Z Master® Professional 7500-D Series Riding Mower

The information screen displays information relative to machine operation; refer to the Software Guide for more information.

The multi-functional buttons are located at the bottom of the panel. The icons displayed on the information screen above the buttons indicate the current function. The buttons allow you to select the engine speed and navigate through system menus.

Refer to the Software Guide for more information.

The LED status light is multi-colored to indicate the system status and is located on the right side of the panel. During startup, the LED illuminates red to orange to green to verify functionality.

• Solid green—indicates normal operating activity

• Blinking red—indicates an active fault

• Blinking green and orange— indicates that a clutch reset is required

Refer to the Software Guide for more information.

If an error occurs, an error message displays, the LED turns red, and the alarm sounds audibly as follows:

• A fast chirp sound indicates critical errors.

• A slow chirping sound indicates less critical errors, such as required maintenance or service intervals.

  Note: During startup, the alarm sounds briefly to verify functionality.

Refer to the Software Guide for more information.

The hour meter records the number of hours the engine has operated. It operates when the engine is running. Use these times for scheduling regular maintenance (Figure 6).

Hours are displayed in Engine-Off screen or in the Engine Hour Counter menu.

Refer to the Software Guide for more information.

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.

While in the operating position, the mirrors should provide a wide-angle view to assist with blind spots.

Adjust the left and right mirror to ensure that you have an optimal viewing angle.

Note: If machine does not pass any of these tests, do not operate the machine. Contact an Authorized Service Dealer.

Note: To prevent engine cut-outs on rough terrain, the seat has a half-second delay before the engine begins to shutdown.

Checking the Normal Engine-Starting Chart

		System
		Motion Control Levers/Parking Brake	PTO	Operator	Outcome
	State of the System	Both Levers Out = Parking Brake Engaged	Blades disengaged	In the seat or out of the seat	Starter should crank
		Both Levers Out = Parking Brake Engaged	Up position, but blades disengaged*	In the seat or out of the seat	Starter should crank

*: The starter will crank with the PTO switch in the ON (pulled up) position; however, the system will disengage the PTO and a reset PTO error will occur. Engaging the PTO will require the operator to reset the PTO switch by turning it OFF (pushed down) and then turning it ON.

Checking the Engine-Starting Circuit Chart

Note: In the Checking the Engine-Starting Circuit Chart, the state of system item that is in bold text is being checked in each scenario.

	System
	Motion Control Levers/Parking Brake	PTO (Blades)	Operator	Outcome
State of the System	Both levers moved in, or right or left lever moved in = Parking Brake Disengaged	Disengaged	Operator in the seat	Starter must not crank

Checking the Shutdown-Circuit Chart

Note: The state of the system items in bold text are being checked in each scenario.

	Engine	Motion Control Levers/Parking Brake	PTO (Blades)	Operator	Outcome
State of the System	Running idle (1/3 throttle or efficient mode)	Both levers moved in, or right or left lever moved in = Parking Brake Disengaged	Disengaged	Raise off the seat (but do not get off)	Engine must begin shutdown within 1 second
	Running idle (1/3 throttle or efficient mode)	Both Levers Out = Parking Brake Engaged	Engaged	Raise off the seat (but do not get off)	PTO must begin shutdown within 1 second; engine stays running.
State of System	Running idle (1/3 throttle or efficient mode)	Both levers moved in, or right or left lever moved in = Parking Brake Disengaged	Engaged and Deck wings up	Operator in the seat	PTO must begin shutdown within 1 second; engine stays running.

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 13).

Figure 13

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 15).

Figure 15

1. Seat-suspension knob

Important: You must unfold the wing decks before you can engage the PTO.

1. Remove the clevis pin and hairpin cotter that secures each wing in the upright position and place them in the storage position (Figure 18 and Figure 19).

   

   Figure 18

   1. Pin storage location
   

   Figure 19

   1. Clevis pin
   2. Hairpin

2. Ensure that all persons are clear of the deck wings.

3. Press and hold the bottom of the deck-lift switch; the wing decks lower first, then the center deck.

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 20

Disengaging the Blade-Control Switch (PTO)

Figure 21

Important: Do not engage the 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 22

Wait until the recommended engine cool-down time symbol (D of Figure 23) disappears from the display before shutting off the engine.

