Z Master® Professional 7000 Series Riding Mower

The engine runs on clean, fresh diesel fuel with a minimum octane rating of 40. Purchase fuel in quantities that can be used within 30 days to ensure fuel freshness.

Use summer-grade diesel fuel (No. 2-D) at temperatures above -7°C (20°F) and winter-grade diesel fuel (No. 1-D or No. 1-D/2-D blend) below -7°C (20°F). Use of winter-grade diesel fuel at lower temperatures provides lower flash point and pour point characteristics, therefore easing startability and lessening chances of chemical separation of the fuel due to lower temperatures (wax appearance, which may plug filters).

Using summer-grade diesel fuel above -7°C (20°F) contributes toward longer life of the pump components.

Important: Do not use kerosene or gasoline instead of diesel fuel. Failure to observe this caution will damage the engine.

This machine can also use a biodiesel blended fuel of up to B20 (20% biodiesel, 80% petrodiesel). The petrodiesel portion should be low or ultra low sulfur.

Observe the following precautions:

• The biodiesel portion of the fuel meet specification ASTM D6751 or EN14214.

• The blended fuel composition should meet ASTM D975 or EN590.

• Painted surfaces may be damaged by biodiesel blends.

• Use B5 (biodiesel content of 5%) or lesser blend in cold weather.

• Monitor seals, hoses, gaskets in contact with fuel as they may degrade over time.

• Fuel filter plugging may be expected for a time after converting to biodiesel blends.

• Contact your distributor for more information on biodiesel.

1. Park the machine on a level surface.

2. Engage the parking brake.

3. Shut off the engine and remove the key.

4. Clean around the fuel-tank cap.

5. Fill the fuel tank to the bottom of the filler neck (Figure 8).

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

   

   Figure 8

Important: Do not allow the machine to run out of fuel, as this can damage the machine.

The fuel-selector valve is located behind the left side of the seat.

The machine has 2 fuel tanks: 1 tank is on the left side and 1 is on the right side. Each tank connects to the fuel-selector valve. From there, a common fuel line leads to the engine (Figure 9).

To use the left fuel tank, rotate the fuel-selector valve to the left. To use the right fuel tank, rotate the fuel-selector valve to the right (Figure 9).

Close the fuel-selector valve before transporting or storing the machine.

Figure 9

1. Left fuel tank
2. Fuel-selector valve

Important: Lower the roll bar only when absolutely necessary.

1. Remove the hairpin cotters and remove the 2 pins (Figure 11).

2. Lower the roll bar to the down position (Figure 10).

   Note: There are 2 down positions; refer to Figure 10.

3. Install the 2 pins and secure them with the hairpin cotters (Figure 11).

   

   Figure 10

   1. Full-down position
   2. Down position with the bagger installed

   Important: Ensure that you secure the rear part of the seat with the seat latch.

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

1. Remove the hairpin cotters and remove the 2 pins (Figure 11).

2. Raise the roll bar to the upright position, install the 2 pins, and secure them with the hairpin cotters (Figure 11).

   

   Figure 11

   1. Roll bar
   2. Raised position
   3. Pin
   4. Hairpin cotter

The safety-interlock system is designed to prevent the engine from starting unless the following occurs:

• The parking brake is engaged.

• The blade-control switch (PTO) is disengaged.

• The motion-control levers are in the NEUTRAL-LOCK position.

The safety-interlock system also is designed to shut off the engine when the motion-control levers are moved from the NEUTRAL-LOCK position with the parking brake engaged or if you rise from the seat when the PTO is engaged.

The hour meter has indicators to notify the user when the interlock component is in the correct position. When the component is in the correct position, an indicator displays on the screen.

Figure 12

1. Indicators display when the interlock components are in the correct position

Test the safety-interlock system before you use the machine each time. If the safety system does not operate as described below, have an Authorized Service Dealer repair the safety system immediately.

1. Sit on the seat, engage the parking brake, and move the blade-control switch (PTO) to the ON position. Try starting the engine; the engine should not start.

2. Sit on the seat, engage the parking brake, and move the blade-control switch (PTO) to the OFF position. Move either motion-control lever out of the NEUTRAL-LOCK position. Try starting the engine; the engine should not start. Repeat for the other control lever.

