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Toro 74991 Z Master Professional 5000 Series, Operator'S Manual

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Toro 74991 Z Master Professional 5000 Series Operator'S Manual Download Page 15

Blade-Control Switch (PTO)

Use the blade-control switch (PTO) to engage the electric
clutch and drive the mower blades. Pull the switch up to
engage the blades and release. To disengage the blades,
push the blade-control switch (PTO) down or move a
motion-control lever into the N

EUTRAL

-

LOCK

position.

Ignition Switch

This switch is used to start the mower engine and has 3
positions:

Start, Run,

and

Off

.

Motion-Control Levers

Use the motion-control levers to drive the machine forward
and reverse, and to turn either direction.

Neutral-Lock Position

Use the N

EUTRAL

-

LOCK

position with the safety-interlock

system to engage and to determine the N

EUTRAL

position.

Fuel-Shutoff Valve

Close the fuel-shutoff valve (under the seat) when
transporting or storing the mower.

Electronic Control Unit Malfunction
Indicator Light

The electronic control unit (ECU) continuously monitors the
operation of the EFI system.

If the system detects a problem or fault, the malfunction
indicator light (MIL) illuminates.

The MIL is the red light located in the right console panel.

If the MIL illuminates, perform the initial troubleshooting
checks; refer to the MIL section in

Troubleshooting (page 69)

.

If these checks do not correct the problem, further diagnosis
and servicing by an Authorized Service Dealer is necessary.

Attachments/Accessories

A selection of Toro approved attachments and accessories is
available for use with the machine to enhance and expand
its capabilities. Contact your Authorized Service Dealer or
Distributor or go to www.Toro.com for a list of all approved
attachments and accessories.

Specifications

Note:

Specifications and design are subject to change

without notice.

Width

Without Deck

135 cm (53 inches)

Deflector Up

157 cm (62 inches)

Deflector Down

192 cm (76 inches)

Length

Roll Bar Up

211 cm (83 inches)

Roll Bar Down

215 cm (85 inches)

Height

Roll Bar Up

Roll Bar Down

179 cm (71 inches)

127.8 cm (50.3 inches)

Weight

Model

Weight

74991

587 kg (1,295 lbs)

15

 

Summary of Contents for 74991 Z Master Professional 5000 Series

Page 1: ...0 705 Rev B Z Master Professional 5000 Series Riding Mower with 60in TURBO FORCE Side Discharge Mower Model No 74991 Serial No 316000001 and Up g029833 Register at www Toro com Original Instructions EN 3400 705 B ...

Page 2: ...urer Introduction This rotary blade riding lawn mower is intended to be used by residential homeowners or professional hired operators It is designed primarily for cutting grass on well maintained lawns on residential or commercial properties It is not designed for cutting brush or for agricultural uses Read this information carefully to learn how to operate and maintain your product properly and ...

Page 3: ...rrester if Equipped 42 Fuel System Maintenance 42 Servicing the Electronic Fuel Injection System 42 Replacing the Low Pressure Fuel Filter 42 Servicing the High Pressure Fuel Filter 43 Servicing the Fuel Tank 43 Electrical System Maintenance 43 Servicing the Battery 43 Servicing the Fuses 45 Jump Starting the Machine 45 Drive System Maintenance 46 Checking the Seat Belt 46 Checking the Rollover Pr...

Page 4: ...approved by the manufacturer Wear appropriate clothing including substantial slip resistant footwear safety glasses and hearing protection Tie back long hair and do not wear jewelry Inspect the area where the equipment is used and remove all objects that can be thrown by the machine Check that operator s presence controls safety switches and shields are attached and functioning properly Do not ope...

Page 5: ...se a nozzle lock open device If you spill fuel on clothing change your clothing immediately Do not overfill the fuel tank Replace the fuel cap and tighten it securely Maintenance and Storage Disengage drives set the parking brake shut off the engine and remove the key or disconnect spark plug wire Wait for all movement to stop before adjusting cleaning or repairing the machine Park the machine on ...