Figure 23

1. Ensure that all persons are clear of the deck wings.

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

3. Press and hold the top of the deck-control switch; the center deck will raise first, then the wing decks.

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

5. Remove the clevis pin and hairpin cotter from the storage location and secure each wing in the upright position (Figure 24 and Figure 25).

   

   Figure 24

   1. Pin storage location
   

   Figure 25

   1. Clevis pin
   2. Hairpin cotter

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 cutting height of the mower deck can be adjusted from 2.54 cm to 14 cm (1 to 5-1/2 inches) in 6.4 mm (1/4 inch) increments.

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

2. Press the top of deck-lift switch to raise the center deck and wing decks.

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

4. Adjust the center deck by performing the following procedure:

   1. Remove the height-of-cut pin from the deck-lift plate on the right side of the center deck.

   2. Insert the height-of-cut pin into the hole corresponding to the desired cutting height.

      See the decal on the side of the deck-lift plate for the cutting heights.

5. Adjust the side wing decks by performing the following procedure:

   1. Ensure that the wing decks are locked in place.

   2. Unlock the cam locks located on the height-of-cut channel on the wing deck (Figure 28).

      

      Figure 28

      1. Cam lock
      2. Height-of-cut pin
      3. Lynch pin

   3. Remove the lynch pin from the height-of-cut pin on both the front and rear channels.

   4. Move the wing deck to the appropriate height and install the height-of-cut pins and lynch pins (Figure 28).

   5. Lock the cam lock.

   6. Repeat for the other wing deck.

6. If you desire additional height-of-cut range, adjust the front and rear gauge wheels on the wing deck as follows:

   1. Remove the mounting hardware from the gauge wheel.

   2. Adjust the front and rear gauge wheels to the appropriate hole location (see the chart below and Figure 29) and install the mounting hardware.

      Hole Location	Height-of-Cut Range
      Top hole (-1 on the decal)	25 to 89 mm (1 to 3-1/2 inches)
      Middle hole (0 on the decal)	51 to 114 mm (2 to 4-1/2 inches)
      Bottom hole (+1 on the decal)	76 to 140 mm (3 to 5-1/2 inches)

      

      Figure 29

      Height-of-cut range

      1. Top hole (-1 on the decal)
      2. Middle hole (0 on the decal)
      3. Bottom hole (+1 on the decal)

   3. Repeat for the other wing deck.

For maximum deck flotation, install the rollers 1 hole position lower. Rollers should maintain a 6 mm (1/4 inch) clearance to the ground. Do not adjust the rollers to support the deck.

1. Park the machine on 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, remove the key, and wait for all moving parts to stop before leaving the operating position.

4. After adjusting the height of cut, adjust the anti-scalp rollers by removing the mounting hardware (Figure 30).

   

   Figure 30

   1. Locknut (3/8 inch)
   2. Anti-scalp rollers
   3. Spacer
   4. Bolt

5. Place the rollers in 1 of the positions shown in Figure 31.

   Note: The rollers will maintain 19 mm (3/4 inch) clearance to the ground to minimize gouging and roller wear or damage. For cutting heights above 90 mm (3-1/2 inches), use the bottom hole. The rollers are still effective against scalping.

   

   Figure 31

   1. Anti-scalp roller mounting bracket
   2. Cutting height

6. Torque the locknut (3/8 inch) to 41 to 47 N∙m (30 to 35 ft-lb) as shown in Figure 30.

The 144-inch deck has 21 anti-scalp roller locations to adjust (Figure 32).

Figure 32

1. Anti-scalp roller

The PTO disengages, an alarm sounds, and a bar graph displays the engine temperature when it reaches an overheat condition. The PTO does not engage until the engine has cooled and you manually shut off the PTO and engage it.

Note: If the engine-coolant level is below the indicator line on the overflow bottle when the engine is cold, the coolant temperature gauge may not register correctly during operation and/or the audible alarm may not sound if the engine overheats.