3. Sit on the seat, engage the parking brake, move the blade-control switch (PTO) to the OFF position, and move the motion-control levers to the NEUTRAL-LOCK position. Now start the engine. While the engine is running, disengage the parking brake, engage the blade-control switch (PTO), and rise slightly from the seat; the engine should shut off.

4. Sit on the seat, engage the parking brake, move the blade-control switch (PTO) to the OFF position, and move the motion-control levers to the NEUTRAL-LOCK position. Now start the engine. While the engine is running, center either motion control and move (forward or reverse); the engine should shut off. Repeat for other motion control.

5. Sit on the seat, disengage the parking brake, move the blade-control switch (PTO) to the OFF position, and move the motion-control levers to the NEUTRAL-LOCK position. Try starting the engine; the engine should not start.

Park the machine on a level surface.

Figure 17

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

Figure 19

Note: The engine shuts off when you move the traction-control with the parking brake engaged.

To stop the machine, pull the motion-control levers to the NEUTRAL position.

1. Disengage the parking brake; refer to Disengaging the Parking Brake.

2. Move the levers to the center, unlocked position.

3. To go forward, slowly push the motion-control levers forward (Figure 26).

   

   Figure 26

1. Move the levers to the center, unlocked position.

2. To go backward, slowly pull the motion-control levers rearward (Figure 27).

   

   Figure 27

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 29, Figure 30, and Figure 31.

   

   Figure 29

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

   Figure 30

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

   Figure 31

   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 32 and Figure 33.

   

   Figure 32

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

   Figure 33

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

This is the fully-rear position. The suggested use for this position is as follows:

• Short, light grass mowing conditions

• Dry conditions

• Smaller grass clippings

• Propels grass clippings farther away from the mower

  

  Figure 35

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

Figure 36

This is the fully-forward position. The suggested use for this position is as follows:

• Tall, dense grass mowing conditions

• Wet conditions

• Lowers the engine-power consumption

• Allows increased ground speed in heavy conditions

  

  Figure 37

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.

Cut grass slightly longer than normal to ensure that the cutting height of the mower deck does not scalp any uneven ground. However, the cutting height used in the past is generally the best one to use. When cutting grass longer than 15 cm (6 inches) tall, you may want to cut the lawn twice to ensure an acceptable quality of cut.

It is best to cut only about a third of the grass blade. Cutting more than that is not recommended unless grass is sparse, or it is late fall when grass grows more slowly.

Alternate the mowing direction to keep the grass standing straight. This also helps disperse clippings, which enhances decomposition and fertilization.

Grass grows at different rates at different times of the year. To maintain the same cutting height, mow more often in early spring. As the grass growth rate slows in mid summer, mow less frequently. If you cannot mow for an extended period, first mow at a high cutting height, then mow again 2 days later at a lower height setting.

To improve cut quality, use a slower ground speed in certain conditions.

When mowing uneven turf, raise the cutting height to avoid scalping the turf.

If you must stop the forward motion of the machine while mowing, a clump of grass clippings may drop onto your lawn. To avoid this, move onto a previously cut area with the blades engaged or you can disengage the mower deck while moving forward.

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.

Maintain a sharp blade throughout the cutting season because a sharp blade cuts cleanly without tearing or shredding the grass blades. Tearing and shredding turns grass brown at the edges, which slows growth and increases the chance of disease. Check the mower blades after each use for sharpness, and for any wear or damage. File down any nicks and sharpen the blades as necessary. If a blade is damaged or worn, replace it immediately with a genuine Toro replacement blade.

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 bypass valves counterclockwise 1 turn to push (Figure 39).

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

   Important: Do not rotate bypass valves more than 1 turn. This prevents valves from coming out of the body and causing fluid to run out.

4. Disengage the parking brake before pushing.

Rotate the bypass valves clockwise 1 turn to operate machine (Figure 39).

Note: Do not over-tighten the bypass valves.

Important: The machine does not drive unless bypass valves are turned in.

Figure 39

1. Side console controls
2. Bypass valve
3. Hydraulic pumps

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

2. If applicable, connect the trailer brakes and lights.

3. Lower the ramp, ensuring that the angle between the ramp and the ground does not exceed 15 degrees (Figure 40).

4. Back the machine up the ramp (Figure 41).

   

   Figure 41

   1. Back the machine up the ramp.
   2. Drive the machine forward down the ramp.

5. Shut off the engine, remove the key, and engage the parking brake.

6. Tie down the machine near the front caster wheels and the rear bumper with straps, chains, cable, or ropes (Figure 42). Refer to local regulations for tie-down requirements.