Page 6: ...he ROPS in areas where there are slopes drop offs or water Check carefully for overhead clearances i e branches doorways electrical wires before driving under any objects and do not contact them Keep the ROPS in safe operating condition by periodically thoroughly inspecting for damage and keeping all mounting fasteners tight Replace a damaged ROPS Do not repair or revise Do not remove the ROPS Any...

Page 7: ... degrees Use the slope chart to determine the degree of slope of hills before operating Do not operate this machine on a slope greater than 15 degrees Fold along the appropriate line to match the recommended slope 2 Align this edge with a vertical surface a tree building fence pole etc 3 Example of how to compare slope with folded edge 7 ...

Page 8: ...20 1 Grease 93 7818 1 Warning read the Operator s Manual for instructions on torquing the blade bolt nut to 115 to 149 N m 85 to 110 ft lb 99 8936 1 Machine speed 4 Neutral 2 Fast 5 Reverse 3 Slow 106 2655 1 Warning do not touch or approach moving belts remove the ignition key and read the instructions before servicing or performing maintenance 106 5517 1 Warning do not touch the hot surface 8 ...

Page 9: ...wer the roll bar only when absolutely necessary do not wear the the seat belt when the roll bar is down 3 Read the Operator s Manual drive slowly and carefully 110 2067 110 2068 1 Read the Operator s Manual 112 9028 1 Warning stay away from moving parts keep all guards in place 114 4466 1 Main 25 A 3 Charge 25 A 2 PTO 10 A 4 Auxiliary 15 A 115 7445 1 Grease pulleys and spindles 2 Maintenance inter...

Page 10: ...7 0346 1 Fuel leak hazard read the Operator s Manual do not attempt to remove the roll bar do not weld drill or modify the roll bar in any way 117 3848 1 Thrown object hazard keep bystanders a safe distance from the machine 2 Thrown object hazard mower do not operate the machine without deflector discharge cover or grass collection system in place 3 Cutting dismemberment of hand or foot stay away ...

Page 11: ... 4x 2 Wheel hub nut torque 319 N m 235 ft lb 3 Read and understand the Operator s manual before performing any maintenance check torque after first 100 hours then every 500 hours thereafter 126 4398 1 Read the Operator s manual 3 Unlock 2 Lock 127 0326 1 Read the Operator s Manual 3 Remove the key from the ignition and read the Operator s Manual before performing maintenance or servicing the machi...

Page 12: ...ause blindness or severe burns 4 Wear eye protection 9 Flush eyes immediately with water and get medical help fast 5 Read the Operator s Manual 10 Contains lead do not discard Manufacturer s Mark 1 Indicates the blade is identified as a part from the original machine manufacturer 125 9383 1 Check hydraulic fluid every 50 operating hours 3 Check the tire pressure every 50 operating hours 2 Read the...

Page 13: ...and that has an incline less than 15 degrees back up the ramp in reverse and drive forward off the ramp 2 Cutting and pinching hazard keep hands and feet away from moving parts keep all guards and shields in place 5 Bodily harm hazard look behind you when mowing in reverse 3 Thrown object hazard keep bystanders away 6 Tipping hazard on slopes do not use on slopes near open water do not use on slop...

Page 14: ...t appears when the fuel level is low approximately 3 8 L 1 US gallon remaining in the fuel tank Figure 6 1 Fuel gauge bars 4 Safety interlock symbols 2 Battery light 5 Low fuel indicator light 3 Hour meter Hour Meter 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 Safety Interlock ...

Page 15: ...ation of the EFI system If the system detects a problem or fault the malfunction indicator light MIL illuminates The MIL is the red light located in the right console panel If the MIL illuminates perform the initial troubleshooting checks refer to the MIL section in Troubleshooting page 69 If these checks do not correct the problem further diagnosis and servicing by an Authorized Service Dealer is...

Page 16: ...operate without entire exhaust system in place and in proper working condition DANGER In certain conditions during fueling static electricity can be released causing a spark that can ignite the gasoline vapors A fire or explosion from gasoline can burn you and others and can damage property Always place gasoline containers on the ground away from your vehicle before filling Do not fill gasoline co...