The drive train brake releases are located on each of the wheel-motor gearboxes.

Releasing the drive train brake allows you to push the machine without the engine running.

1. Park the machine on a level surface.

2. Chock or block the wheels.

3. Remove and retain the bolts from the gearbox (Figure 33).

4. Flip the cap inward to the gearbox.

5. Using the retained bolts, tighten the flipped cap until the brake releases.

6. Reverse this procedure to apply the brake.

   

   Figure 33

   1. Wheel motor gearbox
   2. Cap
   3. Bolts

If the engine loses power, you can manually fold or unfold the wing decks.

To fold the wing decks, do the following:

1. Using a 1/8-inch Allen wrench to hold the set screws, loosen the sealing nuts using a 7/16-inch wrench until the nut is flush with the end of the set screw (approximately 6 turns) as shown in Figure 34.

   

   Figure 34

   1. Sealing nuts
   2. Set screw
   3. Manifold

2. Remove the wrenches and tighten the set screw by hand approximately 4 turns, until you feel a slight resistance.

   Continue to turn by hand 1-1/2 more turns to unseat the load-holding check valves.

   Important: Do not tighten the set screws beyond this point; otherwise, damage may occur.

3. Using a 1/8-inch Allen wrench to hold the set screws, tighten the sealing nuts using a 7/16-inch wrench to the manifold body.

4. Using lifting equipment with at least a 227 kg (500 lb) lifting capacity, carefully pull 1 wing deck outward, then upward to fold it.

   Secure the wing using the transport-lock pin.

5. Repeat this procedure for the other wing deck.

To unfold the wing decks and reset the wing-fold valve, do the following:

1. Using lifting equipment with at least a 227 kg (500 lb) lifting capacity to hold the wing deck up, remove the transport-lock pin, and carefully lower the wing deck.

2. Using a 1/8-inch Allen wrench to hold the set screws, loosen the sealing nut using a 7/16-inch wrench (Figure 34).

3. Loosen the set screw and turn it approximately 6 times.

4. Using a 1/8-inch Allen wrench to hold the set screws, torque the sealing nuts to 10 N∙m (8 ft-lb) using a 7/16-inch wrench to the manifold body.

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 35).

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

Figure 35

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

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.

Refer to the following chart for fitting locations and lubrication schedule.

Note: For easier access to the drive U-joints and splined slip joint, remove the floor pan and fully lower the mower deck.

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.

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.

   

   Figure 38

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

Figure 39

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 dust cap and adjust the caster pivots and keep the dust cap off until greasing is done; refer to Adjusting the Frame Caster-Pivot Bearing.

4. Remove the hex plug.

5. Thread a grease fitting into the hole.

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

7. Remove the grease fitting from the hole. Install the hex plug and cap.

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. Raise the mower for access.

4. Remove the caster wheel from the caster forks.

5. Remove the seal guards from the wheel hub.

   

   Figure 40

   1. Seal guard
   2. Spacer nut with wrench flats

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

   Note: Thread-locking compound 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.

11. If the axle assembly is missing both spacer nuts, apply a thread-locking compound 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 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 compound 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 the nut, then torque it 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 compound.

Inspect the engine-valve clearance. Refer to the engine owner’s manual.

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. Place a drain pan below the fuel filter/water separator.

4. Open the drain plug on the water separator approximately 1 turn to allow water and other contaminates to drain (Figure 46).

   

   Figure 46

   1. Fuel filter/water separator

5. Close the drain plug when only diesel fuel comes out.

   Important: Water or other contaminants in fuel can damage the fuel pump and/or other engine components.

Figure 47

The engine has 2 fuel filters as shown in Figure 48.

Figure 48

1. Filter locations

Inspect the fuel lines for deterioration, damage, chaffing, or loose connections.

The electrical system is protected by fuses. It requires no maintenance, however, if a fuse blows check component/circuit for malfunction or short.

1. Unlatch the engine hood and raise the engine hood to gain access to the fuse block.

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

3. Install a new fuse (Figure 51).

   

   Figure 51

   1. Accessory (15 A)
   2. Chassis (15 A)
   3. Main (25 A)
   4. Power point (15 A)
   5. Fan, photo relay

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

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 the FAST and SLOW positions.

