#  #It is a violation of California Public Resource Code Section 4442 or 4443 to use or operate the engine on any forest-covered, brush-covered, or grass-covered land unless the engine is equipped with a spark arrester, as defined in Section 4442, maintained in effective working order or the engine is constructed, equipped, and maintained for the prevention of fire.  The enclosed engine owner's manual is supplied for information regarding the US Environmental Protection Agency (EPA) and the California Emission Control Regulation of emission systems, maintenance, and warranty. Replacements may be ordered through the engine manufacturer.  Please refer to the engine manufacturer’s information included with the machine.  Gross or Net Torque:  The gross or net torque of this engine was laboratory rated by the engine manufacturer in accordance with the Society of Automotive Engineers (SAE) J1940 or J2723. As configured to meet safety, emission, and operating requirements, the actual engine torque on this class of mower will be significantly lower. Please refer to the engine manufacturer’s information included with the machine.  # WARNING  CALIFORNIA Proposition 65 Warning The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. Use of this product may cause exposure to chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.  # Introduction  This rotary-blade, riding lawn mower is intended to be used by professional, hired operators. It is designed primarily for cutting grass on well-maintained lawns on residential or commercial properties. Using this product for purposes other than its intended use could prove dangerous to you and bystanders.  Read this information carefully to learn how to operate and maintain your product properly and to avoid injury and product damage. You are responsible for operating the product properly and safely.  Whenever you need service, genuine parts, or additional information, contact an Authorized Service Dealer or Customer Service and have the model and serial numbers of your product ready.  Figure 1 identifies the location of the model and serial numbers on the product. Write the numbers in the space provided.  Important:  With your mobile device, you can scan the QR code on the serial number decal (if equipped) to access warranty, parts, and other product information.   
1. Model and serial number location  This manual uses 2 words to highlight information. Important  calls attention to special mechanical  
information and  Note  emphasizes general information worthy of special attention.  The safety-alert symbol ( Figure 2 ) appears both in this manual and on the machine to identify important safety messages that you must follow to avoid accidents. This symbol will appear with the word Danger ,  Warning , or  Caution .  • Danger  indicates an imminently hazardous situation which, if not avoided,  will  result in death or serious injury. • Warning  indicates a potentially hazardous situation which, if not avoided,  could  result in death or serious injury. • Caution  indicates a potentially hazardous situation which, if not avoided,  may  result in minor or moderate injury.  
sa-black  # Figure 2  Safety-alert symbol   # Contents  Safety ....................................................................... 5 General Safety ................................................... 5 Slope Indicator ................................................... 6 Safety and Instructional Decals .......................... 7 Product Overview ................................................... 13 Controls ........................................................... 13 Specifications .................................................. 15 Attachments/Accessories................................. 15 Before Operation ................................................. 16 Before Operation Safety ................................... 16 Adding Fuel ...................................................... 17 Performing Daily Maintenance.......................... 17 Breaking in a New Machine .............................. 18 Using the Rollover-Protection System (ROPS) ......................................................... 18 Using the Safety-Interlock System.................... 19 Positioning the Seat.......................................... 20 Changing the Seat Suspension......................... 20 Adjusting the Rear-Shock Assemblies .............. 20 During Operation ................................................. 21 During Operation Safety ................................... 21 Entering the Operator’s Position ....................... 24 Operating the Parking Brake............................. 24 Operating the Mower Blade-Control Switch (PTO)............................................................ 25 Operating the Throttle....................................... 25 Operating the Choke ........................................ 25 Starting the Engine ........................................... 26 Shutting Off the Engine..................................... 26  Using the Motion-Control Levers....................... 27 Driving the Machine.......................................... 27 Using the Side Discharge ................................. 28 Adjusting the Height of Cut ............................... 29 Adjusting the Height of Cut ............................... 30 Adjusting the Anti-Scalp Rollers........................ 30 Operating Tips ................................................. 31 After Operation .................................................... 32 After Operation Safety ...................................... 32 Using the Fuel-Shutoff Valve............................. 32 Using the Drive-Wheel Release Valves............. 32 Transporting the Machine ................................. 34 Maintenance ........................................................... 36 Maintenance Safety.......................................... 36 Recommended Maintenance Schedule(s) ........... 36 Lubrication .......................................................... 37 Greasing the Machine....................................... 37 Lubricating the Mower Deck-Lift Pivots ............. 38 Greasing the Caster-Wheel Hubs ..................... 38 Engine Maintenance ........................................... 39 Engine Safety ................................................... 39 Identifying the Engine ....................................... 39 Servicing a   Engine.......................... 40 Cleaning the Engine Screen ............................. 50 Checking the Spark Arrester............................. 50 Fuel System Maintenance ................................... 50 Replacing the Fuel Filter................................... 50 Servicing the Fuel Tank..................................... 51 Electrical System Maintenance ........................... 51 Electrical System Safety................................... 51 Servicing the Battery......................................... 51 Servicing the Fuses .......................................... 53 Drive System Maintenance .................................. 54 Checking the Seat Belt ..................................... 54 Adjusting the Tracking ...................................... 54 Checking the Tire Pressure............................... 55 Checking the Wheel Lug Nuts........................... 55 Brake Maintenance ............................................. 55 Adjusting the Parking Brake.............................. 55 Belt Maintenance ................................................ 56 Inspecting the Belts .......................................... 56 Replacing the Mower Belt................................. 56 Replacing the Hydraulic Pump-Drive Belt................................................................ 57 Controls System Maintenance ............................. 58 Adjusting the Control-Handle Position .............. 58 Adjusting the Motion-Control Linkage ............... 59 Hydraulic System Maintenance ........................... 60 Hydraulic System Safety................................... 60 Hydraulic-Fluid Specifications .......................... 60 Checking the Hydraulic-Fluid Level................... 61 Changing the Hydraulic Fluid and Filters............................................................ 61 Bleeding the Hydraulic System ......................... 63 Mower Deck Maintenance.................................... 64 Blade Safety ..................................................... 64 Servicing the Cutting Blades............................. 64  
Adjusting the Side-to-Side Leveling and the Blade Slope .................................................. 67 Removing the Mower Deck............................... 69 Replacing the Grass Deflector .......................... 70 Cleaning .............................................................. 71 Cleaning under the Mower Deck....................... 71 Cleaning the Suspension System ..................... 71 Disposing of Waste........................................... 71 Storage ................................................................... 72 Storage Safety.................................................. 72 Cleaning and Storage....................................... 72 Troubleshooting ...................................................... 73 Schematics ............................................................. 76 This machine has been designed in accordance with ANSI standard B71.4-2017.  
# General Safety  This product is capable of amputating hands and feet and of throwing objects. Always follow all safety instructions to avoid serious personal injury or death.  • Read and understand the contents of this Operator’s Manual  before starting the engine.  • Keep bystanders and children away.  • Do not allow children or untrained people to operate or service the machine. Allow only people who are responsible, trained, familiar with the instructions, and physically capable to operate or service the machine.  • Always keep the roll bar in the fully raised and locked position and use the seat belt.  • Do not operate the machine near drop-offs, ditches, embankments, water, or other hazards, or on slopes greater than   $15^{\circ}$  .  • Do not put your hands or feet near moving components of the machine.  • Do not operate the machine without all guards, safety switches, and other safety protective devices in place and functioning properly.  • Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operator’s position. Allow the machine to cool before servicing, adjusting, fueling, cleaning, or storing it.  You may copy this page for personal use.  
 1. The maximum slope you can operate the machine on is  15 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  
# Safety and Instructional Decals  Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or missing.  
 99-8936   
decal oem markt  # Manufacturer's Mark  1. This mark indicates that the blade is identified as a part from the original machine manufacturer.   Battery Symbols  decal99-8936  4. Neutral 5. Reverse  1. Machine speed 2. Fast 3. Slow  Some or all of these symbols are on your battery.   1. Explosion hazard 2. No fire, open flame, or smoking 3. Caustic liquid/chemical burn hazard 4. Wear eye protection. 5. Read the  Operator's  Manual .  6. Keep bystanders away from the battery. 7. Wear eye protection; explosive gases can cause blindness and other injuries. 8. Battery acid can cause blindness or severe burns. 9. Flush eyes immediately with water and get medical help fast. 10. Contains lead; do not discard  106-5517  decal106-5517  1. Warning—do not touch the hot surface.   
107-3069  
 
