Page 1
Form No. 3329–540
Z257
Z–Master with 72 SFS Side Discharge Mower
Model No. 74232– Serial No. 230006001 & Up
Operator ’s Manual
English (EN)
Page 2
Warning
The engine exhaust from this product contains
chemicals known to the State of California to
cause cancer, birth defects, or other reproductive
harm.
Important This engine is not equipped with a spark
arrester muffler. It is a violation of California Public
Resource Code Section 4442 to use or operate this engine
on any forest–covered, brush–covered or grass–covered
land. Other states or federal areas may have similar laws.
This spark ignition system complies with Canadian
ICES-002.
Ce système d’allumage par étincelle de véhicule est
conforme à la norme NMB-002 du Canada.
The enclosed Engine Owner ’s Manual is supplied for
information regarding The U.S. Environmental
Protection Agency (EPA) and the California Emission
Control Regulation of emission systems, maintenance
and warranty.
Keep this engine Owner ’s Manual with your unit.
Should this engine Owner’s Manual become damaged
or illegible, replace immediately. Replacements may be
ordered through the engine manufacturer.
Contents
Page
Introduction 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe Operating Practices 3. . . . . . . . . . . . . . . . . . .
Slope Chart 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals 8. . . . . . . . . . . . . . .
Gasoline and Oil 13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Gasoline 13. . . . . . . . . . . . . . . . . . .
Using Stabilizer/Conditioner 13. . . . . . . . . . . . . . . .
Filling the Fuel Tank 13. . . . . . . . . . . . . . . . . . . . . .
Check Engine Oil Level 13. . . . . . . . . . . . . . . . . . . .
Setup 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loose Parts 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Drive Wheels 14. . . . . . . . . . . . . . . . .
Checking the Tire Pressure 14. . . . . . . . . . . . . . . . .
Installing the Seat Retaining Rod 14. . . . . . . . . . . .
Installing the Motion Control Levers 15. . . . . . . . .
Activating the Battery 15. . . . . . . . . . . . . . . . . . . . .
Installing the Air Cleaner 16. . . . . . . . . . . . . . . . . . .
Checking the Hydraulic Fluid 17. . . . . . . . . . . . . . .
Greasing the Bearings 17. . . . . . . . . . . . . . . . . . . . .
Checking the Side Discharge Chute 17. . . . . . . . . .
2003 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
Checking the Level of Mower Deck 17. . . . . . . . . .
Checking the Engine Oil Level 17. . . . . . . . . . . . . .
Operation 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Think Safety First 18. . . . . . . . . . . . . . . . . . . . . . . .
Controls 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating the Parking Brake 19. . . . . . . . . . . . . . . .
Starting and Stopping the Engine 19. . . . . . . . . . . .
Operating the Power Take Off (PTO) 20. . . . . . . . .
The Safety Interlock System 21. . . . . . . . . . . . . . . .
Driving Forward or Backward 21. . . . . . . . . . . . . . .
Stopping the Machine 22. . . . . . . . . . . . . . . . . . . . .
Adjusting the Height-of-Cut 22. . . . . . . . . . . . . . . .
Using the Lift Assist Lever 22. . . . . . . . . . . . . . . . .
Adjusting the Anti-Scalp Rollers 23. . . . . . . . . . . . .
Positioning the Seat 23. . . . . . . . . . . . . . . . . . . . . . .
Pushing the Machine by Hand 23. . . . . . . . . . . . . . .
Using a Rollover Protection System (ROPS) 24. . .
Transporting Machines 24. . . . . . . . . . . . . . . . . . . .
Loading Machines 24. . . . . . . . . . . . . . . . . . . . . . . .
Using the Z Stand 25. . . . . . . . . . . . . . . . . . . . . . . . .
Tips for Mowing Grass 26. . . . . . . . . . . . . . . . . . . .
Maintenance 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Maintenance Schedule 28. . . . . . . .
Servicing the Cutting Blades 29. . . . . . . . . . . . . . . .
Servicing the Air Cleaner 31. . . . . . . . . . . . . . . . . .
Servicing the Engine Oil 32. . . . . . . . . . . . . . . . . . .
Servicing the Spark Plug 33. . . . . . . . . . . . . . . . . . .
Servicing the Fuel Filter 34. . . . . . . . . . . . . . . . . . .
Servicing the Fuel Tank 34. . . . . . . . . . . . . . . . . . . .
Greasing and Lubrication 35. . . . . . . . . . . . . . . . . . .
Greasing the Bearings 35. . . . . . . . . . . . . . . . . . . . .
Cleaning the Cooling Systems 36. . . . . . . . . . . . . . .
Checking the Tire Pressure 36. . . . . . . . . . . . . . . . .
Checking the Wheel Hub Slotted Nut 36. . . . . . . . .
Adjusting the Caster Pivot Bearing 37. . . . . . . . . . .
Servicing the Hydraulic System 37. . . . . . . . . . . . .
Adjusting the Handle Neutral 39. . . . . . . . . . . . . . .
Setting the Hydraulic Pump Neutral 40. . . . . . . . . .
Adjusting the Tracking 41. . . . . . . . . . . . . . . . . . . .
Replacing the Pump Drive Belt 42. . . . . . . . . . . . . .
Adjustment Parking Brake 42. . . . . . . . . . . . . . . . . .
Servicing the Fuse 42. . . . . . . . . . . . . . . . . . . . . . . .
Servicing the Battery 43. . . . . . . . . . . . . . . . . . . . . .
Leveling the Mower 45. . . . . . . . . . . . . . . . . . . . . . .
Cleaning Under the Deck 46. . . . . . . . . . . . . . . . . . .
Belt Inspection 46. . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Deck Belt 46. . . . . . . . . . . . . . . . . . .
Replacing the PTO Drive Belt 47. . . . . . . . . . . . . . .
Replacing the Grass Deflector 48. . . . . . . . . . . . . . .
2
Page
All Rights Reserved
Printed in the USA
Page 3
Page
Waste Disposal 49. . . . . . . . . . . . . . . . . . . . . . . . . . .
Mercury Tilt Switch 49. . . . . . . . . . . . . . . . . . . . . . .
Disposing the Mercury Tilt Switch 49. . . . . . . . . . .
Wiring Diagram 50. . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Storage 51. . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Toro Total Coverage Guarantee 56. . . . . . . . . . . . .
Introduction
Read this manual carefully to learn how to operate and
maintain your product properly. The information in this
manual can help you and others avoid injury and product
damage. Although Toro designs and produces safe
products, you are responsible for operating the product
properly and safely.
Whenever you need service, genuine Toro parts, or
additional information, contact an Authorized Service
Dealer or Toro Customer Service and have the model and
serial numbers of your product ready. Figure 1 illustrates
the location of the model and serial numbers on the
product.
1
Warning signals a hazard that may cause serious injury or
death if you do not follow the recommended precautions.
Caution signals a hazard that may cause minor or
moderate injury if you do not follow the recommended
precautions.
This manual uses two other words to highlight
information. Important calls attention to special
mechanical information and Note: emphasizes general
information worthy of special attention.
Safety
This machine meets or exceeds the B71.4 1999
specifications of the American National Standards
Institute, in effect at time of production.
Note: The addition of attachments made by other
manufacturers that do not meet American National
Standards Institute certification will cause noncompliance
of this machine.
Improper use or maintenance by the operator or owner
can result in injury. To reduce the potential for injury,
comply with these safety instructions and always pay
attention to the safety alert symbol, which means
CAUTION, WARNING, or DANGER—“personal
safety instruction.” Failure to comply with the
instruction may result in personal injury or death.
Figure 1
1. Location o f the model and serial numbers
Write the product model and serial numbers in the space
below:
Model No.
Serial No.
This manual identifies potential hazards and has special
safety messages that help you and others avoid personal
injury and even death. Danger, Warning, and Caution are
signal words used to identify the level of hazard.
However, regardless of the hazard, be extremely careful.
Danger signals an extreme hazard that will cause serious
injury or death if you do not follow the recommended
precautions.
This product is capable of amputating hands and feet and
throwing objects. Always follow all safety instructions to
avoid serious injury or death.
This product is designed for cutting and recycling grass or,
when equipped with a grass bagger, for catching cut grass.
Any use for purposes other than these could prove
dangerous to user and bystanders.
Safe Operating Practices
The following instructions are from ANSI standard
B71.4—1999.
Training
• Read the Operator ’s Manual and other training
material. If the operator(s) or mechanic(s) can not read
English it is the owner’s responsibility to explain this
material to them.
• Become familiar with the safe operation of the
equipment, operator controls, and safety signs.
• All operators and mechanics should be trained. The
owner is responsible for training the users.
• Never let children or untrained people operate or
service the equipment. Local regulations may restrict
the age of the operator.
3
Page 4
• The owner/user can prevent and is responsible for
accidents or injuries occurring to himself or herself,
other people or property.
Preparation
• Evaluate the terrain to determine what accessories and
attachments are needed to properly and safely perform
the job. Only use accessories and attachments
approved by the manufacturer.