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.

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

7. Adjust the stop plates as needed.

   • If the machine 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 52).

   • If the machine 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 52).

8. Tighten the stop plate (Figure 52).

   

   Figure 52

   1. Control lever
   2. Bolt
   3. Stop plate

9. 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 53).

   

   Figure 53

10. If alignment is needed, loosen the 2 motion-control lever mounting bolts on the misaligned side (Figure 54).

    

    Figure 54

11. Move motion-control lever to meet the opposite side.

12. Tighten the 2 motion-control lever mounting bolts (Figure 54).

Rear tire air pressure specification: 152 kPa (22 psi)

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

Check the air pressure in the rear tires. Add or remove air as needed to set the air pressure in the tires to the tire air pressure specification.

Important: Maintain pressure in all tires to ensure a good quality of cut and proper machine performance.Check the air pressure in all the tires before operating the machine.

Figure 55

Torque the wheel lug nuts to 129 N∙m (95 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. Remove the dust cap from the caster and tighten the locknut (Figure 56).

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 56).

   Important: Make sure that the spring washers are installed correctly as shown in Figure 56.

5. Install the dust cap (Figure 56).

   

   Figure 56

   1. Spring disc washers

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. Raise the rear of machine and support it using jack stands (or equivalent support) just high enough to allow the drive wheels to turn freely.

4. Remove the wheel and orient the gearbox with the drain port on the bottom and fill port on top (Figure 57).

5. Place a drain pan under each check port (Figure 57).

   Remove and retain the check plug.

6. Ensure that the oil level is up to check port and is correct consistency.

7. Install the check plug when complete.

   

   Figure 57

   1. Wheel gear box
   2. Check plug
   3. Drain plug
   4. Fill plug

8. Repeat on the opposite side.

Important: Do not overfill the gearbox; overfilling the gearbox may damage it.

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. Raise the rear of machine and support it using jack stands (or equivalent support) just high enough to allow the drive wheels to turn freely.

4. Remove the wheel and orient the gearbox with the drain port on the bottom and fill port on top (Figure 57).

5. Place a drain pan under each port.

   Remove the drain plug, check plug, and fill plug to allow the fluid drain (Figure 57).

   Retain the plugs.

6. Install the drain plug and add oil until it comes out of the check port (Figure 57).

7. Install check plug and fill plug.

8. Repeat on the opposite side.

Important: Do not overfill the drive wheel gearbox; otherwise, damage may occur.

Coolant specification: 50/50 solution of water and permanent ethylene-glycol antifreeze

Cooling-system capacity: 7.6 L (8 US qt)

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. Open the hood.

4. Check the level of the coolant in the expansion tank (Figure 58).

   Note: The coolant level should be between the marks on the side of the tank.

   

   Figure 58

   1. Expansion-tank cap
   2. Full line
   3. Add line

5. If coolant level is low, remove the expansion-tank cap, and add the specified coolant (Figure 58).

   Important: Do not overfill.

6. Install the expansion-tank cap.

7. Close the hood.

Clean the radiator and hood screen to prevent the engine from overheating.

Note: If the mower deck or engine shuts off due to overheating, check the radiator for excessive buildup of debris.

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 hood forward.

4. Using compressed air, blow out debris stuck between the fins of the entire radiator, both from the top down and bottom up.

5. Using compressed air, blow out the engine-hood screen.

6. If debris remains, it may be necessary to use water from a low-pressure hose.

   If the radiator is clean, proceed to step 8.

7. Cover the engine with a piece of cardboard or a plastic sheet. Squirt water through the fins. Blow through with low-pressure air from both directions.

   Note: If debris remains, repeat until clean.

8. Lower the hood.

9. Start the engine to ensure that the fan functions properly.

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 hood forward.