115-9625  1. Parking brake—disengaged  
 
decal107-3069  # 116–5610   1. Warning–there is no rollover protection when the roll bar is down. 2. To avoid injury or death from a rollover accident, keep the roll bar in the raised and locked position and wear the seat belt. Lower the roll bar only when absolutely necessary; do not wear the seat belt when the roll bar is down.  1. Hour meter 4. Neutral 2. Power take-off (PTO) 5. Operator presence switch 3. Parking brake 6. Battery  3. Read the  Operator's Manual ; drive slowly and carefully.  
109-6035  
 1. Warning—read the  Operator's Manual  for instructions on torquing the blade bolt/nut to 75 to 81 N∙m (55 to 60 ft-lb).   decal109-6035  
133-8062   
decal117-3848  
 # 117-3848  1. Thrown object hazard—keep bystanders away. 2. Thrown object hazard, raised deflector—do not operate without the deflector, discharge cover, or grass collection system in place. 3. Cutting/dismemberment hazard of hand or foot, mower blade—stay away from moving parts; keep all guards and shields in place.  decal127-0326  # 127-0326  
 3. Remove the key and read the  Operator's Manual  before performing maintenance.  1. Read the  Operator's Manual .  2. Height of cut  
decal126-4363  # 126-4363  
 1. Cutting/dismemberment hazard, fan and entanglement hazard, belt. Shut off the engine and remove the key before adjusting, servicing or cleaning the machine.  126-9939  decal126-9939  
 2. Fill to bottom of filler neck; warning–do not overfill the tank  1. Read the Operator’s Manual  139-6699  1. Height of cut decal139-6699   144-6569  1. Light 2. Fast 3. Slow  
 decal144-2669  # 144-2669  
 4. Grease the caster wheel. 5. Read the  Operator’s Manual  before performing maintenance.  1. Check the engine-oil level. 2. Check the hydraulic-fluid level.  3. Check the tire pressure.  144-2687  decal144-2687 1. Traction belt routing  
 decal126-8383  
 Note:  This machine complies with the industry standard stability test in the static lateral and longitudinal tests with the maximum recommended slope indicated on the decal. Review the instructions for operating the machine on slopes in the  Operator’s Manual  as well as the conditions in which you would operate the machine to determine whether you can operate the machine in the conditions on that day and at that site. Changes in the terrain can result in a change in slope operation for the machine.  1. Warning—read the  Operator’s Manual ; do not operate this machine unless you are trained; wear hearing protection. 2. Cutting/dismemberment hazard of the hand, mower blade; entanglement hazard of the hand, belt—stay away from moving parts; keep all guards and shields in place. 3. Ramp hazard—do not use dual ramps when loading onto a trailer; use 1 ramp wide enough for the machine; use a ramp with a slope less than   $15^{\circ}$  ; back up the ramp when loading the machine and drive forward off the ramp when unloading.  4. Runover/backover hazard—do not carry passengers; look behind you when mowing in reverse. 5. Thrown object hazard—keep bystanders away. 6. Tipping hazard—do not use the machine near drop-offs or on slopes greater than   $15^{\circ}$  ; only operate across slopes less than   $15^{\circ}$  .  132-0871  
 Note:  This machine complies with the industry standard stability test in the static lateral and longitudinal tests with the maximum recommended slope indicated on the decal. Review the instructions for operating the machine on slopes in the  Operator’s Manual  as well as the conditions in which you would operate the machine to determine whether you can operate the machine in the conditions on that day and at that site. Changes in the terrain can result in a change in slope operation for the machine.  1. Warning—read the  Operator’s Manual ; all operators should be trained before operating the machine; wear hearing protection. 2. Cutting/dismemberment hazard of hand—stay away from moving parts; keep all guards and shields in place. 3. Thrown object hazard—keep bystanders away.  4. Tipping hazard—do not use dual ramps when loading onto a trailer; use 1 ramp wide enough for the machine; use a ramp with a slope less than   $15^{\circ}$  ; back up the ramp (in reverse) and drive forward off the ramp. 5. Runover hazard—do not carry passengers; look behind you when moving in reverse. 6. Tipping hazard—do not use the machine near drop-offs or on slopes greater than   $15^{\circ}$  ; only operate across slopes less than   $15^{\circ}$  .  Decal 132-5067 is for machines with MyRide only.   
132-5067  
# Product Overview   
Figure 4  1. Height-of-cut positions 7. Fuel cap 2. Controls 8. Parking-brake lever 3. Motion-control levers 9. Mower deck 4. Electric deck lift (certain 10. Caster wheel models only) 5. Roll bar 11. Anti-scalp roller 6. Shock assembly (machines with MyRide only)  # Controls  Become familiar with all the controls before you start the engine and operate the machine.  # Control Panel   
Figure 5  1. Key switch 4. Light switch (for models with lights only)—optional kit for other models 2. Blade-control switch 5. Hour meter (power takeoff) 3. Throttle control 6. Choke control (for carbureted models only)  # Key Switch  The key switch, used to start and shut off the engine, has 3 positions: O FF , R UN , and S TART . Refer to Starting the Engine (page 26) .  # Light Switch  For Models with Lights Only  Use the light switch to turn the lights to the O N  position or O FF  position ( Figure 5 ).  # Choke Control  Use the choke control to start a cold engine.  
# Throttle Control  The throttle controls the engine speed, and it has a continuous-variable setting from the S LOW  to F AST position ( Figure 5 ).  # Blade-Control Switch (Power Takeoff)  The blade-control switch, represented by a power-takeoff (PTO) symbol, engages and disengages power to the mower blades ( Figure 5 ).  # 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 ).   1. Safety-interlock symbols 3. Battery light 2. Hour meter  # Safety-Interlock Indicators  There are symbols on the hour meter that indicate with a black triangle that the interlock component is positioned correctly ( Figure 6 ).  # Electronic-Control Unit Malfunction-Indicator Light  For Models with an EFI Engine Only  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 light (MIL) illuminates.  The MIL is the red light located in the right console panel.  Once the MIL illuminates, make initial troubleshooting checks; refer to the MIL section under  Troubleshooting (page 73) .  If these checks do not correct the problem, further diagnosis and servicing by an Authorized Service Dealer is necessary.  # Motion-Control Levers  Use the motion-control levers to drive the machine forward, reverse, and turn either direction ( Figure 4 ).  # Neutral-Lock Position  Move the motion-control levers outward from the center to the N EUTRAL - LOCK  position when exiting the machine ( Figure 26 ). Always position the motion-control levers into the N EUTRAL - LOCK  position when you stop the machine or leave it unattended.  # Parking-Brake Lever  Whenever you shut off the engine, engage the parking brake to prevent accidental movement of the machine.  # Fuel-Shutoff Valve  Close the fuel-shutoff valve when transporting or storing the machine; refer to  Using the Fuel-Shutoff Valve (page 32) .  # Battery-Indicator Light  If you turn the key switch to the O N  position for a few seconds, the battery voltage displays in the area where the hours are normally displayed.  The battery light turns on when the key switch is turned on and when the charge is below the correct operating level ( Figure 6 ).  
# Specifications  Width 
 Length 
 Height 
 Weight 
 # Attachments/Accessories  A selection of approved attachments and accessories is available for use with the machine to enhance and expand its capabilities. Contact your Authorized Service Dealer or authorized distributor for a list of all approved attachments and accessories.  To ensure optimum performance and continued safety certification of the machine, use only genuine replacement parts and accessories. Replacement parts and accessories made by other manufacturers could be dangerous, and such use could void the product warranty.  
# Operation  Note:  Determine the left and right sides of the machine from the normal operating position.  # Before Operation  # Before Operation Safety  # General Safety  • Do not allow children or untrained people to operate or service the machine. Local regulations may restrict the age of the operator. The owner is responsible for training all operators and mechanics. • Inspect the area where you will use the machine, and remove all objects that could interfere with the operation of the machine or that the machine could throw. • Become familiar with the safe operation of the equipment, operator controls, and safety signs. • Check that operator-presence controls, safety switches, and guards are attached and working properly. Do not operate the machine unless they are functioning properly. • Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operator’s position. Allow the machine to cool before servicing, adjusting, fueling, cleaning, or storing it. • Before mowing, inspect the machine to ensure that the cutting assemblies are working properly. • Evaluate the terrain to determine the appropriate equipment and any attachments or accessories required to operate the machine properly and safely. • Wear appropriate clothing, including eye protection; long pants; substantial, slip-resistant footwear; and hearing protection. Tie back long hair and do not wear loose clothing or loose jewelry. • Do not carry passengers on the machine. • Keep bystanders and pets away from the machine during operation. Shut off the machine and attachment(s) if anyone enters the area. • Do not operate the machine unless all guards and safety devices, such as the deflectors and the entire grass catcher, are in place and functioning properly. Replace worn or deteriorated parts when necessary.  # Fuel Safety  • Fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property. – To prevent a static charge from igniting the fuel, place the container and/or machine directly on the ground before filling, not in a vehicle or on an object. – Fill the fuel tank outdoors on level ground, in an open area, and when the engine is cold. Wipe up any fuel that spills. – Do not handle fuel when smoking or around an open flame or sparks. – Do not remove the fuel cap or add fuel to the tank while the engine is running or hot. – If you spill fuel, do not attempt to start the engine. Avoid creating a source of ignition until the fuel vapors have dissipated. – Store fuel in an approved container and keep it out of the reach of children.  • Fuel is harmful or fatal if swallowed. Long-term exposure to vapors can cause serious injury and illness.  – Avoid prolonged breathing of vapors. – Keep your hands and face away from the nozzle and the fuel-tank opening. – Keep fuel away from your eyes and skin. • Do not store the machine or fuel container where there is an open flame, spark, or pilot light, such as on a water heater or on other appliances. • Do not fill containers inside a vehicle or on a truck or trailer bed with a plastic liner. Always place containers on the ground and away from your vehicle before filling. • Remove the equipment from the truck or trailer and refuel it while it is on the ground. If this is not possible, then refuel from a portable container rather than from a fuel-dispenser nozzle. • Do not operate the machine without the entire exhaust system in place and in proper working condition. • Keep the fuel-dispenser nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete. Do not use a nozzle lock-open device. • If you spill fuel on your clothing, change your clothing immediately. • Do not overfill the fuel tank. Replace the fuel cap and tighten it securely. • Clean grass and debris from the cutting unit, muffler, drives, grass catcher, and engine compartment to help prevent fires. Clean up oil or fuel spills.  
# Adding Fuel  # Recommended Fuel  • For best results, use only clean, fresh (less than 30 days old), unleaded gasoline with an octane rating of 87 or higher   $((\mathsf{R}\!+\!\mathsf{M})/2$   rating method).  • Ethanol : Gasoline with up to   $10\%$   ethanol (gasohol) or   $15\%$   MTBE (methyl tertiary butyl ether) by volume is acceptable. Ethanol and MTBE are not the same. Gasoline with   $15\%$  ethanol (E15) by volume is not approved for use. Never use gasoline that contains more than  $10\%$   ethanol by volume , such as E15 (contains  $15\%$   ethanol), E20 (contains  $z0\%$   ethanol), or E85 (contains up to  $85\%$   ethanol). Using unapproved gasoline may cause performance problems and/or engine damage which may not be covered under warranty.  • Do not  use gasoline containing methanol.  • Do not  store fuel either in the fuel tank or fuel containers over the winter unless you use a fuel stabilizer.  • Do not  add oil to gasoline.  # Using Stabilizer/Conditioner  Use a fuel stabilizer/conditioner in the machine to provide the following benefits:  • Keeps fuel fresh longer when used as directed by the fuel-stabilizer manufacturer  • Cleans the engine while it runs  • Eliminates gum-like varnish buildup in the fuel system, which causes hard starting  Important:  Do not use fuel additives containing methanol or ethanol.  Add the correct amount of fuel stabilizer/conditioner to the fuel.  Note:  A fuel stabilizer/conditioner is most effective when mixed with fresh fuel. To minimize the chance of varnish deposits in the fuel system, use fuel stabilizer at all times. Note:  Do not fill the fuel tank completely full. The empty space in the tank allows the fuel to expand.  
# Performing Daily Maintenance  Before starting the machine each day, perform the Each Use/Daily procedures listed in  Maintenance (page 36) .  # Filling the Fuel Tank  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 7 ).  