   

   Figure 42

   1. Tie-down loops

1. Lower the ramp, ensuring that the angle between the ramp and the ground does not exceed 15 degrees (Figure 40).

2. Drive the machine forward down the ramp (Figure 41).

Important: Use the Z Stand on a level surface.

1. Raise the mower deck to the transport position.

2. Remove the bracket pin (Figure 43).

   

   Figure 43

   1. Z Stand
   2. Bracket pin
   3. Bracket
   4. Bottom of slot
   5. Latch

3. Raise the latch.

4. Swing the stand foot out front and slide it toward machine, into the bottom of slot (Figure 43 and Figure 44).

   

   Figure 44

   1. Z Stand (positioned in slot)
   2. Crack in side walk or turf
   3. Latch resting on pivot tab

5. Set the foot of the stand on the ground and rest the latch on the pivot tab (Figure 44).

6. Start the engine and put it at half throttle.

   Note: For best results, place the foot of the stand into the seams in sidewalks or into the turf (Figure 44).

7. Drive the machine onto the stand. Stop when the latch drops over the tab into the locked position (Figure 44).

8. Engage the parking brake, shut off the engine, and remove the key.

9. Chock or block the drive wheels.

   Warning

   The parking brake may not hold the machine parked on the Z Stand and could cause personal injury or property damage.

   Do not park on the Z Stand unless the wheels are chocked or blocked.

10. Perform the maintenance.

1. Remove the chocks or blocks.

2. Raise the latch to the unlocked position (Figure 45).

   

   Figure 45

   1. Z Stand
   2. Latch
   3. Locked position
   4. Unlocked position

3. Start the engine and place it at half throttle. Disengage the parking brake.

4. Slowly drive backward off the stand.

5. Return the stand to its rest position (Figure 43).

Use light oil or spray lubricant to lubricate the deck-lift pivots.

Figure 50

Use light oil or spray lubricant to lubricate the machine in the following areas:

• Seat-switch actuator

• Brake-handle pivot

• Brake-rod bushings

• Motion-control bronze bushings

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. Release the latches on the air cleaner and pull the air-cleaner cover off the air-cleaner body (Figure 55).

4. Clean the inside of the air-cleaner cover with compressed air.

5. Gently slide the filter out of the air-cleaner body (Figure 55).

   Note: Avoid knocking the filter into the side of the body.

6. Inspect the filter for damage by looking into the filter while shining a bright light on the outside of the filter.

   Note: Holes in the filter appear as bright spots. If the filter is damaged, discard it.

   

   Figure 55

   1. Air-filter body
   2. Air filter
   3. Air-cleaner cover
   4. Latches

1. If installing a new filter, check the filter for shipping damage. Do not use a damaged filter.

2. Carefully slide the filter into the filter body (Figure 56).

   Note: Ensure that it is fully seated by pushing on the outer rim of the filter while installing it.

   Important: Do not press on the soft inside area of the filter.

3. Install the air-cleaner cover and secure the latches (Figure 56).

   

   Figure 56

   1. Air-filter body
   2. Air filter
   3. Air-cleaner cover
   4. Latches

Oil Type: High-quality detergent oil classified API Service CJ-4 or higher for diesel engines. Do not use special additives with recommended oils.

Crankcase Capacity: 3.7 L (3.9 US qt)

Viscosity: See the table below.

Figure 57

Note: Check the oil when the engine is cold.

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

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

3. Check the engine-oil level (Figure 58).

   

   Figure 58

4. Start the engine, run it at idle for 5 minutes, shut off the engine, wait for 3 minutes, and then check the engine-oil level. If needed, add oil up to the FULL mark on the dipstick.

   Important: Be sure to keep the engine-oil level between the upper and lower limits on the oil gauge. Engine failure may occur as a result.

   Important: Add the oil very slowly and do not block the opening of the filler hole (Figure 40). If you add oil too fast or block the hole, the oil could back up and foul the air intakes, causing engine damage.