4. Drain the coolant when the engine is cool.

5. Remove the radiator cap, place a pan under the radiator, and remove the drain plug at the bottom of the radiator.

6. Remove the coolant hose from the oil cooler and drain the coolant from the engine block (Figure 59).

   

   Figure 59

   1. Coolant hose

7. Install the drain plugs and hoses.

8. Fill radiator with a 50/50 mix of water and ethylene glycol.

   Note: The use of Havoline® Xtended Life coolant is recommended.

   Allow some room (approximately 12.7 mm (1/2 inch)) for expansion. Add 50/50 coolant mix to the overflow bottle on the left side of the engine as required to bring the level up to the indicator line on the bottle.

9. Operate engine until the engine thermostat opens and the coolant is circulating through the radiator core.

   As air purges from the engine block and the coolant level drops, add additional coolant to the radiator.

10. When the radiator is completely full and no additional coolant can be added, continue running and install the radiator cap.

    Ensure that the cap is completely seated by pressing down firmly while turning, until the cap stops. Once the cap is installed, shut off the engine.

Check the belts whenever they squeal while rotating, the blades slip while cutting grass, or if the belts have frayed edges, burn marks, or cracks. If any of these conditions occur, replace the belts.

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 63).

   

   Figure 63

   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.

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 64).

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 65).

   

   Figure 64

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

   Figure 65

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

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. 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. Push the deck-lift pedal, remove the height-of-cut pin, and lower the mower deck to the ground

4. Raise the rear of the machine up and support it with jack stands (or equivalent support) just high enough to allow the drive wheels to turn freely.

5. Remove the electrical connection from the seat safety switch, located under the bottom cushion of the seat.

   Note: The switch is a part of the seat assembly.

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

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

   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.

8. Run the machine 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 you are making any adjustments.

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

10. 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 66).

    

    Figure 66

    1. Turn here to adjust.
    2. Loosen here (right-hand thread).

11. Move the motion-control levers to the REVERSE position and while applying slight pressure to the lever, allow the reverse-indicator springs to bring the levers back to neutral.

    Note: The wheels should stop turning or slightly creep in reverse.

12. Shut off the machine.

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

14. Remove the jack stands.

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

16. Check and ensure that the machine does not creep in neutral with the parking brake disengaged.

You can adjust the top damper-mounting bolt to obtain the desired motion-control lever resistance. Refer to Figure 67 for mounting options.

Figure 67

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)

To ensure a superior quality of cut, keep the blades sharp. For convenient sharpening and replacement, keep extra blades on hand.

Use SAE 75W-90 synthetic gear lube.

1. Park the machine on a level surface and engage the parking brake.

2. Lower the mower deck to the 25 mm (1 inch) height of cut.

3. Disengage the blade-control switch, shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

4. Lift the footrest to expose the top of the mower deck.

5. Remove the dipstick/fill plug from the top of the gearbox and ensure that the lubricant is between the marks on the dipstick (Figure 83).

   

   Figure 83

   1. Fill plug/dipstick

6. If the oil level is low, add enough lubricant until the level is between the marks on the dipstick.

   Important: Do not overfill the gearbox; overfilling the gearbox may damage it.

If the oil becomes contaminated, contact your Toro Distributor because the system must be flushed. Contaminated oil looks milky or black when compared to clean oil.

1. Park the machine on a level surface and engage the parking brake.

2. Lower the mower deck to the 25 mm (1 inch) height of cut.

3. Disengage the blade-control switch, shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

4. Lift the footrest to expose the top of the mower deck.

5. Remove the dipstick/fill plug from the top of the gearbox and ensure that the lubricant is between the marks on the dipstick (Figure 83).

6. Extract the oil through the fill port using a vacuum device or remove the gearbox from the deck and pour out the oil into a drain pan.

7. Install the gearbox (if it was removed to drain).

8. Add approximately 420 ml (14 fl oz), until the level is between the marks on the dipstick

   Important: Do not overfill the gearbox; overfilling the gearbox may damage it.

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 center deck and fold the wings by pressing down the deck-lift switch.

   Hold the switch down until both wing decks are completely folded.

4. Push on the front corners of the deck near the lower bushings.

   If the there is more than 3 mm (1/8 inch) of movement, you need to replace the bushings.

