skid (Figure 37).

   

   Figure 37

   1. Carriage bolt
   2. Skid
   3. Nut

4. Move each skid to the desired position and secure them with the carriage bolts and nuts.

   Note: Only use the top or center sets of holes to adjust the skids. The bottom holes are used when switching sides on the mower deck, at which time they become the top holes on the other side of the mower.

5. To prevent damaging the skid, torque the carriage bolts and nuts for each skid to 12.4 to 14.7 N∙m (110 to 130 in-lb).

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. 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. To adjust the cam locks, swing the lever up to loosen the cam lock (Figure 38).

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 38).

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 38

The following figures are only recommendations for use. Adjustments vary by grass type, moisture content, and the height of the grass.

Note: If the engine power draws down and the mower ground speed is the same, open up the baffle.

Position B

Use this position when bagging. Always align it with the blower opening.

Figure 40

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.

Figure 42

1. ON position
2. OFF position

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; otherwise, severe damage to the hydraulic system can occur.

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. Rotate the release-valve levers vertically to push the machine (Figure 43).

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

4. Disengage the parking brake before pushing the machine.

   

   Figure 43

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

5. Rotate the release valve levers horizontally to run the machine (Figure 43).

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.

Selecting a Trailer

Warning

Loading a machine onto a trailer or truck increases the possibility of tip-over and could cause serious injury or death (Figure 44).

• Use only a full-width ramp; do not use individual ramps for each side of the machine.

• Do not exceed a 15-degree angle between the ramp and the ground or between the ramp and the trailer or truck.

• Ensure that the length of ramp is at least 4 times as long as the height of the trailer or truck bed to the ground. This ensures that ramp angle does not exceed 15 degrees on flat ground.

Figure 44

1. Full-width ramp in stowed position
2. Side view of full-width ramp in loading position
3. Not greater than 15 degrees
4. Ramp is at least 4 times as long as the height of the trailer or truck bed to the ground
5. H=height of the trailer or truck bed to the ground
6. Trailer

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 access the top of the mower deck (Figure 50). Tighten the bolt after maintenance to install the curtain.

Figure 50

1. Bolt
2. Curtain

Loosen the 2 front bolts and remove the sheet-metal guard to access the mower belts and spindles (Figure 51). Install the sheet-metal guard and tighten the bolts after maintenance.

Figure 51

1. Sheet-metal guard
2. Bolt

Grease more frequently when operating conditions are extremely dusty or sandy.

Grease Type: No. 2 lithium or molybdenum grease

1. Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake.

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

3. Clean the grease fittings with a rag.

   Note: Make sure that you scrape any paint off the front of the fitting(s).

4. Connect a grease gun to the fitting.

5. Pump grease into the fittings until grease begins to ooze out of the bearings.

6. Wipe up any excess grease.

Lubricate the deck-lift pivots.

Figure 52

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. 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 53 or Figure 54).

   

   Figure 53

   Machine with Side Discharge Shown

   

   Figure 54

   Machine with Rear Discharge Shown

6. Grease the drive-belt idler arms (Figure 55).

   

   Figure 55

7. Grease the deck-belt idler arms (rear discharge machines only) as shown in Figure 56.

   

   Figure 56

   Machines with Rear Discharge Only

8. Install the sheet-metal guard. Refer to Releasing the Mower-Deck Curtain.

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

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

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

11. Remove the hex plug.

12. Thread a grease fitting into the hole.

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

14. Remove the grease fitting in the hole.

15. Install the hex plug and dust cap (Figure 57).

    

    Figure 57

16. Grease the caster-wheel bearings (Figure 57).

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.

   

   Figure 58

   1. Seal guard
   2. Spacer nut with wrench flats

3. Raise the mower for access.

4. Remove the caster wheel from the caster forks.

5. Remove the seal guards from the wheel hub.

6. 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.

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

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

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

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

    Note: Replace the seals.

11. 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.

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

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

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

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

16. 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.

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

18. 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: Check the filters more frequently if the operating conditions are extremely dusty or sandy.

Ensure that the air gap between the center and side electrodes is correct before installing the spark plug. Use a spark plug wrench for removing and installing the spark plug and a gapping tool or feeler gauge to check and adjust the air gap. Install a new spark plug if necessary.