Figure 7  
# Breaking in a New Machine  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.  # 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 the roll bar only when absolutely necessary. • Do not wear the seat belt when the roll bar is in the down position. • Drive slowly and carefully. • Raise the roll bar as soon as clearance permits. • Check carefully for overhead clearances (i.e., branches, doorways, electrical wires) before driving under any objects and do not contact them.  # Lowering the Roll Bar  Important:  Lower the roll bar only when absolutely necessary.  1. Remove the hairpin cotters and remove the 2 pins ( Figure 9 ). 2. Lower the roll bar to the down position ( Figure 8 ). Note:  There are 2 down positions; refer to Figure 8 . 
 
Figure 8  
3. Install the 2 pins and secure them with the hairpin cotters ( Figure 9 ).  
# Raising the Roll Bar  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 9 ). 2. Raise the roll bar to the upright position, install the 2 pins, and secure them with the hairpin cotters ( Figure 9 ).   1. Roll bar 3. Pin 2. Raised position 4. Hairpin cotter  
# Using the Safety-Interlock System  # WARNING  If the safety-interlock switches are  disconnected or damaged, the machine could operate unexpectedly, causing personal injury.  • Do not tamper with the interlock switches. • Check the operation of the interlock switches daily and replace any damaged switches before operating the machine.  # Understanding the Safety-Interlock System  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 N EUTRAL - LOCK position.  The safety-interlock system also is designed to shut off the engine when the motion-control levers are moved from the N EUTRAL - 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 10  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 O N 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 O FF position. Move either motion-control lever out of the N EUTRAL - 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 O FF position, and move the motion-control levers to the N EUTRAL - 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 O FF position, and move the motion-control levers to the N EUTRAL - 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 O FF position, and move the motion-control levers to the N EUTRAL - LOCK  position. Try starting the engine; the engine should not start.  1. Indicators display when the interlock components are in the correct position  # Testing the Safety-Interlock System  Service Interval:  Before each use or daily  
# Positioning the Seat  The seat can move forward and backward ( Figure 11 ). Position the seat where you have the best control of the machine and are most comfortable.   
Seat for machines with MyRide shown.  # Changing the Seat Suspension Machines without Suspension System Only  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 12 ).   
Figure 12  # Adjusting the Rear-Shock Assemblies  # Machines with Suspension System Only  The suspension system adjusts to provide a smooth and comfortable ride. You can adjust the rear 2-shock assemblies to quickly and easily change the suspension system. Position the suspension system where you are most comfortable.  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 13 ).   
1. Firmest position 3. Detents in the slots 2. Softest position  Note:  Ensure that the left and right rear-shock assemblies are always adjusted to the same positions.  Adjust the rear-shock assemblies ( Figure 14 ).  
 1. Seat-suspension knob  # During Operation  # During Operation Safety  # General Safety  • The owner/operator can prevent and is responsible for accidents that may cause personal injury or property damage. • Use your full attention while operating the machine. Do not engage in any activity that causes distractions; otherwise, injury or property damage may occur. • Do not operate the machine while ill, tired, or under the influence of alcohol or drugs. • Contacting the blade can result in serious personal injury. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. When you turn the key to the OFF position, the engine should shut off and the blade should stop. If not, stop using your machine immediately and contact an Authorized Service Dealer. • Operate the machine only in good visibility and appropriate weather conditions. Do not operate the machine when there is the risk of lightning. • Keep your hands and feet away from the cutting units. Keep clear of the discharge opening. • Do not mow with the discharge deflector raised, removed, or altered unless there is a grass-collection system or mulch kit in place and working properly. • Do not mow in reverse unless it is absolutely necessary. Always look down and behind you before moving the machine in reverse. • Use extreme care when approaching blind corners, shrubs, trees, or other objects that may block your view. • Stop the blades whenever you are not mowing. • If the machine strikes an object or starts to vibrate, immediately shut off the engine, remove the key (if equipped), and wait for all moving parts to stop before examining the machine for damage. Make all necessary repairs before resuming operation. • Slow down and use caution when making turns and crossing roads and sidewalks with the machine. Always yield the right-of-way. • Before you leave the operating position, do the following: – Park the machine on a level surface. – Disengage the power takeoff and lower the attachments. – Engage the parking brake. – Shut off the engine and remove the key.  
– Wait for all moving parts to stop.  • Operate the engine only in well-ventilated areas. Exhaust gases contain carbon monoxide, which is lethal if inhaled.  • Never leave a running machine unattended.  • Attach towed equipment to the machine only at the hitch point. • Do not operate the machine unless all guards and safety devices, such as the deflectors and the entire grass catcher, are in place and functioning properly. Replace worn or deteriorated parts when necessary. • Use only accessories and attachments approved. • This machine produces sound levels in excess of 85 dBA at the operator’s ear and can cause hearing loss through extended periods of exposure.   
Figure 15  1. Wear hearing protection.  • Clean grass and debris from the cutting unit, drives, muffler, and engine to help prevent fires. • Start the engine with your feet well away from the blades. • Be aware of the mower discharge path and direct the discharge away from others. Avoid discharging material against a wall or obstruction because the material may ricochet back toward you. • Stop the blades, slow down the machine, and use caution when crossing surfaces other than grass or when transporting the machine to and from the operating area. • Do not change the engine governor speed or overspeed the engine. • Children are often attracted to the machine and the mowing activity. Never assume that children will remain where you last saw them. • Keep children out of the operating area and under the watchful care of a responsible adult other than the operator. • Be alert and shut off the machine if children enter the operating area.  • Before backing up or turning the machine, look down and all around for small children. • Do not carry children on the machine, even when the blades are not moving. Children could fall off and be seriously injured or prevent you from safely operating the machine. Children who have been given rides in the past could appear in the operating area without warning and be run over or backed over by the machine.  # Rollover Protection System (ROPS) Safety  • The ROPS is an integral safety device. Do not remove any of the ROPS components from the machine. • Ensure that the seat belt is attached and that you can release it quickly in an emergency. • Keep the roll bar in the fully raised and locked position and always wear your seat belt whenever the roll bar is up. • Check carefully for overhead objects before you drive under them, and do not contact them. • Replace damaged ROPS components. Do not repair or alter them. • There is no rollover protection when the roll bar is down. • Wheels dropping over edges, over steep banks, or into water can cause a rollover, which may result in serious injury or death. • Do not wear the seat belt when the roll bar is down. • Lower the roll bar only when absolutely necessary; raise it as soon as clearance permits. • In the event of a rollover, take the machine to an Authorized Service Dealer to inspect the ROPS. • Use only approved accessories and attachments for the ROPS.  # Slope Safety  • Slopes are a major factor related to loss of control and rollover accidents, which can result in severe injury or death. The operator is responsible for safe slope operation. Operating the machine on any slope requires extra caution. Before using the machine on a slope, do the following: – Review and understand the slope instructions in the manual and on the machine. – Use an angle indicator to determine the approximate slope angle of the area. – Never operate on slopes greater than   $15^{\circ}$  .  
– Evaluate the site conditions of the day to determine if the slope is safe for machine operation. Use common sense and good judgment when performing this evaluation. Changes in the terrain, such as moisture, can quickly affect the operation of the machine on a slope.  • Identify hazards at the base of the slope. Do not operate the machine near drop-offs, ditches, embankments, water, or other hazards. The machine could suddenly roll over if a wheel goes over the edge or the edge collapses. Keep a safe distance (twice the width of the machine) between the machine and any hazard. Use a walk-behind machine or a hand trimmer to mow the grass in these areas.  • Avoid starting, stopping, or turning the machine on slopes. Avoid making sudden changes in speed or direction; turn slowly and gradually.  • Do not operate a machine under any conditions where traction, steering, or stability is in question. Be aware that operating the machine on wet grass, across slopes, or downhill may cause the machine to lose traction. Loss of traction to the drive wheels may result in sliding and a loss of braking and steering. The machine can slide even if the drive wheels are stopped.   
Figure 16  1. Safe Zone—use the machine here on slopes less than   $15^{\circ}$   or flat areas. 2. Danger Zone—use a walk-behind mower and/or a hand trimmer on slopes greater than   $15^{\circ}$   and near drop-offs or water.  4. W   $=$  Width of the machine 5. Keep a safe distance (twice the width of the machine) between the machine and any hazard.  3. Water  • Remove or mark obstacles such as ditches, holes, ruts, bumps, rocks, or other hidden hazards. Tall grass can hide obstacles. Uneven terrain could overturn the machine.  • Use extra care while operating with accessories or attachments, such as grass-collection systems. These can change the stability of the machine and cause a loss of control. Follow directions for counterweights.  • If possible, keep the deck lowered to the ground while operating on slopes. Raising the deck while operating on slopes can cause the machine to become unstable.  
# Entering the Operator’s Position  Use the mower deck as a step to get into the operator’s position ( Figure 17 ).   
Figure 17  # Disengaging the Parking Brake   
Figure 19  1. Step here.  # Operating the Parking Brake  Always engage the parking brake when you stop the machine or leave it unattended.  # Engaging the Parking Brake  Park the machine on a level surface.   
Figure 18  
# Operating the Mower Blade-Control Switch (PTO)  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  # Operating the Throttle  You can move the throttle control between F AST  and S LOW  positions ( Figure 22 ).  
 