• Wear appropriate clothing including hard hat, safety
glasses and hearing protection. Long hair, loose
clothing or jewelry may get tangled in moving parts.
• Inspect the area where the equipment is to be used and
remove all objects such as rocks, toys and wire which
can be thrown by the machine.
• Use extra care when handling gasoline and other fuels.
They are flammable and vapors are explosive.
• Use only an approved container
• Never remove gas cap or add fuel with engine
running. Allow engine to cool before refueling.
Do not smoke.
• Never refuel or drain the machine indoors.
• Check that operator ’s presence controls, safety
switches and shields are attached and functioning
properly. Do not operate unless they are functioning
properly.
Operation
• Never run an engine in an enclosed area.
• Only operate in good light, keeping away from holes
and hidden hazards.
• Be sure all drives are in neutral and parking brake is
engaged before starting engine. Start the engine only
from the operator’s position.
• Never raise deck with the blades running.
• Never operate without the PTO shield, or other guards
securely in place. Be sure all interlocks are functioning
properly.
• Never operate with the discharge deflector raised,
removed or altered, unless using a grass catcher.
• Do not change the engine governor setting or
overspeed the engine.
• Stop on level ground, lower implements, disengage
drives, engage parking brake, shut off engine before
leaving the operator ’s position for any reason
including emptying the catchers or unclogging the
chute.
• Stop equipment and inspect blades after striking
objects or if an abnormal vibration occurs. Make
necessary repairs before resuming operations.
• Keep hands and feet away from the cutting units.
• Never carry passengers and keep pets and bystanders
away.
• Be alert, slow down and use caution when making
turns. Look behind and to the side before changing
directions.
• Slow down and use caution when crossing roads and
sidewalks. Stop blades if not mowing.
• Be aware of the mower discharge direction and do not
point it at anyone.
• Do not operate the mower under the influence of
alcohol or drugs.
• Use extreme care when loading or unloading the
machine into a trailer or truck.
• Use care when approaching blind corners, shrubs,
trees, or other objects that may obscure vision.
Slope Operation
• Do not mow slopes greater than 15 degrees.
• Do not mow near drop–offs, ditches, steep banks or
water. Wheels dropping over edges can cause
rollovers, which may result in serious injury, death or
drowning.
• Do not mow slopes when grass is wet. Slippery
conditions reduce traction and could cause sliding and
loss of control.
• Do not make sudden turns or rapid speed changes.
• Use a walk behind mower and/or a hand trimmer near
drop–offs, ditches, steep banks or water.
• Reduce speed and use extreme caution on slopes.
• Remove or mark obstacles such as rocks, tree limbs,
etc. from the mowing area. Tall grass can hide
obstacles.
• Watch for ditches, holes, rocks, dips, and rises that
change the operating angle, as rough terrain could
overturn the machine.
• Avoid sudden starts when mowing uphill because the
mower may tip backwards.
• Be aware that loss of traction may occur going
downhill. Weight transfer to the front wheels may
cause drive wheels to slip and cause loss of braking
and steering.
• Always avoid sudden starting or stopping on a slope. If
tires lose traction, disengage the blades and proceed
slowly off the slope.
4
Page 5
• Follow the manufacturer ’s recommendations for wheel
weights or counterweights to improve stability.
• Use extreme care with grass catchers or other
attachments. These can change the stability of the
machine and cause loss of control.
Using the Rollover Protection System (ROPS)
• A rollbar is available and its use is recommended for
areas where there are slopes, drop–offs or water.
• When operating a machine with ROPS always use the
seat belt.
• Be certain that the seat belt can be released quickly if
the machine is driven or rolls into ponds or water.
• Check carefully for overhead clearances (i.e. branches,
doorways, electrical wires) before driving under any
objects and do not contact them.
Maintenance and storage
• Disengage drives, lower implement, set parking brake,
stop engine and remove key or disconnect spark plug
wire. Wait for all movement to stop before adjusting,
cleaning or repairing.
• Keep all parts in good working condition and all
hardware tightened. Replace all worn or damaged
decals.
• Use only Toro-approved attachments. Warranty may
be voided if used with unapproved attachments.
• Clean grass and debris from cutting units, drives,
mufflers, and engine to help prevent fires. Clean up oil
or fuel spillage.
• Let engine cool before storing and do not store near
flame.
• Shut off fuel while storing or transporting. Do not store
fuel near flames or drain indoors.
• Park machine on level ground. Never allow untrained
personnel to service machine.
• Use jack stands to support components when required.
• Carefully release pressure from components with
stored energy.
• Disconnect battery or remove spark plug wire before
making any repairs. Disconnect the negative terminal
first and the positive last. Reconnect positive first and
negative last.
• Use care when checking blades. Wrap the blade(s) or
wear gloves, and use caution when servicing them.
Only replace blades. Never straighten or weld them.
• Keep hands and feet away from moving parts. If
possible, do not make adjustments with the engine
running.
• Charge batteries in an open well ventilated area, away
from spark and flames. Unplug charger before
connecting or disconnecting from battery. Wear
protective clothing and use insulated tools.
5
Page 6
Slope Chart
6
Page 7
7
Page 8
Safety and Instruction 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 lost.
1-633345
1-523552
1-633706
1-633462
1-643339
1-633766
1-643401
8
Page 9
1-633818
98-3798
98-4387
1. Warning—wear hearing protection.
54-9220
66-1340
98-5954
43-8480
67-5360
103–0262
9
Page 10
93-7818
1. Warning—read the
torquing the blade bolt/nut to 115–149 N⋅m (85–110 -lb.).
Operator’s Manual
for instructions on
99-4632
1. Engine—stop
2. Engine—run
3. Engine—start
1. Explosion hazard
2. No fire, open flames, or
smoking.
3. Caustic liquid/chemical
burn hazard
103-0368
104-4163
4. Wear eye protection
5. Read the
6. Keep bystanders a safe
104-7759
Manual.
Operator’s
distance from the battery.
99-4686
104-8172
104-8569
10
Page 11
1. Contains lead; do not
discard.
2. Recycle
104-4164
3. Wear eye protection;
explosive gases can cause
blindness and other injuries
4. No sparks, flame, or smoking
103-2433
5. Sulfuric acid can cause
blindness or severe burns.
6. Flush eyes immediately with
water and get medical help
fast.
7. Maximum fill line
8. Minimum fill line
9. Instructions for activating the
battery
106-6570
11
Page 12
106-6571
12
Page 13
Gasoline and Oil
Warning
Recommended Gasoline
Use UNLEADED Regular Gasoline suitable for
automotive use (85 pump octane minimum). Leaded
regular gasoline may be used if unleaded regular is not
available.
Important Never use methanol, gasoline containing
methanol, or gasohol containing more than 10% ethanol
because the fuel system could be damaged. Do not mix oil
with gasoline.
Danger
In certain conditions, gasoline is extremely
flammable and highly explosive. A fire or
explosion from gasoline can burn you and others
and can damage property.
• Fill the fuel tank outdoors, in an open area,
when the engine is cold. Wipe up any gasoline
that spills.
• Never fill the fuel tank inside an enclosed
trailer.
• Do not fill the fuel tank completely full. Add
gasoline to the fuel tank until the level is 1/4 to
1/2 in. (6 to 13 mm) below the bottom of the
filler neck. This empty space in the tank allows
gasoline to expand.
• Never smoke when handling gasoline, and stay
away from an open flame or where gasoline
fumes may be ignited by a spark.
• Store gasoline in an approved container and
keep it out of the reach of children. Never buy
more than a 30-day supply of gasoline.
• Always place gasoline containers on the ground
away from your vehicle before filling.
• Do not fill gasoline containers inside a vehicle
or on a truck or trailer bed because interior
carpets or plastic truck bed liners may insulate
the container and slow the loss of any static
charge.
• When practical, remove gas–powered
equipment from the truck or trailer and refuel
the equipment with its wheels on the ground.
• If this is not possible, then refuel such
equipment on a truck or trailer from a portable
container, rather than from a gasoline
dispenser nozzle.
• If a gasoline dispenser nozzle must be used,
keep the nozzle in contact with the rim of the
fuel tank or container opening at all times until
fueling is complete.
Gasoline is harmful or fatal if swallowed.
Long–term exposure to vapors can cause serious
injury and illness.
• Avoid prolonged breathing of vapors.
• Keep face away from nozzle and gas tank or
conditioner opening.
• Keep gas away from eyes and skin.
Using Stabilizer/Conditioner
Use a fuel stabilizer/conditioner in the machine to provide
the following benefits:
• Keeps gasoline fresh during storage of 90 days or less.
For longer storage it is recommended that the fuel tank
be drained.
• 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 gas stabilizer/conditioner to the
gas.
Note: A fuel stabilizer/conditioner is most effective when
mixed with fresh gasoline. To minimize the chance of
varnish deposits in the fuel system, use fuel stabilizer at
all times.
Filling the Fuel Tank
1. Shut the engine off and set the parking brake.
2. Clean around each fuel tank cap and remove the cap.
Add unleaded regular gasoline to both fuel tanks, until
the level is 1/4 to 1/2 inch (6 to 13 mm) below the
bottom of the filler neck. This space in the tank allows
gasoline to expand. Do not fill the fuel tanks
completely full.