   

   Figure 59

   1. Note the clearance left in the filler opening.

1. Start the engine and let it run for 5 minutes.

   Note: This warms the oil so it drains better.

2. Park the machine on a level surface, disengage the blade-control switch (PTO), 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.

   

   Figure 60

   Note: Dispose of the used oil at a recycling center.

1. Drain the oil from the engine; refer to Draining the Engine Oil.

2. Change the engine-oil filter (Figure 61).

   

   Figure 61

3. Add oil; refer to Adding Engine Oil.

1. Start the engine and let it run for 5 minutes.

   Note: This warms the oil so it drains better.

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

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

5. Place a pan below the oil drain. Remove the drain plug and let the oil drain completely (Figure 62).

6. Remove the oil filler cap from the top of the engine (Figure 64).

   Note: This helps the oil to drain.

7. Install the drain plug and tighten it to 35 N∙m (25-1/2 ft-lb).

   Note: Dispose of the used oil at a recycling center.

   

   Figure 62

   1. Back of the machine
   2. Drain plug

1. Tilt the seat forward and remove the front engine panel (Figure 63).

   

   Figure 63

   1. Knob
   2. Front engine panel

2. Remove the oil-fill cap and dipstick (Figure 64).

   

   Figure 64

   1. Engine
   2. Oil-fill cap

3. Use a hose and funnel to add oil to the engine (Figure 65).

4. Add oil slowly, checking the level frequently with the dipstick until the level reaches the upper hole on the dipstick. For the correct oil type and viscosity to use in different temperature conditions, refer to Engine-Oil Specifications.

   

   Figure 65

   1. Engine oil
   2. Funnel and hose

   Important: Add the oil very slowly and do not block the opening of the filler hole (Figure 66). If you add oil too fast or block the hole, the oil could back up and foul the air intakes, causing engine damage.

   

   Figure 66

   1. Note the clearance left in the filler opening.

5. Replace the dipstick and install the front engine panel.

6. Start the engine and run it at idle for 5 minutes.

7. Shut off the engine.

8. Wait 3 minutes and check the oil level.

9. Add oil, if required, to bring the level to the upper hole on the dipstick.

10. Replace the dipstick, filler cap, and the front engine panel.

11. Check for leaks.

    Important: Do not overfill the crankcase with oil because this may cause engine damage.

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. Locate the water separator at the back left of the machine.

4. Place a drain pan below the water separator.

5. Open the drain valve on the water separator approximately 1 turn to allow water and other contaminates to drain (Figure 67).

6. Close the drain valve when only diesel fuel comes out (Figure 67).

   

   Figure 67

   1. Drain valve
   2. Water separator
   3. Back of machine

Never install a dirty fuel filter if it is removed from the fuel line.

1. Allow the machine to cool down.

2. Park the machine on a level surface, disengage the blade-control switch, 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. Close the fuel shut-off valve (Figure 68).

5. Loosen the 2 hose clamps and disconnect the fuel lines from the fuel filter (Figure 68).

6. Install a new filter. Connect the fuel lines to the fuel filter and install the 2 hose clamps (Figure 68).

7. Open the fuel shut-off valve.

8. Start the engine and check for leaks.

   

   Figure 68

   1. Fuel filter
   2. Hose clamp
   3. Fuel pump
   4. Left side of machine
   5. Fuel-shutoff valve

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 battery as shown in Figure 69.

   

   Figure 69

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. Remove the battery from the chassis; refer to Removing the Battery.

2. Charge the battery for 10 to 15 minutes at 25 to 30 A or for 30 minutes at 10 A.

   Note: Do not overcharge the battery.

3. When the battery is fully charged, unplug the charger from the electrical outlet, then disconnect the charger leads from the battery posts (Figure 70).

4. Install the battery in the machine and connect the battery cables; refer to Installing the Battery.

   Note: Do not run the machine with the battery disconnected; electrical damage may occur.

   

   Figure 70

   1. Positive (+) battery post
   2. Negative (–) battery post
   3. Red (+) charger lead
   4. Black (–) charger lead

Note: Position the battery in the tray with the terminal posts opposite from the hydraulic tank (Figure 71).

Figure 71

Use SAE 75W-90 synthetic gear lube.

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 side or rear plug on the gearbox (Figure 76).