Figure 22  Always use the F AST  position when engaging the PTO.  
# Operating the Choke  Use the choke to start a cold engine.  1. Pull up the choke knob to engage the choke before using the key switch ( Figure 23 ). 2. Push down the choke knob to disengage the choke after the engine has started ( Figure 23 ).   
# Starting the Engine  Note:  A warm or hot engine may not require choking.  Important:  Do not engage the starter for more than 5 seconds at a time. Engaging the starter motor for more than 5 seconds can damage the starter motor. If the engine fails to start, wait 10 seconds before operating the engine starter again.   
Figure 24  # Shutting Off the Engine  # CAUTION  Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended.  Always remove the key and engage the parking brake when leaving the machine unattended.   
Figure 25  
# Using the Motion-Control Levers   1. Motion-control 4. Backward lever—N EUTRAL - LOCK position 2. Center, unlocked position 5. Front of machine 3. Forward  # Driving the Machine  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 F AST  position for best performance. Always operate in the full throttle position when mowing.  # WARNING  The machine can spin very rapidly. You may lose control of the machine and cause personal injury or damage to the machine.  • Use caution when making turns. • Slow the machine down before making sharp turns.  # Driving Forward  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 N EUTRAL  position.  1. Disengage the parking brake; refer to Disengaging the Parking Brake (page 24) . 2. Move the levers to the center, unlocked position. 3. To go forward, slowly push the motion-control levers forward ( Figure 27 ).  
 # Driving Backward  1. Move the levers to the center, unlocked position. 2. To go backward, slowly pull the motion-control levers rearward ( Figure 28 ).  
 
Figure 28  # Using the Side Discharge  The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf.  # DANGER  Without a grass deflector, discharge cover, or a complete grass-catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris. Contact with rotating mower blade(s) and thrown debris will cause injury or death.  • Never remove the grass deflector from the mower deck because the grass deflector routes material down toward the turf. If the grass deflector is ever damaged, replace it immediately. • Never put your hands or feet under the mower deck. • Never try to clear the discharge area or mower blades unless you move the blade-control switch (PTO) to the O FF position, rotate the key switch to the O FF position, and remove the key from the key switch. • Make sure that the grass deflector is in the down position.  # Adjusting the Height of Cut For Machines with a Deck-Lift Pedal  # Using the Transport Lock  1. Push the deck-lift pedal fully forward to lock the mower deck in the T RANSPORT  position ( Figure 29 ). 2. Push the deck-lift pedal forward and push the transport lock forward to the U NLOCK  position, then slowly lower the mower deck. ( Figure 29 ).   
Figure 29  1. L OCK  position—the mower deck locks into the transport position.  3. Push on the deck-lift pedal using your foot to raise the mower deck.  # Adjusting the Height-of-Cut Pin  You can adjust the height of cut from 38 to   $140\;\mathsf{m m}$  (1-1/2 to 5-1/2 inches) in   $6\:\mathsf{m m}$   (1/4 inch) increments by relocating the clevis pin into different hole locations.  1. Push the deck-lift pedal fully forward to lock the mower deck in the T RANSPORT  position (also the  $140\;\mathsf{m m}/5{\cdot}1/2$   inches cutting height position) as shown in  Figure 30 . 2. To adjust, remove the pin from the height-of-cut bracket ( Figure 30 ). 3. Select a hole in the height-of-cut bracket corresponding to the height of cut desired, and insert the pin ( Figure 30 ). 4. Push the deck-lift pedal forward, push the transport lock forward, and slowly lower the mower deck.   # Figure 30  1. Deck-lift pedal 3. Height-of-cut pin 2. Height-of-cut bracket 4. Transport-lock lever  2. U NLOCK  position—the mower deck does not lock into the transport position.  
# Adjusting the Height of Cut For Machines with an Electric Deck Lift  1. Push up on the deck-lift switch ( Figure 31 ).   
Figure 31  1. Push up to raise the deck. 2. Push down to lower the deck.  2. Select a hole in the height-of-cut bracket corresponding to the height of cut desired, and insert the pin ( Figure 32 ).   
Figure 32  1. Height-of-cut pin 2. Height-of-cut bracket  
# Adjusting the Anti-Scalp Rollers  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 33 ,  Figure 34 , and  Figure 35 .   
Figure 33  1. Anti-scalp roller 4. Flange nut 2. Spacer 5. Bolt 3. Bushing   
Figure 34  1. Anti-scalp roller 3. Flange nut 2. Bushing 4. Bolt  3. Push down on the deck-lift switch to set the height of cut ( Figure 31 ).  
 
Figure 35  1. Anti-scalp roller 4. Flange nut 2. Spacer 5. Bolt 3. Bushing  # Operating Tips  # Using the Fast Throttle Setting  For best mowing and maximum air circulation, operate the engine at the F AST  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.  # Cutting a Lawn for the First Time  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.  # Cutting a Third of the Grass Blade  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.  # Alternating the Mowing Direction  Alternate the mowing direction to keep the grass standing straight. This also helps disperse clippings, which enhances decomposition and fertilization.  # Mowing at Correct Intervals  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.  # Using a Slower Cutting Speed  To improve cut quality, use a slower ground speed in certain conditions.  # Avoiding Cutting Too Low  When mowing uneven turf, raise the cutting height to avoid scalping the turf.  # Stopping the Machine  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.  # Keeping the Underside of the Mower Deck Clean  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.  # Maintaining the Blade(s)  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 replacement blade.  # After Operation  # After Operation Safety  # General Safety  • Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operator’s position. Allow the machine to cool before servicing, adjusting, fueling, cleaning, or storing it. • Clean grass and debris from the cutting unit, muffler, drives, grass catcher, and engine compartment to help prevent fires. Clean up oil or fuel spills. • Shut off the fuel and remove the key before storing or transporting the machine.  # Using the Fuel-Shutoff Valve  Close the fuel-shutoff valve for transport, maintenance, and storage ( Figure 36 ).   
Ensure that the fuel-shutoff valve is open when starting the engine.  2. O FF  position  # Using the Drive-Wheel Release Valves  WARNING  Hands may become entangled in the rotating drive components below the engine deck, which could result in serious injury.  Shut off the engine, remove the key, and allow all moving parts to stop before accessing the drive-wheel release valves.  
# WARNING  # The engine and hydraulic-drive units can become very hot. Touching a hot engine or hydraulic-drive units can cause severe burns.  Allow the engine and hydraulic-drive units to cool completely before accessing the drive-wheel release valves.  # For Machines with ZT 4400 Hydros  The drive-wheel release valves are located on the left and right sides underneath the engine 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. To push the machine, move both bypass levers forward and lock them into place ( Figure 37 ). 4. Disengage the parking brake before pushing the machine. 5. To run the machine, move the bypass levers rearward and lock them into place ( Figure 37 ).   
Figure 37  # For Machines with ZT 5400 Hydros  The drive-wheel release valves are located on the left and right sides underneath the engine 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. Using a flat-head screwdriver, rotate both cams to the B YPASS  position ( Figure 38 ). 4. Disengage the parking brake before pushing the machine. 5. To run the machine, rotate both cams to the R UN position ( Figure 38 ).   
Figure 38  1. Rotate the cam to the 2. Rotate the cam to the R UN B YPASS  position. position.  
# Transporting the Machine  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.  # WARNING  Driving on the street or roadway without turn signals, lights, reflective markings, or a slow-moving-vehicle emblem is dangerous and can lead to accidents, causing personal injury.  Do not drive the machine on a public street or roadway.  # 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 39 ).  
 