3. Install fuel tank caps securely. Wipe up any gasoline
that may have spilled.
Check Engine Oil Level
Before you start the engine and use the machine, check
the oil level in the engine crankcase; refer to Checking Oil
Level, page 32.
13
Page 14
Setup
Note: Determine the left and right sides of the machine
from the normal operating position.
Loose Parts
Note: Use the chart below to verify all parts have been shipped.
DESCRIPTION QTY. USE
Rear Wheels 2 Installing wheels to traction unit
Retaining rod
Bolt, 5/16 x 1 inch
Locknut, 5/16 inch
Control lever—right
Control lever—left
Bolt, 3/8 x 1 inch
Spring washer, 3/8 inch
Air Filter
Hose Clamp
Key
Operator’s Manual
Engine Operator’s Manual
Parts Catalog
Registration card
Installing the Drive Wheels
1. Uncrate the mower.
2. Remove wheel nuts from rear wheel hubs.
1
1
1
1
1
4
4
1
1
2
1
1
1
1
Installing the seat retaining rod
Installing the motion control levers
Installing the air filter
Read before operating machine
Fill out and return to Toro
1
3. Align holes. Mount drive wheels with the valve stem
to the outside of the traction unit.
4. Secure using wheel nuts provided. Torque to 95 ft–lb
(128 NM).
Important Make sure that wheel nuts are torqued to
95 ft–lb (128 NM).
Checking the Tire Pressure
Check the air pressure in the front and rear tires (Fig. 2).
Pressure: 13 psi (90 kPa)
m–1872
Figure 2
1. Valve stem
Installing the Seat Retaining
Rod
1. Tilt seat up. Remove locknut (5/16 inch) from bolt
attaching seat retaining rod to seat frame (Fig. 3).
14
Page 15
2. Remove retaining rod from seat and insert the L
shaped end of the rod into the hole directly above the
left–side hydraulic pump (Fig. 3).
3. Place the seat retaining rod to the outside of the
mounting tab of the seat frame and secure with one
bolt (5/16 x 1 inch) and locknut (5/16 in.) (Fig. 3).
4. Tighten until snug, then loosen so the rod pivots freely.
1
2
3
m–3750
Figure 3
1. L end of retaining rod
2. Locknut, 5/16 inch
3. Bolt, 5/16 x 1 inch
2
1
4
5
6
3
m–5596
Figure 4
1. Mounting plate
2. Bolt, 3/8 x 1 inch
3. Spring washer, 3/8 inch
4. Top hole
5. Middle hole
6. Bottom hole
5. If the ends of the levers hit against each other, while in
the drive position (Fig 5) (levers rotated in as far as
possible) make adjustments by moving the levers
outward to the neutral lock position and carefully bend
them outward. Move them back to the drive position
and check for clearance. Repeat if necessary.
FRONT
OF
UNIT
Installing the Motion Control
Levers
There are two positions to install the control levers, high
and low. Install levers in the top and middle holes for the
high position. Install levers in the middle and bottom
holes for the low position (Fig. 4).
1. Remove the 4 bolts (3/8 x 1 inch) and 4 spring washers
(3/8 inch) which attach the motion control levers to the
control arm shafts for shipping (Fig. 4).
2. Place the levers (with the mounting plate toward the
rear) on the outside of the control arm shaft and secure
with 4 bolts (3/8 x 1 inch) and 4 spring washers
(3/8 in.) (Fig. 4).
3. Position the levers so the bolts are in the center of the
slots on the lever mounting plate and tighten until
snug.
4. Align the front\rear position of the levers, with each
other, in the neutral position. Loosen hardware and
adjustment by sliding/tilting the lever(s) forward or
backward until properly aligned (Fig. 4).
LEVERS IN
ALIGNMENT
Figure 5
Activating the Battery
Bulk electrolyte with 1.265 specific gravity must be
purchased from a local battery supply outlet.
15
Page 16
Danger
Battery electrolyte contains sulfuric acid which is
a deadly poison and causes severe burns.
• Do not drink electrolyte and avoid contact with
skin, eyes or clothing. Wear safety glasses to
shield your eyes and robber gloves to protect
your hands.
• Fill the battery where clean water is always
available for flushing the skin.
• Follow all instructions and comply with all
safety messages on the electrolyte container.
1. Remove the battery from the machine. Refer to
Removing the Battery on page 44.
2. Clean the top of the battery with a paper towel.
2
3
1
1. Filler caps
2. Upper line
m–5004
Figure 6
3. Lower line
Warning
Note: Never fill the battery with electrolyte while the
battery is installed in the machine. Electrolyte could be
spilled on other parts and cause corrosion.
3. Remove the vent caps from the battery (Fig. 6).
4. Slowly pour electrolyte into each battery cell until the
level is up to the upper line (Fig. 6) on the battery
case.
Important Do not overfill the battery because
electrolyte (sulfuric acid) can cause severe corrosion and
damage to the chassis.
5. Wait five to ten minutes after filling the battery cells.
Add electrolyte, if necessary, until the electrolyte level
is up to the upper line (Fig. 6) on the battery case.
6. Reinstall battery filler caps.
Charging battery produces gasses that can
explode and cause serious injury.
• Keep cigarettes, sparks and flames away from
battery.
• Make sure the ignition switch is off.
• Ventilate when charging or using battery in an
enclosed space.
7. Charge the battery. Refer to Charging the Battery on
page 45.
8. Install the battery into the machine. Refer to Installing
the Battery on page 43.
Note: Do not run the machine with the battery
disconnected, electrical damage may occur.
Installing the Air Cleaner
1. Remove air cleaner from crate. Keep air cleaner and
bracket together. (Fig. 7).
2. Remove the top two valve cover mounting screws
from both valve covers (Fig. 7).
3. Place air cleaner onto engine and align holes in air
cleaner bracket with holes in valve covers (Fig. 7).
4. Install valve cover screws into air cleaner bracket and
valve covers (Fig. 7).
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Page 17
Important Tighten the valve cover screws to 70 in–lb
(5 Nm) torque.
5. Remove plastic plugs from air intake elbow on engine
and air cleaner hose (Fig. 7).
6. Install hose to air intake elbow on engine and air
cleaner. Tighten hose clamps to secure the hose
connections (Fig. 7).
7. With the air intake cap pointing upward, tighten the
tensioning bolt until the clamp ends are a 1/2 inch
(13 mm) apart (Fig. 7).
9
2
8
6
5
4
7
2
3
1
M–5036
Figure 8
1. Spindles
Checking the Side Discharge
Chute
Remove plastic tie holding side discharge chute up and
lower into place.
Checking the Level of Mower
m–4810
Figure 7
1. Air cleaner
2. Valve cover mounting
screws
3. Air cleaner bracket
4. Air intake elbow
5. Air cleaner hose
6. Hose clamp
7. 1/2 inch between clamp
ends
8. T ensioning bolt
9. Air intake cap
Checking the Hydraulic Fluid
Check the hydraulic fluid level before the engine is first
started.
Refer to Checking the Hydraulic Fluid on page 37.
Greasing the Bearings
Important Make sure cutting unit spindles are full of
grease before engine is first started.
Deck
Check the level of the deck before the machine is first put
in use.
Refer to Leveling the Mower on page 45.
Checking the Engine Oil Level
Before you start the engine and use the machine, check
the oil level in the engine crankcase; refer to Checking Oil
Level, page 32.
Grease with No. 2 general purpose lithium base or
molybdenum base grease.
1. Grease the fittings on the three spindle bearings.
Grease until it comes out lower seals (Fig. 8).
17
Page 18
Operation
Caution
Note: Determine the left and right sides of the machine
from the normal operating position.
Think Safety First
Please read all safety instructions and symbols in the
safety section. Knowing this information could help you
or bystanders avoid injury.
Danger
Mowing on wet grass or steep slopes can cause
sliding and loss of control.
Wheels dropping over edges can cause rollovers,
which may result in serious injury, death or
drowning.
A rollbar is available and its use is recommended
for areas where there are slopes, drop–offs or
water.
To avoid loss of control and possibility of rollover:
• Do not mow near drop–offs or near water.
• Do not mow slopes greater than 15 degrees.
• Reduce speed and use extreme caution on
slopes.
• Avoid sudden turns or rapid speed changes.
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.
Wear hearing protection when operating this
machine.
Figure 10
1. Warning—wear hearing protection.
Controls
Become familiar with all the controls (Fig. 11) before you
start the engine and operate the machine.
1
2
7
36
8
2
1
3
m–6478
Figure 9
1. Safe Zone—use the
Z Master here on slopes
less than 15 degrees or
flat areas.
2. Use walk behind mower
and/or hand trimmer near
drop–offs and water.
3. Water
The use of protective equipment for eyes, ears, feet, and
head is recommended.
4
1. Ignition switch
2. Motion control lever
3. Parking brake lever
4. Throttle
5. Choke
9
Figure 11
6. Power take off (PTO)
7. Height-of-Cut lever
8. Fuel cap
9. Fuel shut off lever
10. Hour meter
5
10
M–4507
18
Page 19
Using the 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.