Page 17: ... Allow 40 to 50 hours of break in time for new machines to develop full power and best performance Using the Rollover Protection System ROPS WARNING To avoid injury or death from rollover keep the roll bar in the fully raised locked position and use the seat belt Ensure that the seat is secured to the machine WARNING There is no rollover protection when the roll bar is in the down position Lower t...

Page 18: ...eck as a step to get into the operating position Figure 9 g029797 1 Figure 9 1 Mower deck Think Safety First Please read all safety instructions and symbols in the safety section Knowing this information could help you or bystanders avoid injury DANGER Operating the machine on wet grass or steep slopes can cause sliding and loss of control Do not operate on slopes greater than 15 degrees Reduce sp...

Page 19: ...earing protection when operating this machine Use protective equipment for your eyes ears hands feet and head G009027 1 2 Figure 11 1 Wear eye protection 2 Wear hearing protection Operating the Parking Brake Always set the parking brake when you stop the machine or leave it unattended Setting the Parking Brake WARNING The parking brake may not hold a machine parked on a slope and could cause perso...

Page 20: ...n the ignition key to the START position Figure 17 Note When the engine starts release the key 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 when you start it the first time after the fuel s...

Page 21: ...e key 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 to attempt to start the engine multiple times when you start it for the first time after the fuel system has been without fuel completely STA RT RU N STO P G008947 Figure 20 1 Off ...

Page 22: ...ting the Safety Interlock System Service Interval Before each use or daily 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...

Page 23: ...w the machine down before making sharp turns Using the Motion Control Levers Figure 23 1 Motion control lever NEUTRAL LOCK position 4 Backward 2 Center unlocked position 5 Front of machine 3 Forward Driving Forward Note The engine shuts off if you move the traction control levers with the parking brake engaged To stop pull the motion control levers to the NEUTRAL position 1 Release the parking bra...

Page 24: ...m the ignition switch CAUTION Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended Always remove the ignition key and set the parking brake when leaving the machine unattended even if just for a few minutes Adjusting the Height of Cut Using the Transport Lock The transport lock has 2 positions and is used with the deck lift pedal There is a LO...

Page 25: ...acket corresponding to the height of cut desired and insert the pin Figure 27 5 Push on the deck lift pull back on the transport lock and slowly lower the mower deck Figure 27 1 Deck lift pedal 3 Transport lock 2 Height of cut pin Adjusting the Anti Scalp Rollers Whenever you change the height of cut adjust the height of the anti scalp rollers 1 Disengage the blade control switch PTO move the moti...

Page 26: ...e 30 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 30 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 Adjust the cam lock until you achieve the desired locking pressure Figure 30 Positioning the Flow Baffle The following figures...

Page 27: ...ng the engine power consumption Increased ground speed in heavy conditions Figure 33 Note This position is similar to the benefits of the Toro SFS mower Positioning the Seat The seat can move forward and backward Position the seat where you have the best control of the machine and are most comfortable To adjust the seat move the lever sideways to unlock seat Figure 34 g029830 Figure 34 Unlatching ...

Page 28: ...s 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 36 Figure 36 1 Firmest position 3 Detents in the slots 2 Softest position Note Ensure that the left and right rear sho...

Page 29: ... switch PTO and turn the ignition key to off Move the levers to the NEUTRAL LOCK position and apply the parking brake Remove the key 2 Rotate the release valve levers vertically to push the machine Figure 39 Note This allows the hydraulic fluid to bypass the pump enabling the wheels to turn 3 Disengage the parking brake before pushing the machine g029831 Figure 39 1 Vertical to push the machine 2 ...

Page 30: ...ruck with straps chains cable or ropes Figure 40 g029641 Figure 40 1 Tie down loops Loading the Machine Use extreme caution when loading or the unloading machine onto a trailer or a truck Use a full width ramp that is wider than the machine for this procedure Back the machine up the ramp and drive it forward down the ramp Figure 41 g028043 Figure 41 1 Back the machine up the ramp 2 Drive the machi...