Figure 39  1. Full-width ramp in stowed 4. Ramp is at least 4 times position as long as the height of the trailer or truck bed to the ground 2. Side view of full-width 5.  $\mathsf{H}\!\!=$  height of the trailer or ramp in loading position truck bed to the ground 3. Not greater than 6. Trailer 15 degrees  • 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.  
# Loading the Machine  # WARNING  Loading a machine onto a trailer or truck increases the possibility of tip-over and could cause serious injury or death.  • Use extreme caution when operating a machine on a ramp. • 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 tip-over situation.  
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 39 ).  4. Back the machine up the ramp ( Figure 40 ).   1. Back the machine up the 2. Drive the machine forward ramp. 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 41 ). Refer to local regulations for tie-down requirements.   
Figure 41  1. Tie-down loops  
# Unloading the Machine  1. Lower the ramp, ensuring that the angle between the ramp and the ground does not exceed 15 degrees ( Figure 39 ).  2. Drive the machine forward down the ramp ( Figure 40 ).  # Maintenance  # Maintenance Safety  • If you leave the key in the switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the switch before you perform any maintenance.  • Before you leave the operator’s position, do the following:  • Do not allow untrained personnel to service the machine.  • Keep your hands and feet away from moving parts or hot surfaces. If possible, do not make adjustments with the engine running.  • Carefully release pressure from components with stored energy.  • Check the parking brake operation frequently. Adjust and service it as required. • Never tamper with safety devices. Check their proper operation regularly. • Clean grass and debris from the cutting unit, muffler, drives, grass catcher, and engine compartment to prevent fires. • Clean up oil or fuel spills and remove fuel-soaked debris. • Do not rely on hydraulic or mechanical jacks to support the machine; support the machine with jack stands whenever you raise the machine. • Keep all parts in good working condition and all hardware tightened, especially the blade-attachment hardware. Replace all worn or damaged decals. • Disconnect the battery before repairing the machine. Disconnect the negative terminal first and the positive last. Connect the positive terminal first and the negative last. • To ensure optimum performance, use only genuine replacement parts and accessories. Replacement parts and accessories made by other manufacturers could be dangerous, and such use could void the product warranty.  # Recommended Maintenance Schedule(s)   
Important:  Refer to your engine owner's manual for additional maintenance procedures. 
 # CAUTION  If you leave the key in the switch, someone could accidently start the engine and seriously injure you or other bystanders.  Shut off the engine and remove the key from the switch before you perform any maintenance.  # Lubrication  # Greasing the Machine  Grease the machine more often in dirty or dusty conditions.  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.  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:  Scrape any paint off the front of the fitting(s).  
# Lubricating the Mower Deck-Lift Pivots  Service Interval:  Every 100 hours  Use light oil or spray lubricant to lubricate the deck-lift pivots.   
Figure 42  # Greasing the Caster-Wheel Hubs  Service Interval:  Yearly  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 43  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  $3\:\mathsf{m m}$   (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  $\mathsf{3}\,\mathsf{N{\cdot}m}$   (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.  1. Seal guard 2. Spacer nut with wrench flats  
# Engine Maintenance  # Engine Safety  • Do not change the engine governor speed or overspeed the engine.  • Keep your hands, feet, face, clothing, and other body parts away from the muffler and other hot  # Identifying the Engine  Use the following graphic to identify the engine you have and proceed to the section listed below for service ( Figure 44 ).   
Figure 44  1. Kawasaki engine 2. Kohler engine  # Servicing a particular Engine  This section is only for machines with Kawasaki engines. If your engine looks like the one shown in Figure 45 , you have a Kawasaki engine.  Important:  Refer to your engine owner’s manual for additional maintenance procedures.   # Servicing the Air Cleaner  Service Interval:  Every 250 hours—For Kawasaki engines—replace the primary air filter (more often in dirty or dusty conditions). Every 250 hours—For Kawasaki engines—check the safety air filter (more often in dirty or dusty conditions). Every 500 hours—For Kawasaki engines—replace the safety air filter (more often in dirty or dusty conditions).  Note:  Service the air cleaner more frequently if operating conditions are extremely dusty or sandy.  # Removing the Filters  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 46 ).   
Figure 46  1. Air-cleaner body 4. Air-cleaner cover 2. Primary filter 5. Safety filter 3. Latch  4. Clean the inside of the air-cleaner cover with compressed air. 5. Gently slide the primary filter out of the air-cleaner body ( Figure 46 ). Note:  Avoid knocking the filter into the side of the body. 6. Remove the safety filter only to replace it.  # Inspecting the Filters  1. Inspect the safety filter. If it is dirty, replace both the safety and primary filters. Important:  Do not attempt to clean the safety filter. If the safety filter is dirty, then the primary filter is damaged. 2. Inspect the primary filter for damage by looking into the filter while shining a bright light on the outside of the filter. If the primary filter is dirty, bent, or damaged, replace it. Note:  Holes in the filter appear as bright spots. Do not clean the primary filter.  # Installing the Filters  Important:  To prevent engine damage, always operate the engine with both air filters and the cover installed.  1. If you are installing new filters, check each filter for shipping damage. Note:  Do not use a damaged filter. 2. If you are replacing the inner filter, carefully slide it into the filter body ( Figure 46 ).  
3. Carefully slide the primary filter over the safety filter ( Figure 46 ).  Note:  Ensure that the primary filter is fully seated by pushing on the outer rim while installing it. Important:  Do not press on the soft, inside area of the filter.  4. Install the air-cleaner cover and secure the latches ( Figure 46 ).  # Servicing the Engine Oil  Service Interval:  Before each use or daily—For Kawasaki engines—check the engine-oil level.  Every 100 hours—For Kawasaki engines—change the engine oil (more often in dirty or dusty conditions). Every 200 hours—For Kawasaki engines—change the engine-oil filter (more often in dirty or dusty conditions).  viscosity to accommodate atmospheric conditions. Using 20W-50 engine oil in higher ambient temperatures can reduce oil consumption.  # Checking the Engine-Oil Level  Note:  Check the oil when the engine is cold.  Important:  If you overfill or underfill the engine crankcase with oil and run the engine, you may damage the engine.  1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Note:  Ensure that the engine is cool so that the oil has had time to drain into the sump. 3. To keep dirt, grass clippings, etc., out of the engine, clean the area around the oil-fill cap and dipstick before removing it ( Figure 48 ).  
# Engine-Oil Specifications  Oil Type:  Detergent oil (API service SF, SG, SH, SJ, or SL)  # Crankcase Capacity:  • Kawasaki FX751 and FX801 engines— 2.3 L (78 fl oz) with a filter change; 2.1 L (71 fl oz) without a filter change  • Kawasaki FX921 engines— 1.9 L (64 fl oz) with a filter change; 1.7 L (57 fl oz) without a filter change  Viscosity:  See the table below.   Note:  Although 10W-40 engine oil is recommended for most conditions, you may need to change oil  # Changing the Engine Oil  Note:  Dispose of the used oil at a recycling center.  1. Start the engine and let it run for 5 minutes. Note:  This warms the oil so that it drains better. 2. Park the machine so that the drain side is slightly lower than the opposite side to ensure that the oil drains completely. 3. 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. Drain the oil from the engine ( Figure 49 ).   6. Slowly pour approximately  $80\%$   of the specified oil into the filler tube and slowly add the additional oil to bring it to the Full mark ( Figure 50 ).   
Figure 50  7. Start the engine and drive to a flat area.  8. Check the oil level again.  # Changing the Engine-Oil Filter  1. Drain the oil from the engine; refer to  Changing the Engine Oil (page 42) .  2. Change the engine-oil filter ( Figure 51 ).   Note:  Ensure that the oil-filter gasket touches the engine, and then turn the oil filter an extra  $3/4$   turn. 3. Fill the crankcase with the proper type of new oil; refer to  Engine-Oil Specifications (page 41) .  
# Servicing the Spark Plug(s)  # Service Interval:  Every 100 hours  Ensure that the air gap between the center and side electrodes is correct before installing the spark plug. Use a spark plug wrench for removing and installing the spark plug and a gapping tool or feeler gauge to check and adjust the air gap. Install a new spark plug if necessary.  # Type of Spark Plug:  • Kawasaki FX751 and FX801 engines— NGK ® BPR4ES or equivalent • Kawasaki FX921 engines— NGK ®   BPR5ES or equivalent  Air Gap:    $0.75\;\mathsf{m m}$   (0.030 inch)  # Removing the Spark Plug(s)  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 the area around the base of the plug to keep dirt and debris out of the engine. 4. Locate and remove the spark plug(s) as shown in  Figure 52 .   
Figure 52  If you see light brown or gray on the insulator, the engine is operating properly. A black coating on the insulator usually means the air cleaner is dirty.  Set the gap to   $0.75\:\mathsf{m m}$   (0.03 inch).   # Installing the Spark Plug(s)   # Checking the Spark Plug(s)  Important:  Do not clean the spark plug(s). Always replace the spark plug(s) when it has a black coating, worn electrodes, an oily film, or cracks.  
# Servicing another particular Engine  This section is only for machines with Kohler engines. If your engine looks like the one shown in  Figure 55 , you have a Kohler engine.  
 
Figure 55  Important:  Refer to your engine owner’s manual for additional maintenance procedures.  # Servicing the Air Cleaner  Service Interval:  Every 150 hours—For Kohler engines—inspect the primary filter (more often in dirty or dusty conditions). Every 300 hours/Yearly (whichever comes first)—For Kohler engines—replace the primary air filter (more often in dirty or dusty conditions). Every 300 hours—For Kohler engines—check the inner air filter (more often in dirty or dusty conditions). Every 600 hours—For Kohler engines—replace  6. Release the latches on the air cleaner and pull the air-cleaner cover off the air-cleaner body ( Figure 57 ). 7. Clean the inside of the air-cleaner cover with compressed air. 8. Gently slide the primary filter out of the air-cleaner body ( Figure 57 ). Note:  Avoid knocking the filter into the side of the body.
 
Figure 57  1. Inner filter 4. Latch 2. Primary filter 5. Air-cleaner body 3. Air-cleaner cover   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. the inner air filter.  # Removing the Filters  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-inlet cover off the air-cleaner body ( Figure 56 ). 4. Clean the air-inlet screen and cover. 5. Install the air-inlet cover and secure it with the latches ( Figure 56 ).  
 1. Air-inlet cover 3. Air-cleaner body 2. Air-inlet screen 4. Latch  10. Inspect the primary filter for damage by looking into the filter, while shining a bright light on the outside of the filter.  Note:  Holes in the filter will appear as bright spots. If the filter is damaged, discard it.  # Inspecting the Filters  1. Inspect the inner filter. If it is dirty, replace both the inner and primary filters. Important:  Do not attempt to clean the inner filter. If the inner filter is dirty, then the primary filter is damaged. 2. Inspect the primary filter for damage by looking into the filter while shining a bright light on the outside of the filter. If the primary filter is dirty, bent, or damaged, replace it. Note:  Holes in the filter appear as bright spots. Do not clean the primary filter.  # Installing the Filters  Important:  To prevent engine damage, always operate the engine with both air filters and the cover installed.  1. If you are installing new filters, check each filter for shipping damage. Note:  Do not use a damaged filter. 2. If you are replacing the safety filter, carefully slide it into the filter body ( Figure 57 ). 3. Carefully slide the primary filter over the safety filter ( Figure 57 ).  Note:  Ensure that the primary filter is fully seated by pushing on the outer rim while installing it.  Important:  Do not press on the soft, inside area of the filter.  4. Install the air-cleaner cover and secure the latches ( Figure 57 ).  # Servicing the Engine Oil  Service Interval:  Before each use or daily—For Kohler Engines—check the  engine-oil level. Every 100 hours—For Kohler Engines—change the engine oil (more often in dirty or dusty conditions). Every 200 hours—For Kohler Engines—change the engine-oil filter (more often in dirty or dusty conditions).  # Engine-Oil Specifications  Oil Type: : Detergent oil (API service SJ or higher)  Oil Capacity:  1.9 L (64 fl oz) with a filter change; 1.6 L (54 fl oz) without a filter change  Viscosity:  See the table below.   # Checking the Engine-Oil Level  Note:  Check the oil when the engine is cold.  Important:  If you overfill or underfill the engine crankcase with oil and run the engine, you may damage the engine.  1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.  
Note:  Ensure that the engine is cool so that the oil has had time to drain into the sump.  3. To keep dirt, grass clippings, etc., out of the engine, clean the area around the oil-fill cap and dipstick before removing it ( Figure 59 ).   Note:  This warms the oil so that it drains better. 2. Park the machine so that the drain side is slightly lower than the opposite side to ensure that the oil drains completely. 3. 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. Drain the oil from the engine ( Figure 60 ).   # Changing the Engine Oil  Note:  Dispose of the used oil at a recycling center. 1. Start the engine and let it run for 5 minutes.  6. Slowly pour approximately  $80\%$   of the specified oil into the filler tube and slowly add the additional oil to bring it to the Full mark ( Figure 61 ).   7. Start the engine and drive to a flat area.  8. Check the oil level again.  # Changing the Engine-Oil Filter  1. Drain the oil from the engine; refer to  Changing the Engine Oil (page 47) .  2. Change the engine-oil filter ( Figure 62 ).   Note:  Ensure that the oil-filter gasket touches the engine, and then turn the oil filter an extra  $3/4$   turn.  3. Fill the crankcase with the proper type of new oil; refer to  Engine-Oil Specifications (page 46) .  # Servicing the Spark Plug(s)  Service Interval:  Every 200 hours—For Kohler Engines—check the spark plug(s).  Every 500 hours—For Kohler Engines—replace the spark plug(s).  Type:  Champion XC12YC Air Gap:    $0.76\;\mathsf{m m}$   (0.030 inch)  
# Removing the Spark Plug  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 the area around the base of the plug(s) to keep dirt and debris out of the engine. 4. Locate and remove the spark plug(s) as shown in  Figure 63 .   # Installing the Spark Plug   # Checking the Spark Plug(s)  Important:  Do not clean the spark plug(s). Always replace the spark plug(s) when it has a black coating, worn electrodes, an oily film, or cracks.  If you see light brown or gray on the insulator, the engine is operating properly. A black coating on the insulator usually means the air cleaner is dirty.  Set the gap to   $0.76\:\mathsf{m m}$   (0.030 inch).   
# Cleaning the Engine Screen Fuel System  Service Interval:  Before each use or daily—Clean the engine screen, engine-oil cooler, and the area around the engine.  Before each use or daily—Clean around the engine-exhaust system.  Before each use remove any buildup of grass, dirt, or other debris from the engine screen, engine exhaust, engine-oil cooler, and the area around the engine. This helps ensure adequate cooling and correct engine speed and reduces the possibility of overheating and mechanical damage to the engine.  # Checking the Spark Arrester  For Machines with a Spark Arrester  Service Interval:  Every 50 hours  Hot exhaust-system components may ignite fuel vapors even after you shut off the engine. Hot particles exhausted during engine operation may ignite flammable materials, resulting in personal injury or property damage.  Do not refuel or run the engine unless the spark arrester is installed.  1. Park the machine on a level surface, disengage the PTO, and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Wait for the muffler to cool. 4. If you see any breaks in the screen or welds, replace the arrester. 5. If the screen is plugged, remove the arrester, shake loose particles out of the arrester, and clean the screen with a wire brush (soak the screen in solvent if necessary). 6. Install the arrester on the exhaust outlet.  # Maintenance  # DANGER  In certain conditions, fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property.  Refer to  Fuel Safety (page 16)  for a complete list of fuel related precautions.  # Replacing the Fuel Filter  Service Interval:  Every 500 hours/Yearly (whichever comes first) (more often in dusty, dirty conditions).  Important:  Install the fuel line hoses and secure with plastic ties the same as they were originally installed at the factory to keep the fuel line away from components that can cause fuel line damage.  Never install a dirty filter after removing it from the fuel line.  The fuel filter is located near the engine on the left front of the engine.  1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Allow the machine to cool down. 4. Replace the fuel filter ( Figure 66 ). Note:  Ensure that the flow-direction arrow on the replacement filter points toward the engine.  
 