1
Warning
Parking brake may not hold machine parked on a
slope and could cause personal injury or property
damage.
Do not park on slopes unless wheels are chocked
or blocked
m–3077
Figure 12
1. Hour meter
Switching Fuel Tanks
The unit has two fuel tanks, located on the left and right
sides. Each tank connects to the fuel shut off valve in the
control panel. From there a common fuel line leads to the
engine (Fig. 13).
To use the right side fuel tank rotate the fuel shut off valve
1/4 turn to the right from the off location. This uses fuel
from the right side tank only. When the right hand fuel
tank is empty, move the fuel shut off valve 1/4 turn to the
left from the off position.
Close fuel shut off valve, on front panel before
transporting or storing machine.
1
Releasing the Parking Brake
1. Push forward and down on the parking brake lever to
release the parking brake (Fig. 14). The parking brake
is disengaged and the lever rests against the brake
stop.
1
2
3
m–4163
Figure 14
1. Parking brake-ON
2. Parking brake-OFF
3. Brake Stop
Figure 13
1. Shut off valve
Operating the Parking Brake
Always set the parking brake when you stop the machine
or leave it unattended.
Setting the Parking Brake
1. Move the motion control levers (Fig. 11) out to the
neutral lock position.
2. Pull back and up on the parking brake lever to set the
parking brake (Fig. 14). The parking brake lever
should stay firmly in the engaged position.
Starting and Stopping the
Engine
Starting the Engine
1. Sit on the seat and move the motion controls to neutral
locked position.
2. Set the parking brake; refer to Setting the Parking
Brake, page 19.
3. Move the PTO (power take off) switch to off (Fig. 15).
4. Move the choke control to on position before starting a
cold engine.
Note: A warm or hot engine may not require choking.
After engine starts, move choke control to run position.
5. Move the throttle control to the fast position before
starting a cold engine.
19
Page 20
6. Turn ignition key start to energize starter. When
engines starts, release key.
Important Do not engage starter for more than 10
seconds at a time. If engine fails to start allow 30 second
cool-down period between attempts. Failure to follow
these instructions can burn out starter motor.
7. After the engine starts, move the choke to off
(Fig. 16). If the engine stalls or hesitates, move the
choke back to on for a few seconds. Then move the
throttle lever to desired setting. Repeat this as
required.
5. Pull wire off spark plug(s) to prevent possibility of
someone accidentally starting the machine before
transporting or storing machine.
6. Close fuel shut off valve, on front panel before
transporting or storing machine.
Important Make sure that the fuel shut off valve is
closed before transporting or storing the machine, as fuel
leakage may occur. Set the parking brake before
transporting. Make sure to remove the key as the fuel
pump may run and cause the battery to lose charge.
Figure 15
1. PTO-On
2. PTO-Off
2
m–4201
Caution
1
2
1
m–2719
Figure 16
1. Choke–On
2. Choke–Off
1
1
2
3
2
Children or bystanders may be injured if they
move or attempt to operate the tractor while it is
unattended.
Always remove the ignition key and set the
parking brake when leaving the machine
unattended, even if just for a few minutes.
Operating the Power Take Off
(PTO)
The power take off (PTO) switch engages and disengages
power to the electric clutch.
Engaging the PTO
1. While seated in the seat, release pressure on the
traction control levers and place in neutral.
2. Place throttle to the fast position.
3. Pull out on the power take off (PTO) switch to engage
(Fig. 19).
M–4268
Figure 17
1. Throttle–Fast
2. Throttle–Slow
m–2720
Figure 18
1. Off
2. Run
3. Start
Stopping the Engine
1. Push the PTO to off (Fig. 17).
2. Move the throttle lever midway between the slow and
fast positions (Fig. 17).
3. Let the engine idle for 60 seconds (Fig. 18).
4. Turn the ignition key to off (Fig. 18).
2
1
m–4201
Figure 19
1. PTO – Off 2. PTO – On
20
Page 21
Disengaging the PTO
1. To disengage push the PTO switch to the off position
(Fig. 19).
The Safety Interlock System
Caution
the engine is running, release the parking brake,
engage the PTO and rise slightly from the seat; the
engine should stop.
4. Sitting on the seat, engage the parking brake, move
PTO switch to off and move the motion control levers
to neutral lock position. Now start the engine. While
the engine is running, center either motion control and
move (forward or reverse); the engine should stop.
Repeat for other motion control.
If 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:
• You are sitting on the seat.
• The parking brake is engaged.
• The power take off (PTO) is disengaged.
• The motion control levers are in neutral locked
position.
The safety interlock system also is designed to stop the
engine when the traction controls are moved from the
locked position with the parking brake engaged or if you
rise from the seat when the PTO is on engaged.
Testing the Safety Interlock System
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. Sitting on the seat, engage the parking brake and move
PTO to on. Try starting the engine; the engine should
not crank.
2. Sitting on the seat, engage the parking brake and move
PTO to off. Move either motion control lever (out of
neutral locked position). Try starting the engine; the
engine should not crank. Repeat for other control
lever.
3. Sitting on the seat, engage the parking brake, move
PTO switch to off and move the motion control levers
to neutral lock position. Now start the engine. While
5. Sitting on the seat, disengage the parking brake, move
PTO switch to off and move the motion control levers
to neutral lock position. Try starting the engine; the
engine should not crank.
Driving Forward or Backward
The throttle control regulates the engine speed as
measured in rpm (revolutions per minute). Place the
throttle control in the fast position for best performance.
Always operate in the full throttle position when mowing.
Caution
Machine can spin very rapidly. Operator may lose
control of machine and cause personal injury or
damage to machine.
• Use caution when making turns.
• Slow the machine down before making sharp
turns.
Driving Forward
1. Release the parking brake; refer to Releasing the
Parking Brake, page 19.
2. Move levers to the center, un-locked position.
3. To go forward, slowly push the motion control levers
forward (Fig. 20).
Note: Engine will kill if traction control levers are moved
with parking brake engaged.
To go straight, apply equal pressure to both motion control
levers (Fig. 20).
To turn, move the motion control lever toward neutral in
the direction you want to turn (Fig. 20).
The farther you move the traction control levers in either
direction, the faster the machine will move in that
direction.
To stop pull the motion control levers to neutral.
21
Page 22
3
4
1. Motion control
lever-neutral lock position
2. Center un-lock position
Figure 20
3. Forward
4. Backward
1. Raise the height-of-cut lever to the transport position
(also the 5 inch (127 mm) cutting height position)
2
(Fig. 21).
2. To adjust, remove hairpin cotter and clevis pin from
1
height-of-cut bracket (Fig. 21).
3. Select hole in height-of-cut bracket corresponding to
the height-of-cut desired and, insert clevis pin
(Fig. 21).
m–2715
4. Secure clevis pin with hairpin cotter (Fig. 21).
5. Move lever to selected height.
1
Driving Backward
1. Move levers to the center, un-locked position.
2. To go backward, slowly pull the motion control levers
rearward (Fig. 20).
To go straight, apply equal pressure to both motion control
levers (Fig. 20).
To turn, release pressure on the motion control lever
toward the direction you want to turn (Fig. 20).
To stop push the motion control levers to neutral.
Stopping the Machine
To stop the machine, move the traction control levers to
neutral and move to locked position, disengage the power
take off (PTO), and turn the ignition key to off. Also set
the parking brake when you leave the machine; refer to
Setting the Parking Brake, page 19. Remember to remove
the key from the ignition switch.
Caution
2
3
M–4164
Figure 21
1. Height of cut lever
2. Clevis Pin
3. Hairpin Cotter
Using the Lift Assist Lever
The lift assist lever is used along with the height–of–cut
lever for raising the deck. This allows for easier raising of
the deck.
1. Place your foot onto lift assist lever.
2. Press on lift assist while pulling up on height–of–cut
lever (Fig. 22).
Children or bystanders may be injured if they
move or attempt to operate the tractor while it is
unattended.
Always remove the ignition key and set the
parking brake when leaving the machine
unattended, even if just for a few minutes.
Adjusting the Height-of-Cut
The height-of-cut is adjusted from 1-1/2 to 5 inch
(38 to 127 mm) in 1/4 inch (6 mm) increments by
relocating clevis pin in different hole locations.
1
m–5028
Figure 22
1. Lift Assist Lever
22
Page 23
Adjusting the Anti-Scalp
Rollers
Whenever you change the height-of-cut it is
recommended to adjust the height of the anti-scalp rollers.
1. Disengage the power take off (PTO) and turn the
ignition key to off. Move levers to neutral locked
position and apply parking brake. Remove the key.
2. After adjusting height-of-cut remove flange nut and
spring disk while holding stud with wrench (Fig. 23).
Note: Do not remove the wheel nut and washer (Fig. 23).
3. Select hole so gage wheel is positioned to the nearest
corresponding height-of-cut desired (Fig. 23).
4. Reinstall the flange nut and spring disk. Torque to
40–45 ft–lb (54–61 Nm) (Fig. 23).