4. The oil should be up to the opening of the gearbox.

5. Add oil if needed to bring it to the correct level.

   

   Figure 76

   1. Gearbox
   2. Side plug
   3. Pulley
   4. Rear plug

Contact an Authorized Service Dealer to change the gearbox oil.

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. Remove the belt covers (Figure 83).

   

   Figure 83

   1. Belt cover
   2. Latch
   3. Insert slot into the tab

6. Remove the idler spring.

7. Remove the belt guide on the spring-loaded idler pulley shown in Figure 84.

8. Remove the existing belt.

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

   

   Figure 84

   1. Mower belt
   2. Mower spindle pulley
   3. Spring-loaded idler pulley
   4. Belt guide at a 45° angle
   5. Gearbox pulley
   6. Idler spring
   7. Idler plate (for 72-inch mowers only)

10. Install the belt guide on the spring-loaded idler at a 45° angle as shown in Figure 84. Torque the bolt to 37 to 45 N∙m (27 to 33 ft-lb).

11. Install the idler spring to the 2 posts (Figure 84).

12. Install the belt covers by sliding the cover into the tab, install the bolts, and close the latches (Figure 85).

    

    Figure 85

    1. Belt cover
    2. Latch
    3. Insert slot into the tab

13. Install the sheet-metal guard.

14. Tighten the bottom bolt holding the mower-deck curtain to the mower deck.

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. 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. Remove the belt covers and the bolts attached to them.

6. Loosen the fixed idler arm and adjust it to relieve belt tension (Figure 86).

7. Remove the old belt.

8. Install the new belt on the pulleys.

9. Insert a ratchet with a short extension or a breaker bar into the square hole in the fixed idler arm (Figure 86).

10. Adjust the mower deck to the 76 mm (3 inch) height-of-cut position.

11. To increase the belt tension, rotate the ratchet or breaker bar counterclockwise to move the fixed idler arm until there is 16.5 cm (6-1/2 inches) between the spring hooks (Figure 86).

    

    Figure 86

    1. Ratchet with short extension or breaker bar
    2. 16.5 cm (6-1/2 inches) between the spring hooks
    3. Spring-loaded idler pulley
    4. Fixed Idler pulley

12. While holding the belt in tension, tighten the 2 bolts that secure the fixed idler arm.

13. Remove the ratchet or breaker bar from the square hole in the fixed idler arm.

14. Install the belt covers with the tabs in the slots. Install the screws and close the latches (Figure 87).

    

    Figure 87

    1. Belt cover
    2. Latch
    3. Bolt
    4. Install tab into the slot

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.

17. Check the tension on the drive belts.

If the alternator belt needs to be replace, take your machine to an Authorized Service Dealer.

1. Place a handle between the alternator and cylinder block.

2. Adjust the alternator to the outside until there is 7 to 9 mm (1/4 to 11/32 inch) deflection in the belt between the engine and the alternator pulleys with 10 kg (22.1 lb) of force (Figure 91).

3. Tighten the alternator bolts.

4. Check the deflection in the belt again and adjust the belt if needed.

5. If the deflection is correct, tighten the bottom and upper bolt (Figure 91).

   

   Figure 91

   1. Alternator
   2. Alternator belt
   3. Deflection—7 to 9 mm (1/4 to 11/32 inch) with 10 kg (22.1 lb) of force
   4. Top bolt
   5. Bottom bolt

1. Apply 44 N (10 lb) of force to the alternator belt, midway between the pulleys.

2. If the deflection is not 10 mm (3/8 inch), loosen the alternator mounting bolts (Figure 92).

   

   Figure 92

   1. Mounting bolt
   2. Alternator

3. Increase or decrease the alternator-belt tension.

4. Tighten the mounting bolts.

5. Check the deflection of the belt again to ensure that the tension is correct.

1. Start the engine, open the throttle 1/2 way and disengage parking brake; refer to Starting the Engine in Normal Weather.

   Note: The motion-control lever must be in neutral while making any adjustments.

2. Adjust the pump rod length by rotating the knob, in the appropriate direction, until the wheel is still or slightly creeping in reverse (Figure 99).

3. Move the motion-control lever forward and reverse, then back to neutral.

   Note: The wheel must stop turning or slightly creep in reverse.