Page 31: ...amp 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 Back the machine up the ramp and drive it forward down the ramp Avoid sudden acceleration or deceleration while driving the machine on a ramp as this could cause a loss of control or a ...

Page 32: ... 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 Adjusting the Cutting Speed To improve cut quality use a slower ground speed in certain conditions Avoiding Cutting Too Low If the cutting width of the mower is wider than the mower that you previously used raise the cutting height to ensure that un...

Page 33: ... Every 200 hours Change the engine oil filter more often in dirty or dusty conditions Clean the engine oil cooler Check clean and gap the spark plug Replace the fuel filter more often in dirty or dusty conditions Every 250 hours Change the hydraulic filters and hydraulic fluid when using Mobil 1 fluid more often in dirty or dusty conditions Every 300 hours Replace the primary air filter more often...

Page 34: ...e the motion control levers to the NEUTRAL LOCK position and set 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 to scrape any paint off the front of the fitting s 4 Connect a grease gun to the fitting and pump grease into the fittings until grease begins to ooze...

Page 35: ...ts to stop before leaving the operating position 3 Grease the mower deck idler pulley pivot until grease come out the bottom Figure 45 4 Grease the 3 spindle bearings until grease comes out the lower seals Figure 45 G009029 Figure 45 5 Grease the drive belt idler arm Figure 45 Figure 46 6 Remove the dust cap and adjust the caster pivots Note Keep the dust cap off until greasing is complete Refer t...

Page 36: ... 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 10 Insert the assembled nut and axle into the wheel on the side with the new seal and bearing 11 With the open end of the wheel facing up fill the area inside the wheel around the axle full of general purpose grease 12 Insert the second bearing and new seal...

Page 37: ...sed air 8 Gently slide the primary filter out of the air cleaner body Figure 49 Note Avoid knocking the filter into the side of the body 9 Remove the inner filter only if you intend to replace it Important Never attempt to clean the inner filter If the safety filter is dirty then the primary filter is damaged replace both filters 10 Inspect the primary filter for damage by looking into the filter ...

Page 38: ...or daily Note Check the oil when the engine is cold WARNING Contact with hot surfaces may cause personal injury Keep hands feet face clothing and other body parts away from the muffler and other hot surfaces Important Do not overfill the crankcase with oil because damage to the engine may result Do not run engine with oil below the low mark because the engine may be damaged 1 Disengage the blade c...

Page 39: ...l drains completely 3 Disengage the blade control switch PTO move the motion control levers to the NEUTRAL LOCK position and set the parking brake 4 Shut off the engine remove the key and wait for all moving parts to stop before leaving the operating position Figure 52 G029644 Figure 52 5 Slowly pour approximately 80 of the specified oil into the filler tube and slowly add the additional oil to br...

Page 40: ...Oil Cooler Service Interval Every 200 hours 1 Keep the oil cooler free of debris by cleaning the fins with a brush 2 Remove the bolts holding the oil cooler to the engine housing 3 Clean the inside of the oil cooler with a brush 4 Install the oil cooler to the engine housing G029644 g01301 1 1 2 2 Figure 55 1 Engine oil cooler 2 Bolts Servicing the Spark Plug Service Interval Every 200 hours Check...

Page 41: ...he direction of the arrow 3 Pull the shroud off this frame tab in the direction of the arrow 2 Pull the shroud off this frame tab in the direction of the arrow 4 Shroud 4 Remove the spark plug Figure 57 g029646 B A g027478 Figure 57 5 Install the left hydraulic unit shroud Figure 56 Checking the Spark Plug Important Replace the spark plug s when it has a black coating worn electrodes an oily film ...

Page 42: ... possible explosion Use only approved fuel lines and fuel filters Servicing the Electronic Fuel Injection System This machine contains an electronic fuel injection system It controls the fuel flow under different operating conditions The electronic control unit ECU continuously monitors the operation of the EFI system If a problem or fault within the system is detected the malfunction indicator li...