5. Repeat adjustment on other gage wheels.
1. To adjust, move the lever sideways to unlock seat
(Fig. 24).
2. Slide the seat to the desired position and release lever
to lock in position.
1
m–3655
Figure 24
1. Adjustment lever
Pushing the Machine by Hand
4
3
2
1. Gage Wheel
2. Stud
3. Spring Disk
Figure 23
4. Flange Nut
5. Wheel nut and washer.
Do Not Remove.
1
5
m–4161
Positioning the Seat
The seat can move forward and backward. Position the
seat where you have the best control of the machine and
are most comfortable.
Important Always push the machine by hand. Never
tow the machine because hydraulic damage may occur.
To Push the Machine
1. Disengage the power take off (PTO) and turn the
ignition key to off. Move levers to neutral locked
position and apply parking brake.
2. Rotate the by-pass valves counterclockwise 1 turn to
push. This allows hydraulic fluid to by-pass the pump
enabling the wheels to turn (Fig. 25).
Important Do not rotate by-pass valves more than 1
turn. This prevents valves from coming out of the body
and causing fluid to run out.
3. Disengage parking brake before pushing.
To Operate the Machine
1. Rotate the by-pass valves clockwise 1 turn to operate
machine (Fig. 25).
Note: Do not over tighten the by–pass valves.
23
Page 24
Note: The machine will not drive unless by-pass valves
are turned in.
Warning
1
m–6124
Figure 25
1. By-pass valve
Using a Rollover Protection
System (ROPS)
A ROPS is available and its use is recommended for areas
where there are slopes, drop–offs or water. Contact an
Authorized Service Dealer for information on obtaining
ROPS for your machine.
Important When operating a machine with ROPS
always use the seat belt.
Driving on 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 machine on a public street or
roadway.
Loading Machines
Use extreme caution when loading units on trailers or
trucks. One full width ramp that is wide enough to extend
beyond the rear tires is recommended instead of individual
ramps for each side of the unit (Fig. 26). The lower rear
section of the tractor frame extends back between the rear
wheels and serves as a stop for tipping backward. Having
a full width ramp provides a surface for the frame
members to contact if the unit starts to tip backward. If it
is not possible to use one full width ramp, use enough
individual ramps to simulate a full width continuous ramp.
The ramp should be long enough so that the angles do not
exceed 15 degrees (Fig. 26). A steeper angle may cause
mower deck components to get caught as the unit moves
from ramp to trailer or truck. Steeper angles may also
cause the unit to tip backward. If loading on or near a
slope, position the trailer or truck so it is on the down side
of the slope and the ramp extends up the slope. This will
minimize the ramp angle. The trailer or truck should be as
level as possible.
Transporting Machines
Use a heavy–duty trailer or truck to transport the machine.
Ensure that the trailer or truck has all necessary lighting
and marking as required by law. Please carefully read all
the safety instructions in the safety section. Knowing this
information could help you, your family, pets or
bystanders avoid injury.
To transport the machine:
• Lock brake and block wheels.
• Securely fasten the machine to the trailer or truck with
straps, chains, cable, or ropes.
• Secure a trailer to towing vehicle with safety chains.
Important Do Not attempt to turn the unit while on
the ramp; you may lose control and drive off the side.
Avoid sudden acceleration when driving up a ramp and
sudden deceleration when backing down a ramp. Both
maneuvers can cause the unit to tip backward.
24
Page 25
Warning
Loading a unit onto a trailer or truck increases
the possibility of backward tip–over and could
cause serious injury or death.
• Use extreme caution when operating a unit on a
ramp.
• Use only a single, full width ramp; DO NOT use
individual ramps for each side of the unit.
• If individual ramps must be used, use enough
ramps to create an unbroken ramp surface
wider than the unit.
• Do not exceed a 15 degree angle between ramp
and ground or between ramp and trailer or
truck.
• Avoid sudden acceleration while driving unit up
a ramp to avoid tipping backward.
• Avoid sudden deceleration while backing unit
down a ramp to avoid tipping backward.
1
4
Using the Z Stand
The Z Stand is used for raising the front end of the
machine. This allows for cleaning of the deck and
removal of the blades.
Warning
Unit could fall onto someone and cause serious
injury or death.
• Use extreme caution when operating unit on
Z Stand.
• Use only for cleaning deck and removing
blades.
• Do not keep unit on Z Stand for extended
periods of time.
• Always shut engine off and set parking brake
before performing any maintenance to deck.
Driving up onto the Z Stand
Important Use the Z Stand on a level surface.
1. Raise deck to transport position.
1
m–6841
1. Trailer
2. Full width ramp
3. Not greater than
15 degrees
Figure 26
4. Full width ramp—side
view
2. Remove bracket pin (Fig. 27).
2
3
4
2
5
1
3
m–5599
Figure 27
1. Z Stand
2. Latch
3. Bracket
4. Bracket Pin
5. Bottom of slot
25
Page 26
4
1
3
2
m–5600
Figure 28
1. Z Stand (Positioned in
slot)
2. Crack in side walk or turf
3. Latch resting on pivot tab
3. Raise latch. Swing stand foot out front and slide stand
toward machine, into the bottom of slot
(Fig. 27 and 28).
4. Set foot of stand on the ground and rest latch on pivot
tab (Fig. 28).
5. Start engine and put at half throttle.
Note: For best results, place foot of stand into seams in
sidewalks or into turf (Fig. 28).
6. Drive onto stand. Stop when latch drops over tab into
locked position (Fig. 28). Once onto stand, engage
parking brake. Shut off engine.
3
2
1
m–5601
Figure 29
1. Z Stand
2. Latch
3. Locked position
4. Unlocked position
Tips for Mowing Grass
Fast Throttle Setting
For best mowing and maximum air circulation, operate
the engine at fast. Air is required to thoroughly cut grass
clippings, so do not set the height-of-cut so low as to
totally surround the mower by uncut grass. Always try to
have one side of the mower free from uncut grass, which
allows air to be drawn into the mower.
7. Chock or block the drive wheels.
Warning
Parking brake may not hold machine parked on
Z Stand and could cause personal injury or
property damage.
Do not park on Z Stand unless wheels are chocked
or blocked.
8. Perform maintenance.
9. Remove chocks or blocks.
Driving off the Z Stand
1. Raise latch to unlocked position (Fig. 29).
2. Start engine and place at half throttle. Disengage
parking brake.
3. Slowly drive backwards off of stand.
4. Return stand to its rest position (Fig. 27).
Cutting a Lawn for the First Time
Cut grass slightly longer than normal to ensure the cutting
height of the mower 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 six
inches tall, you may want to cut the lawn twice to ensure
an acceptable quality of cut.
Cut 1/3 of the Grass Blade
It is best to cut only about 1/3 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.
Mowing Direction
Alternate mowing direction to keep the grass standing
straight. This also helps disperse clippings which enhances
decomposition and fertilization.
Mow at Correct Intervals
Normally, mow every four days. But remember, grass
grows at different rates at different times. So to maintain
the same cutting height, which is a good practice, mow
more often in early spring. As the grass growth rate slows
26
Page 27
in mid summer, mow less frequently. If you cannot mow
for an extended period, first mow at a high cutting height;
then mow again two days later at a lower height setting.
Cutting Speed
To improve cut quality, use a slower ground speed in
certain conditions.
Avoid Cutting Too Low
If the cutting width of the mower is wider than the mower
you previously used, raise the cutting height to ensure that
uneven turf is not cut too short.
Long Grass
If the grass is ever allowed to grow slightly longer than
normal, or if it contains a high degree of moisture, raise
the cutting height higher than usual and cut the grass at
this setting. Then cut the grass again using the lower,
normal setting.
When Stopping
If the machine’s forward motion must be stopped 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.
Keep the Underside of the Mower Clean
Clean clippings and dirt from the underside of the mower
after each use. If grass and dirt build up inside the mower,
cutting quality will eventually become unsatisfactory.
Blade Maintenance
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 cutter blades
daily for sharpness, and for any wear or damage. File
down any nicks and sharpen the blades as necessary. If a
blade is damaged or worn, replace it immediately with a
genuine TORO replacement blade.
27
Page 28
Maintenance
Note: Determine the left and right sides of the machine
from the normal operating position.
Recommended Maintenance Schedule
Maintenance Service
Interval
After first 5 hours
Each Use
Every 5 Hours
Every 25 Hours
Every 50 Hours
Every 100 Hours
Every 200 Hours
Maintenance Procedure
• Hydraulic fluid—check level
• Engine Oil—change
• Hydraulic filter—change
• Oil—check level
• Safety System—check
• Mower Housing—clean
• Engine Cooling System—clean
1
• Cutting Blades—check
• Blade Spindle Bearings—grease
• Chassis—grease
• Linkage bushings—oil
1
1
• Hydraulic fluid—check level
• Battery—check electrolyte
• Belts—check for wear/cracks
• Tires—check pressure
• Engine Oil—change
1
• Hydraulic lines—check
• Engine Cooling System—clean
1
• Oil Filter—change (200 hours or every other oil change)
• Hydraulic filter—change
• Spark Plug(s)—check
• Fuel Filter—replace
• Primary air cleaner—service
1
1
Every 500 Hours or at
Storage
Every 600 Hours or at
Storage
Before Storage Service
1
More often in dusty, dirty conditions
• Caster Pivot— adjustment
• Wheel Hub Slotted Nut— adjustment
• Safety air cleaner—replace
1
• Battery–charge, Disconnect cables
• Gasoline—drain
• Chipped Surfaces—paint
• Perform all maintenance procedures listed above before storage
28
Page 29
Caution
If you leave the key in the ignition switch, someone could accidently start the engine and
seriously injure you or other bystanders.