Figure 66  # Servicing the Fuel Tank  Do not attempt to drain the fuel tank. Ensure that an Authorized Service Dealer drains the fuel tank and services any components of the fuel system.  # Electrical System Maintenance  # Electrical System Safety  • Disconnect the battery before repairing the machine. Disconnect the negative terminal first and the positive last. Connect the positive terminal first and the negative last. • Charge the battery in an open, well-ventilated area, away from sparks and flames. Unplug the charger before connecting or disconnecting the battery. Wear protective clothing and use insulated tools.  # Servicing the Battery  Service Interval:  Monthly  # 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 installing the battery, do not allow the battery terminals to touch any metal parts of the machine. • Do not allow metal tools to short between the battery terminals and metal parts of the machine.  # WARNING  Incorrectly removing the cables from battery could damage the machine and cables, causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury.  • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. • Always connect the positive (red) battery cable before connecting the negative (black) cable. 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 67 .   
Figure 67  4. Install the battery in the machine and connect the battery cables; refer to  Installing the Battery (page 53) .  Note:  Do not run the machine with the battery disconnected; electrical damage may occur.   1. Positive   $(+)$   battery post 3. Red   $(+)$   charger lead 2. Negative   $(-)$   battery post 4. Black   $(-)$   charger lead  # Charging the Battery  # WARNING  Charging the battery produces gasses that can explode.  Never smoke near the battery and keep sparks and flames away from the 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   $\mathtt{0^{\circ}C}$     $({\pmb3}{\pmb2}^{\circ}{\pmb F})$  .  1. Remove the battery from the chassis; refer to Removing the Battery (page 51) . 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 68 ).  
# Installing the Battery  1. Position the battery in the tray with the terminal posts opposite from the hydraulic tank ( Figure 67 ).  2. Install the positive (red) battery cable to the positive   $(+)$   battery terminal.  3. Install the negative (black) battery cable and ground wire to the negative (-) battery terminal. Note:  For MyRide machines, ensure that the ground cable does not rub against the trailing arm or lower shock mount ( Figure 70 ).   
Figure 69  1. Ensure that the ground 3. Ground cable cable does not rub against the lower shock mount.  # Servicing the Fuses  The electrical system is protected by fuses. It requires no maintenance; however, if a fuse blows check the component and circuit for a malfunction or short.  The fuses are located on the right console next to the seat ( Figure 70 ).  1. To replace the fuses, pull out the fuse to remove it.  2. Install a new fuse ( Figure 70 ).   1. Fuse cover 3. Fuel-shutoff valve 2. Fuse holder  2. Ensure that the ground cable does not rub against the trailing arm.  4. Secure the cables with 2 bolts, 2 washers, and 2 locknuts ( Figure 67 ).  5. Slide the red terminal boot onto the positive   $(+)$  battery terminal.  6. Secure the battery with the rubber strap ( Figure 67 ).  
# Drive System Maintenance  # 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.  # Adjusting the Tracking  1. Disengage the blade-control switch (PTO).  2. Drive to an open, flat area and move the motion-control levers to the N EUTRAL - LOCK position.  3. Move the throttle midway between the F AST  and S LOW  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, insert a 3/16 inch hex wrench through the access hole in the left, front cover panel and rotate the tracking screw clockwise or counterclockwise to adjust the travel of the lever ( Figure 71 ).   
Figure 71 Right control lever shown  2. Access hole on the front cover panel  1. Tracking screw  7. If the machine tracks to the left, insert a 3/16 inch hex wrench through the access hole in the right, front cover panel and rotate the tracking screw clockwise or counterclockwise to adjust the travel of the lever ( Figure 71 ).  8. Drive the machine and check the full forward tracking.  9. Repeat the adjustment until the desired tracking is obtained.  
# Checking the Tire Pressure Brake Maintenance For Machines with Pneumatic  Service Interval:  Every 50 hours/Monthly (whichever comes first) For machines with pneumatic tires only.  # Adjusting the Parking Brake  If you need to adjust the parking brake, contact an Authorized Service Dealer.  Maintain the air pressure in the rear tires at  $90~\mathsf{k P a}$  (13 psi). Uneven tire pressure can cause uneven cut. Check the tires when they are cold to get the most accurate pressure reading.   
Figure 72  # Checking the Wheel Lug Nuts  Check and torque the wheel lug nuts to 122 to 136  $\mathsf{N{\cdot}m}$   (90 to 100 ft-lb).  
# Belt Maintenance  # Inspecting the Belts  Service Interval:  Every 50 hours  Replace the belt if it is worn. The signs of a worn belt include squealing while the belt is rotating; the blades slipping while cutting grass; and frayed edges, burn marks, and cracks on the belt.  # Replacing the Mower Belt  1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Lower the mower to the  $76\,\mathsf{m m}$   (3 inches) height of cut.  4. Remove the belt covers ( Figure 73 ).   
Figure 73  5. Use a   $3/8$  -inch ratchet in the square hole in the idler arm to remove tension on the idler spring ( Figure 74 ). 6. Remove the belt from the mower-deck pulleys and the clutch pulley. 7. Remove the belt guide on the spring-loaded idler arm ( Figure 74 ). 8. Remove the existing belt. 9. Install the new belt around the mower pulleys and the clutch pulley under the engine ( Figure 74 ).   
Figure 74  1. Spring 4. Spring-loaded idler assembly 2. Clutch pulley 5. Ratchet 3. Mower belt 6. Square hole in the idler arm for the ratchet  10. Install the belt guide on the idler arm ( Figure 74 ).  11. Using the   $3/8$  -inch ratchet in the square hole, install the idler spring ( Figure 74 ). Note:  Ensure that the spring ends are seated in the anchor grooves.  12. Install the belt covers ( Figure 75 ).  
 