Page 43: ... and causes severe burns Do not drink electrolyte and avoid contact with skin eyes or clothing Wear safety glasses to shield your eyes and wear rubber gloves to protect your hands Removing the Battery WARNING Battery terminals or metal tools could short against metal machine components causing sparks Sparks can cause the battery gasses to explode resulting in personal injury When removing or insta...

Page 44: ...tery WARNING Charging the battery produces gasses that can explode Never smoke near the battery and keep sparks and flames away from battery Important Always keep the battery fully charged 1 265 specific gravity This is especially important to prevent battery damage when the temperature is below 0 C 32 F 1 Charge battery for 10 to 15 minutes at 25 to 30 A or for 30 minutes at 10 A 2 When the batte...

Page 45: ...that the booster battery is a good and fully charged lead acid battery at 12 6 V or greater Note Use properly sized jumper cables with short lengths to reduce voltage drop between systems Make sure that the cables are color coded or labeled for the correct polarity CAUTION Connecting the jumper cables incorrectly wrong polarity can immediately damage the EFI system Be certain of battery terminal p...

Page 46: ...nance Checking the Seat Belt Service Interval Before each use or daily Inspect the seat belt for wear cuts and proper operation of the retractor and buckle Replace the seat belt if it is damaged Checking the Rollover Protection System ROPS Knobs Service Interval Before each use or daily WARNING To avoid injury or death from rollover keep the roll bar in the fully raised locked position and use the...

Page 47: ... FAST and SLOW positions 4 Move both motion control levers forward until they both hit the stops in the T slot 5 Check which way the machine tracks 6 If 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 67 7 If the machine tracks to the left loosen the bolts and adjust the right stop plate rearward o...

Page 48: ...g Note The front tires are semi pneumatic tires and do not require air pressure maintenance Figure 68 Checking the Wheel Lug Nuts Check and torque the wheel lug nuts to 122 to 129 N m 90 to 95 ft lb Checking the Wheel Hub Slotted Nut Service Interval After the first 100 hours Every 500 hours Check and ensure that the torque of the slotted nut is 286 to 352 N m 211 to 260 ft lb Note Do not use anti...

Page 49: ...igure 70 5 Install the dust cap Figure 70 Figure 70 1 Spring washers 3 Dust cap 2 Locknut Using the Clutch Shim Some later model year units have been built with clutches that contain a brake shim When the clutch brake has worn to the point where the clutch no longer engages consistently you can remove the shim to extend the clutch life Figure 71 1 Armature 5 Brake spacer 2 Field shell 6 Regap shim...

Page 50: ...emove the shim Note Do not discard the shim until you confirm that the clutch functions properly Figure 74 1 Shim C Using a pneumatic line blow out any debris under the brake pole and around the brake spacers D Torque each bolt M6 x 1 to 12 3 to 13 7 N m 9 5 to 10 5 ft lb E Using a 0 010 inch thick feeler gauge verify that a gap is present between the rotor and armature face on both sides of the b...

Page 51: ... blade control switch PTO 10 consecutive times to ensure that the clutch is functioning properly Note If the clutch does not engage properly refer to Troubleshooting page 69 Cooling System Maintenance Cleaning the Engine Screen and Engine Oil Cooler Service Interval Before each use or daily Remove any buildup of grass dirt or other debris from the oil cooler Figure 77 This helps ensure adequate co...

Page 52: ...d grass from the engine parts 5 Install the air intake screen recoil starter and fan housing Figure 78 Figure 78 1 Engine guard 4 Fan housing 2 Engine air intake screen 5 Screw 3 Bolt Cleaning the Hydraulic Units Service Interval Before each use or daily 1 Disengage the blade control switch PTO and set the parking brake 2 Shut off the engine remove the key and wait for all moving parts to stop bef...

Page 53: ...le gap between the L bracket and the linkage stop Figure 80 Figure 80 Left Side Shown 1 L bracket 4 Rear linkage assembly 2 Linkage stop 5 Caliper 3 Gap 6 Wheel hub 9 Disengage the parking brake 10 Turn the wheel hub by hand in both directions relative to the caliper Note The wheel hub should move freely between the caliper 11 If a gap is needed or the wheel hub does not move freely A Disengage th...