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 and retain the clevis pins and hairpin cotters from each wing deck storage location.

4. Ensure that all persons are clear of the deck wings.

5. Press and hold the top of the deck-control switch; the center deck will raise first, then the wing decks.

6. Secure each wing deck in the upright position using the clevis pins and hairpin cotters.

7. Loosen the bolts that secure the upper pivot pins to the deck but do not remove the bolts (Figure 84).

   

   Figure 84

   1. Front pivot pin
   2. Rear pivot pin

8. Remove and retain the clevis pins and hairpin cotters from each wing deck.

   Remove the height-of-cut pin from the deck-lift plate on the right side of the center deck.

9. Lower the wing decks, but do not draw them into the operating position.

10. Remove and retain the left and right wing deck belt shield lynch pins, belt shield, and wing deck belts.

11. Remove and retain the locking cotter pins and cylinder pins that attach to the rod end of the deck-fold cylinders and wing decks (Figure 85).

    Note: Do not pull the wing decks into the operating position in order to remove the cylinder pins.

    

    Figure 85

    1. Cylinder rod end
    2. Cotter pin
    3. Cylinder pin

12. Remove and retain the bolts that secure the upper pivot pins to the deck and then remove the pivot pins (Figure 86).

    

    Figure 86

    1. Upper pivot pins
    2. Bolt
    3. Pull outward
    4. Left wing deck

13. Pull the wing deck outward to separate it from the center deck section (Figure 86).

14. Remove the flanged bushings from the upper pivot points and clean the bore (Figure 87).

    

    Figure 87

    1. Upper pivot point bushing
    2. Lower pivot point bolt
    3. Deck pin assembly
    4. Bushing

15. Apply a thin bead of Loctite^® 680 to the entire circumference of the rear edge of the new bushings.

16. Insert and gently tap the new bushings into the opening and properly seat them into place.

17. Place a block of wood under the inside edge of the center deck to make it easier to work on the lower pivot point bushings.

18. Remove and retain the lower pivot point bolts (Figure 84 and Figure 87).

19. Remove and discard the flanged bushing from the front and rear of the wing deck and clean the bore.

20. Apply a thin bead of Loctite^® 680 to the entire circumference of the rear edge of the new bushings.

21. Insert and gently tap the new bushings into the opening and properly seat them into place.

22. Install the lower deck pin assemblies and bolts into the lower deck pivot points and hand-tighten.

23. To ease installing the wing deck sections, carefully remove the exposed end of the spring that applies pressure to the rear of the wing deck cover (Figure 88).

    

    Figure 88

    1. Spring

24. Push the left wing deck back to the center deck.

    Align and install the upper pivot deck pins in the front and rear of the deck and secure it using the previously removed bolts (Figure 86).

25. Align the lift-cylinder arm and install the previously removed pin and ensure that the locking tab aligns with the associated opening in the mount.

    Install the locking cotter pin to secure.

26. Attach the spring that was removed in step 23 that applies pressure to the rear of the wing deck cover.

27. Install the wing deck belts.

28. Install the wing deck belt shields and secure them using the lynch pins.

29. Raise the wing decks to the TRANSPORT position and secure them using the clevis pins and hairpin cotters.

30. Install the height-of-cut pin.

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 dust cap from the caster and tighten the locknut (Figure 89).

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 89).

   Important: Make sure that the spring washers are installed correctly as shown in Figure 89.

5. Install the dust cap (Figure 89).

   

   Figure 89

   1. Spring disc washers

Important: Do not use water to clean the engine. Use low-pressure compressed air. See the engine owner's manual.

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. Open the hood.

4. Clean all debris from the hood screens.

5. Clean around the flywheel, cylinder head, injectors, and injector pump.

6. Clean all debris from the exhaust system area.

7. Wipe up any excessive grease or oil around the engine and exhaust area.

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. Clean off any oil, debris, or grass build-up on the machine and mower deck, especially under the deck-belt shields, around the fuel tank, and around the engine and exhaust area.

4. Raise the center deck and wing decks. Lock each wing deck in the upright position.

5. Clean out any grass build-up from the underside of deck and in the discharge deflector.

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