Type of Spark Plug: NGK^® BPR4ES or equivalent

Air Gap: 0.75 mm (0.03 inch)

Checking the Spark Plug

Important: Do not clean the spark plug(s). Always replace the spark plug(s) when it has a black coating, worn electrodes, an oily film, or cracks.

If you see light brown or gray on the insulator, the engine is operating properly. A black coating on the insulator usually means the air cleaner is dirty.

Set the gap to 0.75 mm (0.03 inch).

Figure 67

Installing the Spark Plug

Figure 68

1. Park the machine on a level surface, disengage the 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. Wait for the muffler to cool.

4. If you see any breaks in the screen or welds, replace the arrester.

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

6. Install the arrester on the exhaust outlet.

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.

The fuel filter is located near the engine on the left front of the engine.

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. Allow the machine to cool down.

4. Close the fuel-shutoff valve under the seat.

5. Replace the fuel filter (Figure 69).

   

   Figure 69

6. Open the fuel-shutoff valve.

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.

The fuses are located on the console to the right of the seat (Figure 73).

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

2. Install a new fuse (Figure 73).

   

   Figure 73

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

Inspect the seat belt for wear, cuts, and proper operation of the retractor and buckle. Replace the seat belt if it is 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.

  Note: The upper hoop of the roll bar may need to be pushed forward or pulled rearward to fully engage both knobs (Figure 74 and Figure 75).

Figure 74

1. Roll bar in the upright position
2. Roll-bar knob in the latched position
3. Pull the roll-bar knob out and rotate it 90 degrees.
4. Rotate the roll-bar knob 90 degrees.
5. Roll-bar knob in the unlatched position
6. Roll bar in the folded position

Figure 75

1. Engaged
2. Partially engaged—do not operate with the roll bar in this position.

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

2. Drive to an open flat area, 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 all the way forward until they both hit the stops in the T-slot.

5. Check which way the machine tracks.

   • 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 76).

   • 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 76).

6. Tighten the stop plate (Figure 76).

   

   Figure 76

   Left control lever shown

   1. Control lever
   2. Bolt
   3. Stop plate

Maintain the air pressure in the front and 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.

Figure 77

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.

Figure 78

1. Slotted nut

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 dust cap from caster and tighten the locknut (Figure 79).

4. Tighten the locknut until the spring washers are flat, and then back off a 1/4 turn to properly set the preload on the bearings (Figure 79).

   Important: Make sure that the spring washers are installed correctly as shown in Figure 79.

5. Install the dust cap (Figure 79).

   

   Figure 79

   1. Spring washers
   2. Locknut
   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, you can remove the shim to extend the clutch life.

Figure 80

1. Armature
2. Field shell
3. Rotor
4. Brake-mounting bolt
5. Brake spacer
6. Re-gap shim
7. Brake pole

Remove any buildup of grass, dirt, or other debris from the oil cooler and the engine screen (Figure 86).

Figure 86

Remove any buildup of grass, dirt, or other debris from the engine screen. This helps ensure adequate cooling and correct engine speed and reduces the possibility of overheating and mechanical damage to the engine (Figure 83).

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 87).

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

5. Install the air-intake screen, the recoil starter, and the fan housing (Figure 87).

   

   Figure 87

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

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. Move the seat forward.

4. Clean the debris and grass from the hydraulic-unit shrouds (Figure 88).

5. Position the seat.

   

   Figure 88

   1. Hydraulic-unit shrouds

Note: Perform this procedure at the recommended service interval or when a brake component has been removed or replaced.

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

   Caution

   Raising the machine for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous. The mechanical or hydraulic jacks may not be enough support or may malfunction allowing the machine to fall, which could cause injury.

   Do not rely solely on mechanical or hydraulic jacks for support. Use adequate jack stands or equivalent support.

4. Remove the rear tires from the machine.

5. Remove any debris from the brake area.

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

7. Check to see if there is a visible gap between the L-bracket and the linkage stop (Figure 89).

   

   Figure 89

   Left Side Shown

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

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

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

10. 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.

11. Engage the parking brake and check the gap.

12. Repeat steps 8 through 12 until a visible gap is achieved and the wheel hub rotates freely.

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

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

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

16. 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. 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 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 90).

   

   Figure 90

   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 91).

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

9. Remove the belt guide on the spring-loaded idler arm (Figure 91).

10. Remove the existing belt.

11. Install the new belt around the mower pulleys and the clutch pulley under the engine (Figure 91).

    

    Figure 91

    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 91).