Page 54: ...t 4 Remove the belt covers Figure 81 Figure 81 5 Use a ratchet in the square hole in the idler arm to remove tension on the idler spring Figure 82 6 Remove the belt from the mower deck pulleys 7 Remove the belt guide on the spring loaded idler arm Figure 82 8 Remove the existing belt 9 Install the new belt around the mower pulleys and the clutch pulley under the engine Figure 82 g017627 Figure 82 ...

Page 55: ... hydraulic pump pulley 2 Clutch pulley 6 Square hole in idler arm 3 Pump drive belt 7 Idler spring 4 Right hydraulic pump pulley 5 Use a ratchet in the square hole in the idler arm to remove the idler spring Figure 84 6 Unhook the idler spring from the frame Figure 84 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...

Page 56: ... Linkage The pump control linkages are located on either side of the fuel tank below the seat Rotate the pump linkage with a 1 2 inch wrench for fine tuning adjustments so that the machine does not move in neutral Make any adjustments for neutral positioning only WARNING The engine must be running and the drive wheels must be turning so the motion control adjustment can be performed Contact with m...

Page 57: ...ion 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 10 Shut off the machine 11 Remove the jumper wire from wire harness and plug the connector into the seat switch 12 Remove the jack stands 13 Raise the deck and install the height of cut pin 14 Check that the machi...

Page 58: ...on a level surface 2 Disengage the blade control switch PTO move the motion control levers to the NEUTRAL LOCK position and set 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 Wait for the engine and hydraulic system to cool for 10 minutes Note The fluid level on the dipstick is incorrect if you check the fluid wh...

Page 59: ...rs Change the hydraulic filters and hydraulic fluid Every 250 hours Change the hydraulic filters and hydraulic fluid when using Mobil 1 fluid more often in dirty or dusty conditions Every 500 hours Change the hydraulic filters and hydraulic fluid when using Toro HYPR OIL 500 hydraulic fluid more often in dirty or dusty conditions To replace the hydraulic fluid you need to remove the filters Replac...

Page 60: ...re matching the height of cut HOC 1 Position the mower on a flat surface 2 Disengage the blade control switch PTO move the motion control levers to the NEUTRAL LOCK position and set the parking brake 3 Shut off the engine remove the key and wait for all moving parts to stop before leaving the operating position 4 Check the pressure of the drive tires Note Proper inflation pressure for the tires is...

Page 61: ...height Figure 95 Note To increase the height turn the adjuster screw clockwise to decrease the height turn it counterclockwise g029650 1 2 3 4 1 2 Figure 95 1 Flanged locknut 3 Jam nut 2 Adjuster screw 4 Yoke 12 If the front deck links do not have enough adjustment to achieve accurate cut height loosen the 2 bolts at the bottom of the height of cut plate to adjust the single point system Figure 96...

Page 62: ...keep the blades sharp For convenient sharpening and replacement keep extra blades on hand WARNING A worn or damaged blade can break and a piece of the blade could be thrown at you or bystanders resulting in serious personal injury or death Inspect the blades periodically for wear or damage Replace a worn or damaged blade Before Inspecting or Servicing the Blades 1 Park the machine on a level surfa...

Page 63: ...and 5 must not exceed 3 mm 1 8 inch Note If this dimension exceeds 3 mm 1 8 inch the blade is bent and must be replaced WARNING A blade that is bent or damaged could break apart and could seriously injure or kill you or bystanders Always replace bent or damaged blade with a new blade Do not file or create sharp notches in the edges or surfaces of the blade Removing the Blades Replace a blade if it...

Page 64: ...ed and ready to use Figure 102 1 Blade 2 Balancer 3 If the blade is not balanced file some metal off the end of the sail area only Figure 100 4 Repeat this procedure until the blade is balanced Installing the Blades 1 Install the blade onto the spindle shaft Figure 103 Important The curved part of the blade must point upward toward the inside of the mower to ensure proper cutting 2 Install the spr...