Figure 75  # Replacing the Hydraulic Pump-Drive Belt  1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake.  2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.  3. Remove the mower belt; refer to  Replacing the Mower Belt (page 56) .  4. Raise the machine and support it with jack stands.  5. Use a 1/2-inch ratchet or breaker bar in one of the square holes in the idler arm to remove tension on the idler spring ( Figure 76 ).  6. Remove the existing belt from the idler pulley, 2 hydraulic-pump-drive pulleys, and engine pulley ( Figure 76 ).  7. Install the new belt around the idler pulley, engine pulley, and 2 hydraulic-pump pulleys ( Figure 76 ).   
Figure 76  1. Idler pulley 6. Right hydraulic-pump pulley 2. Square hole in the idler 7. Mower belt arm for the ratchet 3. Engine pulley 8. Idler-spring post 4. Idler arm 9. Left hydraulic-pump pulley  5. Hydraulic pump-drive belt  8. Using the 1/2-inch ratchet or breaker bar in one of the square holes, install the idler spring.  9. Install the mower belt; refer to  Replacing the Mower Belt (page 56) .  
# Controls System Maintenance  # Adjusting the Control-Handle Position  If the ends of the levers hit against each other, refer to Adjusting the Motion-Control Linkage (page 59) .  # Adjusting the Height  You can adjust the motion control levers higher or lower for maximum comfort.  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 hardware holding the control lever to the control-arm shaft.   
Figure 77  # Adjusting the Tilt  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 upper bolt holding the control lever to the control arm shaft. 4. Loosen the lower bolt just enough to pivot the control lever fore or aft. Tighten both bolts to secure the control in the new position. 5. Repeat the adjustment for the opposite control  lever.   
Figure 78  1. Bolts 3. Control lever 2. Slotted hole 4. Control-arm shaft  4. Move the control lever to the next set of holes. Secure the lever with the hardware.  5. Repeat the adjustment for the opposite control lever.  
# Adjusting the Motion-Control Linkage  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.  # WARNING  # The engine must be running and the drive wheels turning so that you can perform the adjustments. Contact with moving parts or hot surfaces may cause personal injury.  Keep your fingers, hands, and clothing clear of rotating components and hot surfaces.  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 N EUTRAL position. 10. Check and ensure that the control-plate tabs touch the return-to-neutral plates on the hydraulic units.  11. Adjust the pump-control-rod lengths by rotating the nut in the appropriate direction until the wheels slightly creep in reverse ( Figure 79  and Figure 80 ).   
1. Access hole for   $_{1/2}$  -inch socket   
Figure 80  1. Nut 4. Return-to-neutral plate 2. Stationary plate 5. Tabs touching return to neutral plate  3. Control plate  12. Move the motion-control levers to the R EVERSE 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.  
Note:  You may need to remove the motion-control cover to gain access. 13. Shut off the machine. 14. Remove the jumper wire from the wire harness and plug the connector into the seat switch. 15. Remove the jack stands. 16. Raise the mower deck and install the height-of-cut pin. 17. Check and ensure that the machine does not creep in neutral with the parking brake disengaged.  # Hydraulic System Maintenance  # Hydraulic System Safety  • Seek immediate medical attention if fluid is injected into skin. Injected fluid must be surgically removed within a few hours by a doctor. • Ensure that all hydraulic-fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to the hydraulic system. • Keep your body and hands away from pinhole leaks or nozzles that eject high-pressure hydraulic fluid. • Use cardboard or paper to find hydraulic leaks. • Safely relieve all pressure in the hydraulic system before performing any work on the hydraulic system.  # Hydraulic-Fluid Specifications  Hydraulic Fluid Type:  500 hydraulic fluid  Important:  Use the specified fluid. Other fluids could damage the hydraulic system. ZT 4400 Hydros Hydraulic System Capacity (with filters removed):  7.57 L (8 US qt) ZT 5400 Hydros Hydraulic System Capacity (with filters removed):  9.46 L (10 US qt)  
# Checking the Hydraulic-Fluid Level  Service Interval:  Before each use or daily  1. Allow the hydraulic fluid to cool down. Check the oil level when the fluid is cold. 2. Check expansion reservoir and if necessary add 500 hydraulic fluid to the FULL COLD line ( Figure 81 ).   # Changing the Hydraulic Fluid and Filters  Service Interval:  After the first 100 hours—Change the hydraulic-system filters and fluid.  Every 400 hours or yearly, whichever comes first—After the initial change—change the hydraulic-system filters and fluid when using 500 fluid (change it more often under dirty or dusty conditions).  To replace the hydraulic fluid, the filters need to be removed. Replace both at the same time; refer to Hydraulic-Fluid Specifications (page 60)  for fluid specifications.  Purge any air in the system after you install the new filters and add fluid. Refer to  Bleeding the Hydraulic System (page 63) . Repeat the bleeding process until the fluid remains at the F ULL  C OLD  line in the reservoir after purging.  Important:  Failure to properly perform this procedure can result in irreparable damage to the transaxle drive system.  # Removing Hydraulic Fluid and Filters  This procedure varies depending on the drive system of the model. If it is unclear which drive system is on the model, contact your Authorized Service Dealer.  1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Allow the engine to cool. 4. Locate and remove the vent plug as follows: Note:  Ensure that you keep track of the vent plug after removal, as it can be easy to misplace. • For ZT 4400 Hydros , use an extension and 7/16-inch socket, access the vent plug from the top of the machine through the holes near the roll-bar mounts ( Figure 82 ).  
 
Figure 82  1. Access holes for the vent plugs  • For ZT 5400 Hydros , use a 7/16-inch wrench to access the vent plug from underneath the machine ( Figure 83 ).   
Figure 83  1. Vent plug  Important:  Do not allow dirt to enter the hydraulic system; otherwise, contamination may occur.  6. Place a drain pan below the filter to catch the fluid that drains when the filter and vent plugs are removed. 7. Remove the hydraulic-fluid filter cover from the transaxle to drain the fluid ( Figure 84 ).   1. Hydraulic-filter housing 2. Cover  8. Remove the O-ring from the filter cover and discard the O-ring. 9. After the hydraulic fluid drains from the transaxle, remove the filter from the transaxle housing. 10. Repeat this procedure on the other side of the machine.  # Installing the Hydraulic Fluid and Filters  1. Install a new filter in the transaxle and a new O-ring onto the filter cover. 2. Install the filter cover. 3. Torque the filter cover as follows: • ZT 4400 Hydros:  22.6 to   $33.8\;\mathsf{N}\!\cdot\!\mathsf{m}$   (200 to 300 in-lb) • ZT 5400 Hydros:  54.3 to   $65.5\:\mathsf{N{\cdot}m}$   (480 to 580 in-lb) 4. Remove the cap from the expansion tank and fill the transaxles with the specified fluid until the proper fluid capacities are met. Note:  Filling the transaxles may take more time than expected. 5. Install the previously removed vent plugs and torque the plugs to 395 to 904 N∙cm (35 to 80 in-lb). 6. Proceed to  Bleeding the Hydraulic System (page 63) .  
Important:  Failure to perform the  Bleeding the Hydraulic System  procedure after changing hydraulic filters and fluid can result in irreparable damage to the transaxle drive system.  4. Check the fluid level in the expansion reservoir a final time. Add the specified fluid as until it reaches the F ULL  C OLD  line on the expansion reservoir.  # Bleeding the Hydraulic System  1. Raise the rear of machine and support it with jack stands (or equivalent support) just high enough to allow the drive wheels to turn freely.   
Figure 85  1. Jacking points  2. Start the engine, move the throttle control ahead to the 1/2 throttle position, and disengage the parking brake.  A. Move the bypass levers into the pushing the machine position. With the bypass valves open and the engine running, slowly move the motion-control levers in both forward and reverse 5 or 6 times. B. Move the bypass levers into the operating the machine position. C. With the bypass valve closed and the engine running, slowly move the control lever in both forward and reverse directions 5 to 6 times. D. Shut off the engine and check the fluid level in the expansion reservoir. Add the specified fluid until it reaches the F ULL  C OLD line on the expansion reservoir.  3. Repeat step  2  until all the air is completely purged from the system.  Note:  When the transaxle operates at normal noise levels, moves smoothly forward, and reverses at normal speeds, it is purged.  
# Mower Deck Maintenance  # Blade Safety  • Inspect the blades periodically for wear or damage.  • Use care when checking the blades. Wrap the blades or wear gloves, and use caution when servicing the blades. Only replace or sharpen the blades; never straighten or weld them.  • On multi-bladed machines, take care as rotating one blade can cause other blades to rotate.  
 • Replace worn or damaged blades and bolts in sets to preserve balance.  # Servicing the Cutting Blades  To ensure a superior quality of cut, keep the blades sharp. For convenient sharpening and replacement, you may want to keep extra blades on hand.  # Before Inspecting or Servicing the Blades  1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake.  2. Shut off the engine, remove the key, and disconnect the spark-plug wires from the spark plugs.  # Inspecting the Blades  Service Interval:  Before each use or daily 1. Inspect the cutting edges ( Figure 86 ).   1. Cutting edge 3. Wear/slot forming 2. Curved area 4. Crack2. If the edges are not sharp or have nicks, remove and sharpen the blade; refer to  Sharpening the Blades (page 66) .  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 86 ).  
# Checking for Bent Blades  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 87 ).   
Figure 87  1. Deck 3. Blade 2. Spindle housing  3. Measure from the tip of the blade to the flat surface ( Figure 88 ).   
Figure 88  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 89 ).   
Figure 89  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 90 ).  
 