Remove the key from the ignition and disconnect the wire from the spark plug(s) before you do
any maintenance. Set the wire aside so that it does not accidentally contact the spark plug.
Servicing the Cutting Blades
Maintain sharp blades throughout the cutting season
because sharp blades cut 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 cutter blades daily for sharpness, and for any
wear or damage. File down any nicks and sharpen the
blades as necessary. If a blade is damaged or worn,
replace it immediately with a genuine TORO replacement
blade. For convenient sharpening and replacement, you
may want to keep extra blades on hand.
Danger
A worn or damaged blade can break, and a piece
of the blade could be thrown into the operator’s
or bystander’s area, resulting in serious personal
injury or death.
• Inspect the blade periodically for wear or
damage.
• Replace a worn or damaged blade.
1
1. Cutting Edge
2. Curved Area
2
Figure 30
3. Wear/slot Forming
Checking for Bent Blades
1. Rotate the blades until the ends face forward and
backward (Fig. 31). Measure from a level surface to
the cutting edge of the blades (Fig. 32). Note this
dimension.
3
m–151
Before Inspecting or Servicing the
Blades
Disengage the blade control (PTO) and set the parking
brake. Turn the ignition key to off. Remove the key and
disconnect the spark plug wire(s) from the spark plug(s).
Inspecting the Blades
1. Inspect the cutting edges (Fig 30). If the edges are not
sharp or have nicks, remove and sharpen the blades.
Refer to Sharpening the Blades on page 30.
2. Inspect the blades, especially the curved area (Fig. 30).
If you notice any damage, wear, or a slot forming in
this area (item 3 in Fig. 30), immediately install a new
blade.
Front
m–1078
Figure 31
29
Page 30
Sharpening the Blades
Warning
MEASURE FROM CUT-
TING EDGE TO A LEV-
EL SURFACE
m–2539
Figure 32
2. Rotate the opposite ends of the blades forward.
3. Measure from a level surface to the cutting edge of the
blades at the same position as in step 1 above. The
difference between the dimensions obtained in steps 1
and 2 must not exceed 1/8 inch (3 mm). If this
dimension exceeds 1/8 inch (3 mm), the blade is bent
and must be replaced. Refer to Removing the Blades,
and Installing the Blades on page 30.
Warning
A blade that is bent or damaged could break
apart and could seriously injure or kill you or
bystanders.
• Always replace bent or damaged blade with a
new blade.
• Never file or create sharp notches in the edges
or surfaces of blade.
When sharpening blade, pieces of blade could be
thrown and cause serious injury.
Wear proper eye protection when sharpening
blade.
1. Use a file to sharpen the cutting edge at both ends of
the blade (Fig. 33). Maintain the original angle. The
blade retains its balance if the same amount of
material is removed from both cutting edges.
1
m–1854
Figure 33
1. Sharpen a t original angle
2. Check the balance of the blade by putting it on a blade
balancer (Fig. 34). If the blade stays in a horizontal
position, the blade is balanced and can be used. If the
blade is not balanced, file some metal off the end of
the sail area only (Fig. 35). Repeat this procedure until
the blade is balanced.
Removing the Blades
Blades must be replaced if a solid object is hit, if the blade
is out of balance or is bent. To ensure optimum
performance and continued safety conformance of the
machine, use genuine TORO replacement blades.
Replacement blades made by other manufacturers may
result in non-conformance with safety standards.
Warning
Contact with sharp blade can cause serious injury.
Wear gloves or wrap sharp edges of the blade
with a rag.
1. Hold the blade end using a rag or thickly-padded
glove. Remove the blade bolt, spring disk and blade
from the spindle shaft (Fig. 35).
2
1
m–1855
Figure 34
1. Blade 2. Balancer
Installing the Blades
1. Install the blade onto the spindle shaft (Fig. 35).
Important The curved part of the blade must be
pointing upward toward the inside of the mower to ensure
proper cutting.
2. Install the spring disk and blade bolt (Fig. 35). Torque
the blade bolt to 85–110 ft-lb (115–150 Nm).
30
Page 31
3
5
4
1
4
Figure 35
1. Sail Area of Blade
2. Blade
3. Spring Disk
4. Blade Bolt
5. Cone T owards Bolt Head
Servicing the Air Cleaner
3
4
1
2
3
5
M–4226
2
1
m–4815
Figure 36
1. Latches
2. Air cleaner cover
3. Air filter body
4. Primary filter
5. Safety filter
Primary Filter: Check and/or replace after every 200
operating hours or more often in dusty conditions.
Safety Filter: Replace after every 600 operating hours.
Note: Check the filters more frequently if operating
conditions are extremely dusty or sandy.
Removing the Filters
1. Disengage the power take off (PTO), set the parking
brake, and turn the ignition key to off. Remove the
key. Remove spark plug wire(s).
2. Release the latches on the air cleaner and pull the air
cleaner cover off of the air cleaner body (Fig. 36).
3. Clean the inside of the air cleaner cover with
compressed air.
4. Gently slide the primary filter out of the air cleaner
body (Fig. 36). Avoid knocking the filter into the side
of the body.
5. Remove the safety filter only if you intend to replace
it.
Important Never attempt to clean the safety filter. If
the safety filter is dirty, then the primary filter is damaged
and you should replace both filters.
6. Inspect the primary filter for damage by looking into
the filter while shining a bright light on the outside of
the filter. Holes in the filter will appear as bright spots.
If the filter is damaged discard it.
Servicing the Primary Filter
Check and/or replace it after 200 operating hours.
If the primary filter is dirty, bent, or damaged then replace
the filter.
Do not clean the primary filter.
Servicing the Safety Filter
Replace it after 600 operating hours.
Important Never attempt to clean the safety filter. If
the safety filter is dirty, then the primary filter is damaged
and you should replace both filters.
Installing the Filters
Important To prevent engine damage, always operate
the engine with both air filters and cover installed.
1. If installing new filters, check each filter for shipping
damage. Do not use a damaged filter.
2. If the safety filter is being replaced, carefully slide it
into the filter body (Fig. 36).
3. Carefully slide the primary filter over the safety filter
(Fig. 36). Ensure that it is fully seated by pushing on
the outer rim of the filter while installing it.
Important Do not press on the soft inside area of the
filter.
4. Install the air cleaner cover with the side indicated as
UP facing up and secure the latches (Fig. 36).
31
Page 32
Servicing the Engine Oil
Change oil:
• After the first 8 operating hours.
• After every 100 operating hours.
Note: Change oil more frequently when operating
conditions are extremely dusty or sandy.
Oil Type: Detergent oil (API service SG or SH)
Crankcase Capacity: w/filter, 67 oz. (2.0 l)
Viscosity: See table below
USE THESE SAE VISCOSITY OILS
2
m–4811
1. Oil dipstick
2. Filler tube
3
1
m–3219
Figure 37
3. Metal end
10W–30, 10W–40
5W–20, 5W–30
–20 0 20
40 60
32
80 100
F
–30 –20 –10
01020
30 40
C
Checking the Engine Oil Level
Note: Check oil when engine is cold.
1. Disengage the power take off (PTO) and turn the
ignition key to off. Move levers to neutral locked
position and apply parking brake. Remove the key.
2. Clean around the oil dipstick (Fig. 37) so dirt cannot
fall into the filler hole and damage the engine.
3. Pull the oil dipstick and wipe the metal end clean
(Fig. 37).
4. Slide the oil dipstick fully into the filler tube. Pull the
dipstick out and look at the metal end (Fig. 37). If oil
level is low, slowly pour only enough oil into the filler
tube to raise the level to the full mark.
Changing the Engine Oil
1. Start the engine and let it run five minutes. This warms
the oil so it drains better.
2. Park the machine so that the drain side is slightly
lower than the opposite side to assure the oil drains
completely. Disengage the power take off (PTO), set
the parking brake, and turn the ignition key to off.
Remove the key.
3. Place a pan below the oil drain. Use either a flat screw
driver, 3/8 inch or 10 mm wrench to open valve
(Fig. 38).
4. Rotate valve end clockwise to close valve. Rotate
valve end counterclockwise to open valve (Fig. 38).
Note: Dispose of the used oil at a certified recycling
center.
1
Important Do not overfill the crankcase with oil
because the engine may be damaged. Do not run engine
with oil below the low mark because the engine may be
damaged.
m–5624
Figure 38
1. Oil drain valve
5. Slowly pour approximately 80% of the specified oil
into the filler cap (Fig. 37). Refer to Servicing the
Engine Oil, page 32.