13. Using the ratchet in the square hole, install the idler spring (Figure 91).

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

14. Install the belt covers (Figure 92).

    

    Figure 92

    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. 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 mower belt; refer to Replacing the Mower Belt for Side-Discharge Mower Decks or Replacing the Mower Belt for Rear-Discharge Mower Decks.

4. Raise the machine and support it with jack stands (Figure 97).

   

   Figure 97

   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 97).

6. Unhook the idler spring from the frame (Figure 97).

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 97).

10. Install the mower belt; refer to Replacing the Mower Belt for Side-Discharge Mower Decks or Replacing the Mower Belt for Rear-Discharge Mower Decks.

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

1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake.

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

3. Loosen the bolts and flange nuts installed in the levers (Figure 98).

4. 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 99).

   

   Figure 98

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

   Figure 99

5. If the ends of the levers hit against each other, refer to Adjusting the Motion-Control Neutral-Lock Pivot.

6. Repeat to adjust the control levers.

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

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. Push the deck-lift pedal, and remove the height-of-cut pin.

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

   Note: Before starting the engine, ensure that the parking brake is engaged and that the motion-control levers are out. You do not have to be in the seat.

9. Run the machine 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 must be in neutral while making any necessary adjustments.

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

11. 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 100).

    

    Figure 100

    1. Double nuts

12. 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.

13. Shut off the machine.

14. Remove the jumper wire from the wire harness and plug the connector into the seat switch.

15. Remove the jack stands.

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

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

You can adjust the top damper-mounting bolt to obtain the desired motion-control lever resistance. Refer to Figure 101 for mounting options.

Figure 101

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)

You can adjust the flanged nut to obtain the desired motion-control lever resistance when moving it to the NEUTRAL-LOCK position. See Figure 102 for adjustment options.

1. Loosen the jam nut.

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

   • For more resistance, tighten the flanged nut.

   • For less resistance, loosen the flanged nut

3. Tighten the jam nut.

   

   Figure 102

   1. Flanged nut
   2. Jam nut

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.

Lock out the spring-loaded deck arms before servicing or removing the mower 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. Place the height adjustment pin in the 7.6 cm (3 inch) cutting-height location.

   Note: This locks the deck-lift arms in the lowest position when the deck is removed and the stored energy in the deck spring is released.

4. Remove the belt covers.

5. Lift up the floor pan and insert a ratchet into the square hole in the deck idler (Figure 119 or Figure 120).

6. Rotate the deck idler clockwise, lift up on the belt-guide tab (rear-discharge machines only), and remove the mower belt (Figure 119 or Figure 120).

   

   Figure 119

   Side-Discharge Machines

   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
   

   Figure 120

   Rear-Discharge Machines

   1. Clutch pulley
   2. Mower belt
   3. Spring-loaded idler pulley
   4. Ensure that the belt-guide tab hits against the pivot hub.
   5. Belt guide
   6. Spring-loaded idler pulley
   7. Square hole in the idler arm for the ratchet
   8. Spring

7. Remove and retain the hardware on both sides of the deck as shown in Figure 121.

   

   Figure 121

   1. Right stabilizer
   2. Deck strut (right side shown)
   3. Remove the shoulder bolt and nut.
   4. Remove the shoulder bolt and nut.

8. Raise the deck struts and secure them in the raised position.

9. Slide the deck out to the right side of the machine.

1. Remove the locknut, bolt, spring, and spacer holding the deflector to the pivot brackets (Figure 122).

2. Remove the damaged or worn grass deflector (Figure 122).

   

   Figure 122

   1. Bolt
   2. Spacer
   3. Locknut
   4. Spring
   5. Spring installed
   6. Grass deflector
   7. J-hook end of spring

3. Place the spacer and the spring onto grass deflector.

4. Place 1 J-hook end of the spring behind the deck edge.

   Note: Make sure that 1 J-hook end of the spring is installed behind the deck edge before installing the bolt as shown in Figure 122.

5. Install the bolt and the nut.

6. Place 1 J-hook end of the spring around the grass deflector (Figure 122).

   Important: The grass deflector must be able to rotate. Lift the deflector up to the full open position and ensure that it rotates into the full down position.

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.

Use compressed air to clean the suspension system.

Note: Do not clean the shock assemblies with pressurized water (Figure 123).

Figure 123

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