Figure 90  1. Opposite blade edge (in position for measuring) 2. Level surface 3. Second measured distance between blade and surface (B)  Note:  The variance should be no more than 3 mm (1/8 inch).  A. 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 (page 66)  and  Installing the Blades (page 66) .  Note:  If a bent blade is replaced with a new blade, and the dimension obtained continues to exceed  $3\:\mathsf{m m}$   (1/8 inch), the blade spindle could be bent. Contact an Authorized Service Dealer for service. B. If the variance is within constraints, move to the next blade. Repeat this procedure on each blade.  
# Removing the Blades  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 91 ).   
Figure 91  1. Sail area of the blade 4. Bushing 2. Blade 5. Blade bolt 3. Flat of the spindle shaft  # Sharpening the Blades  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 92 ).  1. Blade 2. Balancer  3. Repeat this procedure until the blade is balanced.  # Installing the Blades  1. Install the bushing through the blade with the bushing flange on the bottom (grass) side of the blade ( Figure 94 ).   
Figure 94  1. Bushing  2. Install the bushing/blade assembly into the spindle shaft ( Figure 95 ).   1. Use a file to sharpen the cutting edge at both ends of the blade ( Figure 92 ).   
Figure 92  1. Sharpen at original angle.  Note:  Maintain the original angle.  Note:  The blade retains its balance if the same amount of material is removed from both cutting edges.   
Figure 93  2. Flat of the spindle shaft  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).  # Adjusting the Side-to-Side Leveling and the Blade Slope  Check to ensure that the mower deck is level any time you install the mower or when you see an uneven cut on your lawn.  Check the mower deck for bent blades prior to leveling, and remove and replace any bent blades; refer to  Servicing the Cutting Blades (page 64)  before continuing.  Level the mower deck side-to-side first; then you can adjust the front-to-rear slope.  # Requirements:  • The machine must be on a level surface. • All tires must be properly inflated; refer to  Checking the Tire Pressure (page 55) . 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 tire pressure in the drive tires; refer to Checking the Tire Pressure (page 55) . 4. Position the mower deck in the transport-lock position. 5. Carefully rotate the blades from side to side. 6. Measure between the blade tip and the flat surface ( Figure 96 ). If both measurements are not within   $5\:\mathsf{m m}$   (3/16 inch), adjust the leveling; continue with this procedure.   
Figure 96  1. Blades side to side 3. Measure from the tip of the blade to the flat surface here.  2. Blade tip  7. Check the front-to-rear blade level ( Figure 97 ). Ensure the front blade tip is lower than the rear blade tip as shown in the block height and rake table. If adjustment is needed, continue with this procedure.   
Figure 97  g037880  1. Blades front to rear 3. Measure from the tip of the blade to the flat surface here.  2. Blade tip  8. Set the anti-scalp rollers to top holes or remove them completely for this adjustment.  
9. For 60-inch mower decks only:  A. Raise the deck to the transport position (140 mm or 5-1/2 inches). B. Slowly loosen the adjusting screw on the lift-assist spring until you can remove the screw ( Figure 98 ). Note:  Save the screw for installation.   
Figure 98  1. Adjusting screw 3. Set the gap to 22 to 29 mm (7/8 to 1-1/8 inches).  2. Bracket  10. Place 2 blocks (see Block Height and Rake Table) under the rear edge of the cutting deck skirt; 1 on each side of the cutting deck ( Figure 99 ).   11. Set the height-of-cut lever to the   $76~\mathsf{m m}$   (3 inches) position. 12. Place 2 blocks under each side of the front edge of the deck, but not under the anti-scalp roller brackets or welds.  1. Block—73 mm (2-7/8 2. Welds inches)  # Block Height and Rake Table   13. Carefully rotate the blades side to side ( Figure 96 ). 14. Loosen the locknuts ( Figure 100 ) on all 4 corners and ensure that the mower deck is sitting securely on all 4 blocks. 15. Remove any slack from the deck hangers and make sure the deck-lift foot lever is pushed back against the stop. 16. Tighten the 4 lock nuts.   
Figure 100  1. Locknuts 3. Deck hanger 2. Deck lift arm 4. Chain  
17. Ensure that the blocks fit snugly under the deck skirt and that all attachment bolts are tight 18. Continue leveling the deck by checking the front-to-rear blade slope. 19. Check the blades for levelness and repeat deck leveling procedure if necessary.  # 20. For 60-inch mower decks only:  A. Raise the deck to the transport position (  $140~\mathsf{m m}$   or 5-1/2 inches). B. Install the lift-assist spring adjusting screw previously removed in step  9 . C. Set the gap between the spring and the bracket to 22 to  $\sf{29\,m m}$   (7/8 to 1-1/8 inches).  # Removing the Mower Deck  Before servicing or removing the mower deck, lock out the spring-loaded deck arms.  1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Place the height-adjustment pin in the 7.6 cm (3 inch) cutting-height location. 4. Remove the belt covers. 5. Loosen the mower deck idler and remove the mower belt; refer to  Belt Maintenance (page 56) . 6. Remove the bolts and nuts from the front of the plate under the footrest. 7. Remove and retain the bolts and nuts on both sides of the machine ( Figure 101 ).   
Figure 101  1. Remove the nuts and bolts here. 2. Remove the nuts and bolts here.  8. Slide the deck out to the right side of the machine.  
# Replacing the Grass Deflector  # WARNING  An uncovered discharge opening could allow the machine to throw objects toward you or bystanders, resulting in serious injury. Also, contact with the blade could occur.  Never operate the machine unless you install a mulch plate, discharge deflector, or grass collection system.  1. Remove the locknut, bolt, spring, and spacer holding the deflector to the pivot brackets ( Figure 102 ). 2. Remove the damaged or worn grass deflector ( Figure 102 ).   
Figure 102  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 -hook end of the spring is installed behind the deck edge before installing the bolt as shown in  Figure 102 . 5. Install the bolt and the nut. 6. Place 1  J -hook end of the spring around the grass deflector ( Figure 102 ). Important:  The grass deflector must be able to rotate. Lift the deflector up to the full open position and ensure that it rotates into the full down position.  
# Cleaning  # Cleaning under the Mower Deck  Service Interval:  After each use  1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Raise the mower deck to the T RANSPORT position.  # Cleaning the Suspension System  Machines with Suspension System Only  Service Interval:  Before each use or daily  Use compressed air to clean the suspension system.  Note:  Do not clean the shock assemblies with pressurized water ( Figure 103 ).   # Disposing of Waste  Engine oil, batteries, hydraulic fluid, and engine coolant are pollutants to the environment. Dispose of these according to your state and local regulations.  
# Storage  # Storage Safety  • Shut off the engine, remove the key, and wait for all moving parts to stop before you leave the operator’s position. Allow the machine to cool before adjusting, servicing, cleaning, or storing it. • Do not store the machine or fuel near flames or drain the fuel indoors or inside an enclosed trailer. • Do not store the machine or fuel container where there is an open flame, spark, or pilot light, such as on a water heater or on other appliances.  # Cleaning and Storage  1. Disengage the blade-control switch (PTO), and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine and hydraulic system. Clean dirt and chaff from the outside of the engine cylinder head fins and blower housing. Important:  You can wash the machine with mild detergent and water. Do not pressure wash the machine. Avoid excessive use of water, especially near the control panel, engine, hydraulic pumps, and motors. 4. Check the parking brake operation; refer to Adjusting the Parking Brake (page 55) . 5. Service the air cleaner; refer to  Servicing the Air Cleaner (page 40) . 6. Grease the machine; refer to  Lubrication (page 37) . 7. Change the crankcase oil; refer to  Servicing the Engine Oil (page 41) . 8. Check the tire pressure; refer to  Checking the Tire Pressure (page 55) . 9. Change the hydraulic filters; refer to  Changing the Hydraulic Fluid and Filters (page 61) . 10. Charge the battery; refer to  Charging the Battery (page 52) . 11. Scrape any heavy buildup of grass and dirt from the underside of the mower, then wash the mower with a garden hose. Note:  Run the machine with the blade-control switch (PTO) engaged and the engine at high idle for 2 to 5 minutes after washing.  # 12. Check the condition of the blades; refer to Servicing the Cutting Blades (page 64) .  13. Prepare the machine for storage when non-use occurs over 30 days. Prepare the machine for storage as follows:  A. Add a petroleum-based stabilizer/conditioner to fuel in the tank. Follow mixing instructions from the stabilizer manufacturer. Do not use an alcohol-based stabilizer (ethanol or methanol).  Note:  A fuel stabilizer/conditioner is most effective when mixed with fresh fuel and used at all times.  B. Run the engine to distribute conditioned fuel through the fuel system for 5 minutes.  C. Shut off the engine, allow it to cool, and drain the fuel tank.  D. Start the engine and run it until it stops.  E. Dispose of fuel properly. Recycle the fuel according to local codes.  Important:  Do not store fuel containing stabilizer/conditioner longer than the duration recommended by the  fuel-stabilizer manufacturer. 14. Remove and check the condition of the spark plug(s); refer to  Servicing the Spark Plug(s) (page 44) . With the spark plug(s) removed from the engine, pour   $30\,\mathsf{m}$   (2 tablespoons) of engine oil into the spark plug hole. Use the starter to crank the engine and distribute the oil inside the cylinder. Install the spark plug(s). Do not install the wire on the spark plug(s). 15. Check and tighten all bolts, nuts, and screws. Repair or replace any part that is damaged. 16. Paint all scratched or bare metal surfaces. Paint is available from your Authorized Service Dealer. 17. Store the machine in a clean, dry garage or storage area. Remove the key from the switch and keep it out of reach of children or other unauthorized users. Cover the machine to protect it and keep it clean.  
 
 
 
 Engines Electrical Schematic—Page 1 (Rev. A)  
 Engines Electrical Schematic—Page 2 (Rev. A)  
 Engines Electrical Schematic (Rev. A)  
# California Proposition 65 Warning Information  What is this warning?  # WARNING:  Cancer and Reproductive Harm.  # What is Prop 65?  Prop 65 applies to any company operating in California, selling products in California, or manufacturing products that may be sold in or brought into California. It mandates that the Governor of California maintain and publish a list of chemicals known to cause cancer, birth defects, and/or other reproductive harm. The list, which is updated annually, includes hundreds of chemicals found in many everyday items. The purpose of Prop 65 is to inform the public about exposure to these chemicals.  Prop 65 does not ban the sale of products containing these chemicals but instead requires warnings on any product, product packaging, or literature with the product. Moreover, a Prop 65 warning does not mean that a product is in violation of any product safety standards or requirements. In fact, the California government has clarified that a Prop 65 warning “is not the same as a regulatory decision that a product is ‘safe’ or ‘unsafe.’” Many of these chemicals have been used in everyday products for years without documented harm. A Prop 65 warning means that a company has either (1) evaluated the exposure and has concluded that it exceeds the “no significant risk level”; or (2) has chosen to provide a warning based on its understanding about the presence of a listed chemical without attempting to evaluate the exposure.  # Does this law apply everywhere?  Prop 65 warnings are required under California law only. These warnings are seen throughout California in a wide range of settings, including but not limited to restaurants, grocery stores, hotels, schools, and hospitals, and on a wide variety of products. Additionally, some online and mail order retailers provide Prop 65 warnings on their websites or in catalogs.  # How do the California warnings compare to federal limits?  Prop 65 standards are often more stringent than federal and international standards. There are various substances that require a Prop 65 warning  $0.5\;\upmu\up g/d a y,$  the federal and international standards.  # Why don’t all similar products carry the warning?  • Products sold in California require Prop 65 labelling while similar products sold elsewhere do not. • A company involved in a Prop 65 lawsuit reaching a settlement may be required to use Prop 65 warnings for its products, but other companies making similar products may have no such requirement. • The enforcement of Prop 65 is inconsistent. • Companies may elect not to provide warnings because they conclude that they are not required to do so under Prop 65; a lack of warnings for a product does not mean that the product is free of listed chemicals at similar levels.  # Why does it include this warning?  It has been chosen to provide consumers with as much information as possible so that they can make informed decisions about the products they buy and use. It provides warnings in certain cases based on its knowledge of the presence of one or more listed chemicals without evaluating the level of exposure, as not all the listed chemicals provide exposure limit requirements. While the exposure from products may be negligible or well within the “no significant risk” range, out of an abundance of caution, it has elected to provide the Prop 65 warnings. Moreover, if it does not provide these warnings, it could be sued by the State of California or by private parties seeking to enforce Prop 65 and subject to substantial penalties.