6. Check the oil level; refer to Checking the Oil Level,
page 32.
7. Slowly add additional oil to bring it to the full mark.
32
Page 33
Changing the Engine Oil Filter
Removing the Spark Plug(s)
Replace the oil filter every 200 hours or every other oil
change.
Note: Change oil filter more frequently when operating
conditions are extremely dusty or sandy.
1. Drain the oil from the engine; refer to
Changing/Draining Oil, page 32.
2. Remove the old filter and wipe the filter adapter
(Fig. 39) gasket surface.
3. Pour new oil of the proper type in through the center
hole. Stop pouring when the oil reaches the bottom of
the threads. Allow a minute or two for the oil to be
absorbed by filter material.
4. Apply a thin coat of new oil to the rubber gasket on
the replacement filter (Fig. 39).
3
1. Disengage the power take off (PTO) and turn the
ignition key to off. Move levers to neutral locked
position and apply parking brake. Remove the key.
2. Pull the wire(s) off the spark plug(s) (Fig. 40). Now
clean around the spark plug(s) to prevent dirt from
falling into the engine and potentially causing damage.
3. Remove the spark plug(s) and metal washer.
1
2
m–3218
Figure 40
1. Spark plug wire 2. Spark plug
1
2
m–1256
Figure 39
1. Oil filter
2. Gasket
3. Adapter
5. Install the replacement oil filter to the filter adapter.
Turn the oil filter clockwise until the rubber gasket
contacts the filter adapter, then tighten the filter an
additional 1/2 turn (Fig. 39).
6. Fill the crankcase with the proper type of new oil;
refer to Changing the Engine Oil, page 32.
Servicing the Spark Plug
Check the spark plug(s) after every 200 operating hours.
Make sure 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(s) and a gapping tool/feeler gauge to check and
adjust the air gap. Install a new spark plug(s) if necessary.
Type: Champion RC12YC or equivalent
Air Gap: 0.030 inch (0.76 mm)
Checking the Spark Plug
1. Look at the center of the spark plug(s) (Fig. 41). 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.
Important Never clean the spark plug(s). Always
replace the spark plug(s) when it has: a black coating,
worn electrodes, an oily film, or cracks.
2. Check the gap between the center and side electrodes
(Fig. 41). Bend the side electrode if the gap is not
correct (Fig. 41).
33
Page 34
2
1
3
0.030 inch
(0.76 mm)
m–3215
Figure 41
1. Center electrode insulator
2. Side electrode
3. Air gap (not to scale)
Installing the Spark Plug(s)
1. Install the spark plug(s). Make sure the air gap is set
correctly.
2. Tighten the spark plug(s) to 20 ft-lb (27 N.m).
3. Push the wire(s) onto the spark plug(s) (Fig. 40).
Servicing the Fuel Filter
Replace the fuel filter after every 200 operating hours or
yearly, whichever occurs first.
Replacing the Fuel Filter
Never install a dirty filter if it is removed from the fuel
line.
1
2
m–3217
Figure 42
1. Filter 2. Hose clamp
Servicing the Fuel Tank
Draining The Fuel Tank
Danger
In certain conditions, gasoline is extremely
flammable and highly explosive. A fire or
explosion from gasoline can burn you and others
and can damage property.
• Drain gasoline from the fuel tank when the
engine is cold. Do this outdoors in an open area.
Wipe up any gasoline that spills.
• Never smoke when draining gasoline, and stay
away from an open flame or where a spark may
ignite the gasoline fumes.
1. Disengage the power take off (PTO) and turn the
ignition key to off. Move levers to neutral locked
position and apply parking brake. Remove the key.
2. Close fuel shut–off valve on console.
3. Squeeze the ends of the hose clamps together and slide
them away from the filter (Fig. 42).
4. Remove the filter from the fuel lines.
5. Install a new filter and move the hose clamps close to
the filter (Fig. 43).
6. Wipe up any spilled fuel.
7. Open fuel shut-off valve on console.
1. Park the machine on a level surface, to assure fuel tank
drains completely. Then disengage the power take off
(PTO), set the parking brake, and turn the ignition key
to off. Remove the key.
2. Close fuel shut–off valve (Fig. 43).
3. Loosen the hose clamp at the fuel filter and slide it up
the fuel line away from the fuel filter (Fig. 43).
4. Pull the fuel line off fuel filter (Fig. 43). Open fuel
shut-off valve and allow gasoline to drain into a gas
can or drain pan.
Note: Now is the best time to install a new fuel filter
because the fuel tank is empty.
34
Page 35
5. Install the fuel line onto the fuel filter. Slide the hose
clamp close to the fuel filter to secure the fuel line
(Fig. 43).
3
1
5. Remove grease zerk in hole. Reinstall hex plug and
cap.
Where to Add Grease
Lubricate the grease fittings as shown on the Check
Service Reference Aid decal (Fig. 44).
4
1. Fuel shut-off valve
2. Fuel filter
2
Figure 43
3. Hose clamp
4. Fuel line
m–3717
Greasing and Lubrication
Lubricate the machine when shown on the Check Service
Reference Aid decal (Fig. 44). Grease more frequently
when operating conditions are extremely dusty or sandy.
Grease Type: General-purpose grease.
How to Grease
1. Disengage the power take off (PTO) and turn the
ignition key to off. Move levers to neutral locked
position and apply parking brake. Remove the key.
2. Clean the grease fittings with a rag. Make sure to
scrape any paint off the front of the fitting(s).
3. Connect a grease gun to the fitting. Pump grease into
the fittings until grease begins to ooze out of the
bearings.
Figure 44
Where to Add Light Oil or Spray
Lubrication
Lubricate the machine in the following areas with spray
type lubricant or light oil. Lubricate every 160 hours.
• Seat switch actuator.
• Brake handle pivot.
• Brake rod bushings.
• Motion control bronze bushings.
4. Wipe up any excess grease.
Greasing the Front Caster Pivots
Lubricate the front caster pivots once a year.
1. Remove the dust cap and adjust the caster pivots. Keep
dust cap off until greasing is done.
2. Adjust the caster pivot bearing. Refer to Adjusting the
Caster Pivot Bearing, page 37.
3. Remove the hex plug. Thread a grease zerk into hole.
4. Pump grease into zerk until it oozes out around top
bearing.
Greasing the Bearings
The cutting unit must be lubricated daily. Refer to the
Service Interval Chart on page 28. Grease with No. 2
general purpose lithium base or molybdenum base grease.
Important Make sure cutting unit spindles are full of
grease daily.
1. Stop the engine, set the parking brake, remove the key
and disconnect the spark plug wire(s) from the spark
plug(s).
2. Grease the fittings on the three spindle bearings until
grease comes out lower seals (Fig. 45).
3. Grease the fittings on the push arms(Fig. 45).
35
Page 36
M–5036
1
2
1. Panel
2. Engine shroud
3
m–5766
Figure 47
3. Screws
Figure 45
Cleaning the Cooling Systems
Cleaning the Engine Screen and the Oil
Cooler
Before each use, check and clean engine screen and oil
cooler. Remove any build–up of grass, dirt or other debris
from the oil cooler screen and engine air intake (Fig. 46).
1
2
m–3801
Figure 46
1. Engine screen 2. Oil cooler
Checking the Tire Pressure
Maintain the air pressure in the front and rear tires as
specified. Uneven tire pressure can cause uneven cut.
Check the pressure at the valve stem after every 50
operating hours or monthly, whichever occurs first
(Fig. 48). Check the tires when they are cold to get the
most accurate pressure reading.
Pressure: 13 psi (90 kPa) drive wheels and caster wheels.
1
m–1872
Figure 48
1. Valve stem
Checking the Wheel Hub
Slotted Nut
Cleaning the Engine Fins
Every 100 hours clean the engine cylinder and cylinder
head cooling fins. Also clean around carburetor, governor
levers and linkage. This will ensure adequate cooling of
the engine and will reduce the possibility of overheating
and mechanical damage.
1. Remove the panels from the engine shroud.
2. Clean the engine cooling fins.
3. Install the panels onto the engine shroud.
Check after every 500 operating hours.
The slotted nut needs to be torqued to 125ft–lb
(169 Nm).
1. Stop the engine, set the parking brake, remove the key
and disconnect the spark plug wire(s) from the spark
plug(s).
2. Remove cotter pin.
3. Torque slotted nut to 125ft–lb (169 Nm) (Fig. 49).
4. Check the distance from bottom of slot in nut to inside
edge of hole. Two threads or less should be showing
(Fig. 49).
5. If more than two threads are showing remove nut and
install washer between hub and nut (Fig. 49).
36
Page 37
6. Torque the slotted nut to 125ft–lb (169 Nm) (Fig. 49).
7. Tighten nut until the next set of slots line up with the
hole in the shaft (Fig. 49).
3
2
8. Replace cotter pin.
1
4
3
2
m–4638
Figure 49
1. Slotted Nu t
2. Two threads or less
showing
3. Hole in threaded rod
4. Washer (if needed)
Adjusting the Caster Pivot
Bearing
Check after every 500 operating hours or at storage, which
ever comes first.