4. Open the throttle to FAST.

   Note: Make sure that the wheel remains stopped or slightly creeps in reverse; adjust if necessary.

   

   Figure 99

   1. Tracking knob
   2. Hydraulic tank
   3. Hydraulic pumps
   4. Turn this way to track right
   5. Turn this way to track left

1. Loosen the locknuts at the ball joints on the pump control rod (Figure 100).

2. Start the engine, open the throttle 1/2 way and disengage parking brake; refer to Starting the Engine in Normal Weather.

   Note: The motion-control lever must be in neutral while making any adjustments.

   Note: The front nut on the pump rod has left-hand threads.

3. Adjust the pump rod length by rotating double nuts on rod, in the appropriate direction, until wheel is still or slightly creeps in reverse (Figure 100).

4. Move the motion-control lever forward and reverse, then back to neutral. The wheel must stop turning or slightly creep in reverse.

5. Open the throttle to fast. Make sure that the wheel remains stopped or slightly creeps in reverse, adjust if necessary.

6. Tighten the locknuts at the ball joints (Figure 100).

   

   Figure 100

   1. Double nuts
   2. Pump rod
   3. Adjustment bolt
   4. Locknut
   5. Ball joint
   6. Pumps

   Warning

   The electrical system does not perform proper safety shut off with the jumper wire installed.

   • Remove the jumper wire from the wire harness connector and plug the connector into the seat switch when you complete the adjustment.

   • Never operate the machine with the jumper installed and the seat switch bypassed.

7. After both pump neutrals are set, shut off the machine.

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

9. Install the seat rod and lower the seat into position.

10. Remove the jack stands.

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.

1. Inspect the cutting edges (Figure 101).

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 101).

   

   Figure 101

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

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 102).

   

   Figure 102

   1. Deck
   2. Spindle housing
   3. Blade

3. Measure from the tip of the blade to the flat surface (Figure 103).

   

   Figure 103

   1. Blade (in position for measuring)
   2. Level surface
   3. Measured distance between blade and the surface (A)

4. Rotate the same blade 180 degrees so that the opposing cutting edge is now in the same position (Figure 104).

   

   Figure 104

   1. Blade (side previously measured)
   2. Measurement (position used previously)
   3. Opposing side of blade being moved into measurement position

5. Measure from the tip of the blade to the flat surface (Figure 105).

   Note: The variance should be no more than 3 mm (1/8 inch).

   

   Figure 105

   1. Opposite blade edge (in position for measuring)
   2. Level surface
   3. Second measured distance between blade and surface (B)

   1. If the difference between A and B is greater than 3 mm (1/8 inch), replace the blade with a new blade; refer to Removing the Blades and Installing the Blades.

      Note: If a bent blade is replaced with a new blade, and the dimension obtained continues to exceed 3 mm (1/8 inch), the blade spindle could be bent. Contact an Authorized Service Dealer for service.

   2. If the variance is within constraints, move to the next blade.

6. Repeat this procedure on each blade.

Replace the blades if they hit a solid object, or if the blade is out of balance or bent.

1. Place a wrench on the flat of the spindle shaft or hold the blade end using a rag or thickly padded glove.

2. Remove the blade bolt, bushing, and blade from the spindle shaft (Figure 106).

   

   Figure 106

   1. Sail area of the blade
   2. Blade
   3. Flat of the spindle shaft
   4. Bushing
   5. Blade bolt

1. Use a file to sharpen the cutting edge at both ends of the blade (Figure 107).

   Note: Maintain the original angle.

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

   

   Figure 107

   1. Sharpen at original angle.

2. Check the balance of the blade by putting it on a blade balancer (Figure 108).

   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 107).

   

   Figure 108

   1. Blade
   2. Balancer

3. Repeat this procedure until the blade is balanced.

1. Install the bushing through the blade with the bushing flange on the bottom (grass) side of the blade (Figure 109).

   

   Figure 109

   1. Bushing

2. Install the bushing/blade assembly into the spindle shaft (Figure 110).

   

   Figure 110

   1. Top spindle nut
   2. Flat of the spindle shaft
   3. Blade bolt

3. Apply copper-based lubricant or grease to the threads of the blade bolt as needed to prevent seizing. Install the blade bolt finger-tight.