Page 65: ...nd lower the deck to the ground 3 Place the height adjustment pin in the 7 6 cm 3 inch height of cut location Note This locks the deck lift arms in the lowest position so that when you remove the deck the stored energy in the deck spring is released 4 Remove the belt covers 5 Lift the floor pan and insert a ratchet into the square hole in the deck idler Figure 104 6 Rotate the deck idler clockwise...

Page 66: ... bolt spring and spacer holding the deflector to the pivot brackets Figure 106 2 Remove the damaged or worn grass deflector Figure 106 g015594 1 6 2 4 7 3 5 Figure 106 1 Bolt 5 Spring installed 2 Spacer 6 Grass deflector 3 Locknut 7 J hook end of spring 4 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 ho...

Page 67: ...ngine hydraulic pumps and motors 3 Check the brake 4 Service the air cleaner refer to Servicing the Air Cleaner page 37 5 Grease the machine refer to Lubrication page 34 6 Change the crankcase oil refer to Changing the Engine Oil page 39 7 Check the tire pressure refer to Checking the Tire Pressure page 48 8 Change the hydraulic filters refer to Replacing the Hydraulic Filters and Hydraulic Fluid ...

Page 68: ...l bolts nuts and screws Repair or replace any part that is damaged 14 Paint all scratched or bare metal surfaces Paint is available from your Authorized Service Dealer 15 Store the machine in a clean dry garage or storage area 16 Remove the key from the ignition switch and keep it out of reach of children or other unauthorized users 17 Cover the machine to protect it and keep it clean 68 ...

Page 69: ... battery 6 The electrical connections are corroded or loose 6 Check the electrical connections for good contact 7 The fuse is blown 7 Replace the fuse The starter does not crank 8 The relay or switch is worn or damaged 8 Contact an Authorized Service Dealer 1 The fuel tank is empty 1 Fill the fuel tank 2 The fuel shutoff valve is closed 2 Open the fuel shutoff valve 3 The oil level in the crankcas...

Page 70: ...ing The machine does not drive 5 The hydraulic fluid level is low or too hot 5 Add hydraulic fluid to reservoirs or let it cool down 1 The cutting blade s is are bent or unbalanced 1 Install new cutting blade s 2 The blade mounting bolt is loose 2 Tighten the blade mounting bolt 3 The engine mounting bolts are loose 3 Tighten the engine mounting bolts 4 The engine pulley idler pulley or blade pull...

Page 71: ...e supply at the clutch 2 Check the coil resistance battery charge charging system and wiring connections and replace parts if necessary 3 The coil is damaged 3 Replace the clutch 4 There is inadequate current supply 4 Repair or replace the clutch lead wire or electrical system Clean the connector contacts The clutch does not engage 5 The rotor armature air gap is too large 5 Remove the shim or rep...

Page 72: ... B MAG ECU REG START AC STARTER AC IGNITION MODULES SPARK PLUG SPARK PLUG KOHLER EFI NEUT_L SW4 12 B 10 KEY_S 9 KEY_A 4 SEAT 11 BRAKE 2 NEUTRAL 3 PTO 5 FUEL 1 START_RELAY 7 MAGNETO 6 FUEL_SOLENOID 8 GROUND HOUR METER 2 R A I A 4 7 1 3 6 5 A 3 SW1 1 B B C B 8 2 4 5 IGNITION 6 5 1 KEY SW OPTIONAL ACCESSORIES 2 S Ignition switch terminal locations viewed from back OFF no connections ON BRIA START BRI...

Page 73: ...Notes 73 ...

Page 74: ...Notes 74 ...

Page 75: ...Notes 75 ...

Page 76: ...performed by a dealer or by you is at your expense Items and Conditions Not Covered There is no other express warranty except for special emission system coverage and engine warranty coverage on some products This express warranty does not cover the following Cost of regular maintenance service or parts such as filters fuel lubricants oil changes spark plugs air filters blade sharpening or worn bl...

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