4. Place a wrench on the flat of the spindle shaft and torque the blade bolt to 75 to 81 N∙m (55 to 60 ft-lb).

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. Check tire pressure of the tires; if needed, adjust to 90 kPa (13 psi).

4. Lower the mower to the 76 mm (3 inches) height-of-cut position.

5. Inspect the 4 chains.

   Note: The chains need to have tension.

   Note: Adjust the rear chains to the top of the slot, where they are attached to the mower deck.

   • If a rear chain is loose, lower (loosen) the front-support arm on the same side; refer to Adjusting the Front-to-Rear Mower Deck Pitch.

   • If a front chain is loose, raise (tighten) the front-support arm for that chain; refer to Adjusting the Front-to-Rear Mower Deck Pitch.

1. Position the right blade side-to-side (Figure 111).

   

   Figure 111

   1. Measure here from blade to hard surface
   2. Measure at B and C

2. Measure the right blade at the B location, from a level surface to the cutting edge of the blade tip (Figure 111).

3. Record this measurement. This measurement needs to be 80 to 83 mm (3-1/8 to 3-1/4 inches).

4. Position the left blade side-to-side (Figure 111).

5. Measure the left blade at the C location (Figure 111), from a level surface to the cutting edge of the blade tip.

6. Record this measurement. This measurement needs to be 80 to 83 mm (3-1/8 to 3-1/4 inches).

7. If the measurements at positions B or C are not correct, loosen the bolt attaching the rear chain to the rear-support arm (Figure 112).

   

   Figure 112

   1. Rear chain
   2. Rear-support arm
   3. Bolt
   4. Jam nut
   5. Adjustment bolt
   6. Front swivel
   7. Front-support arm

8. Loosen the jam nut under the rear-support arm and adjust the adjustment bolt to get a measurement of 80 to 83 mm (3-1/8 to 3-1/4 inches); refer to Figure 112.

   Note: It is recommended that both sides of the mower are adjusted the same distance.

9. Tighten the jam nut under the rear-support arm and tighten the bolt securing the chain to the rear-support arm.

10. Adjust the opposite side if needed.

1. Position the right blade front-to-rear (Figure 113).

   

   Figure 113

   1. Measure here from blade to hard surface
   2. Measure at A and B

2. Measure the right blade at the A location, from a level surface to the cutting edge of the blade tip (Figure 113).

3. Record this measurement.

4. Measure the right blade at the B location, from a level surface to the cutting edge of the blade tip (Figure 113).

5. Record this measurement.

6. The mower blade should be 6 to 10 mm (1/4 to 3/8 inch) lower at position A than at position B (Figure 113). If it is not correct, proceed to the following steps.

   Note: Adjust both of the front swivels the same amount to maintain equal chain tension.

7. Loosen the front swivel jam nuts, at the front of the right and left swivels, approximately 13 mm (1/2 inch) (Figure 112).

8. Adjust the lift nuts on both the left and the right side of the machine to achieve 6 to 10 mm (1/4 to 3/8 inch) lower in front at A than in the rear at B (Figure 112).

9. Tighten both swivel jam nuts against the front swivel to lock the height.

10. Ensure that there is equal tension on the chains and adjust again if needed.

1. Raise the mower deck lift lever to the transport position.

2. Check the distance between the 2 large washers, it needs to be 28.2 cm (11-1/8 inches) for 52-inch mower decks, 26.7 cm (10-1/2 inches) for 60-inch mower decks, or 29.2 cm (11-1/2 inches) for 72-inch mower decks (Figure 114).

   

   Figure 114

   1. 28.2 cm (11-1/8 inches) between the large washers for 52-inch mower decks
   2. Front nut
   3. Spring-jam nut
   4. Front swivel
   5. Swivel jam nut
   6. Lift nut
   7. Front-support arm
   8. Large washer
   9. 26.7 cm (10-1/2 inches) between the large washers for 60-inch mower decks
   10. 29.2 cm (11-1/2 inches) between the large washers for 72-inch mower decks

3. Adjust this distance, by loosening the spring-jam nut and turning the nut in front of each spring (Figure 114).

   Note: Turning the nut clockwise shortens the spring; counter-clockwise lengthens the spring.

4. Lock the nut into position by tightening the spring-jam nut (Figure 114).