1. Stop the engine, set the parking brake, remove the key
and disconnect the spark plug wire(s) from the spark
plug(s).
1
M–4640
Figure 50
1. Spring Washers
2. Lock Nut
3. Dust Cap
Servicing the Hydraulic
System
Checking the Hydraulic Fluid
Check the hydraulic fluid level before engine is first
started.
Check the hydraulic fluid level after first 8 operating
hours.
Check the hydraulic fluid level after every 25 operating
hours.
Fluid Type: Mobil 1 15W-50 synthetic motor oil or
equivalent synthetic oil.
2. Remove dust cap from caster and tighten lock nut
(Fig. 50).
3. Tighten until spring washers are flat and then back off
a 1/4 turn to properly set the pre–load on the bearings
(Fig. 50).
Important Make sure spring washers are installed
correctly as shown in figure 50.
Important Use oil specified or equivalent. Other
fluids could cause system damage.
Hydraulic System Oil Capacity: 67 oz. (2.0 l)
Note: There are two ways of checking the hydraulic oil.
One is when the oil is warm and one is when the oil is
cold. The baffle inside the tank has two levels depending
if the oil is warm or cold.
1. Position machine on a level surface and set the parking
brake.
2. Clean area around filler neck of hydraulic tank
(Fig. 51).
3. Remove cap from filler neck. Look inside to check if
there is fluid in the reservoir. (Fig. 51).
4. If there is no fluid, add fluid to the reservoir until it
reaches the cold level of the baffle.
37
Page 38
5. Run the machine at low idle for 15 minutes to allow
any air to purge out of the system and warm fluid.
Refer to Starting and Stopping the Engine on page 19.
6. Recheck the fluid level while the fluid is warm. If
required, add fluid to the reservoir until it reaches the
hot level of the baffle.
Note: The fluid level should be to the top of the hot level
of the baffle, when the fluid is warm (Fig. 51).
7. Install cap on filler neck.
1
2
4
m–5615
Figure 51
1. Cap
2. Baffle
3. Cold fluid level—full
4. Hot fluid level—full
Replacing the Hydraulic Filter
Change the hydraulic filter:
• After the first 8 operating hours.
• After every 200 operating hours.
1. Disengage the power take off (PTO) and turn the
ignition key to off. Move levers to neutral locked
position and apply parking brake. Remove the key.
Important Do not substitute automotive oil filter or
severe hydraulic system damage may result.
2. Remove hydro cap and temporarily cover opening
with a plastic bag and rubber band to prevent all hydro
fluid from draining out.
3. Place drain pan under filter, remove the old filter and
wipe the filter adapter gasket surface clean (Fig. 52).
3
1
M–4763
Warning
Hydraulic fluid escaping under pressure can
penetrate skin and cause injury.
• If hydraulic fluid is injected into the skin it
must be surgically removed within a few hours
by a doctor familiar with this type of injury.
Gangrene may result if this is not done.
• Keep body and hands away from pin hole 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.
• Make sure all hydraulic fluid hoses and lines
are in good condition and all hydraulic
connections and fittings are tight before
applying pressure to hydraulic system.
Figure 52
1. Hydraulic filter
4. Apply a thin coat hydro fluid to the rubber gasket on
the replacement filter (Fig. 53).
5. Install replacement hydraulic filter onto the filter
adapter. Do not tighten.
6. Remove plastic bag from tank opening and allow filter
to fill with hydro fluid.
7. When fluid overflows filter turn the oil filter clockwise
until the rubber gasket contacts the filter adapter, then
tighten the filter an additional 1/2 turn (Fig. 53).
8. Clean up any spilled fluid.
9. If there is no fluid, add fluid to reservoir
approximately a 1/4 inch (6mm) below the top of
baffle.
10.Start engine and let run for about two minutes to purge
air from the system. Stop the engine and check for
leaks. If one or both wheels will not drive, refer
Bleeding the Hydraulic System, page 39.
38
Page 39
11. Recheck level while fluid is warm. Add fluid to raise
level to top of the baffle, if required. Do not overfill.
1. Hydraulic filter
2. Gasket
1
Figure 53
3. Adapter
3
2
m–1256
Bleeding the Hydraulic System
The traction system is self bleeding, however, it may be
necessary to bleed the system if fluid is changed or after
work is performed on the system.
1. Raise rear of the machine so wheels are off the ground
and support with jack stands.
2. Start the engine and run at idle speed. Engage traction
on one side and spin the wheel by hand.
3. When the wheel begins to spin on its own, keep it
engaged until wheel drives smoothly. (minimum
2 minute)
4. Check hydraulic fluid level as it drops and add as
required to maintain proper level.
5. Repeat procedure on opposite wheel.
Checking the Hydraulic Lines
After every 100 operating hours, check hydraulic lines and
hoses for leaks, loose fittings, kinked lines, loose
mounting supports, wear, weather and chemical
deterioration. Make necessary repairs before operating.
Warning
Hydraulic fluid escaping under pressure can
penetrate skin and cause injury.
• If hydraulic fluid is injected into the skin it
must be surgically removed within a few hours
by a doctor familiar with this type of injury.
Gangrene may result if this is not done.
• Keep body and hands away from pin hole 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.
• Make sure all hydraulic fluid hoses and lines
are in good condition and all hydraulic
connections and fittings are tight before
applying pressure to hydraulic system.
Adjusting the Handle Neutral
If motion control levers do not align, or move easily into
the console notch, adjustment is required. Adjust each
lever, spring and rod separately.
Note: Motion control levers must be installed correctly.
See Installing the Motion Control Levers, page 15.
1. Stop the engine, remove ignition key and tilt seat
forward.
2. Begin with either the left or right motion control lever.
3. Move lever to the neutral position but not locked
(Fig. 55).
4. Pull lever back until the clevis pin (on arm below pivot
shaft) contacts the end of the slot (just beginning to put
pressure on the spring) (Fig. 55).
5. Check where the control lever is relative to notch in
console (Fig. 54). It should be centered allowing lever
to pivot outward to the neutral lock position.
Note: Keep areas around hydraulic system clean from
grass and debris build up.
39
Page 40
Setting the Hydraulic Pump
2
3
Neutral
Note: Adjust handle neutral first. That has to be correct
before the following adjustment can be made.
1
m–6282
Figure 54
1. Neutral locked position
2. Control lever
3. Neutral potion
6. If adjustment is needed, loosen the nut and jam nut
against the yoke (Fig. 55).
7. Apply slight rearward pressure on the motion control
lever, turn the head of the adjustment bolt in the
appropriate direction until the control lever is centered
in neutral lock position (Fig. 54).
Note: Keeping rearward pressure on the lever will keep
the pin at the end of the slot and allow the adjustment bolt
to move the lever to the appropriate position.
8. Tighten the nut and jam nut (Fig. 55).
9. Repeat on the opposite side of unit.
1
2
9
6
7
3
Danger
Mechanical or hydraulic jacks may fail to support
machine and cause a serious injury.
• Use jack stand when supporting machine.
• Do not use hydraulic jacks.
Warning
Engine must be running so motion control
adjustment can be performed. Contact with
moving parts or hot surfaces may cause personal
injury.
Keep hands, feet, face, clothing and other body
parts away from rotating parts, muffler and other
hot surfaces.
This adjustment must be made with drive wheels turning.
1. Raise the frame and block up the machine so drive
wheels can rotate freely.
2. Disconnect electrical connector from the seat safety
switch. Temporarily install a jumper wire across
terminals in the wiring harness connector.
3. Slide seat forward, disconnect prop rod and tilt seat
fully forward.
1011
4
1. Clevis pin in slot
2. Nut against yoke
3. Adjustment bolt
4. Pump rod
5. Double nuts
6. Jam Nut
Figure 55
7. Spring
8. Pivot shaft
9. Yoke
10. Locknut
11. Ball joint
Setting the Right–hand Hydraulic Pump
Neutral
1. Start the engine, open throttle 1/2 way and release
parking brake. Refer to Starting and Stopping the
8
11
10
5
M–6278
40
Engine, page 19.
Note: Motion control lever must be in neutral while
making any adjustments.
2. Adjust pump rod length by rotating the knob, in the
appropriate direction, until the wheel is still or slightly
creeping in reverse (Fig. 56).
3. Move motion control lever forward and reverse, then
back to neutral. Wheel must stop turning or slightly
creep in reverse.
4. Open throttle to fast. Make sure wheel remains
stopped or slightly creeps in reverse, adjust if
necessary.
Page 41
2
1
4
Electrical system will not perform proper safety
shut off with jumper wire installed.
• Remove jumper wire from wire harness
connector and plug connector into seat switch
when adjustment is completed.
• Never operate this unit with jumper installed
and seat switch bypassed.
7. After both pump neutrals are set, shut off the machine.
8. Remove jumper wire from wire harness connector and
plug connector into seat switch.
Warning
3
m–6281
Figure 56
1. Tracking knob
2. Pump rod
3. Adjustment bolt
4. Yoke
Setting the Left–hand Hydraulic Pump
Neutral
1. Loosen the locknuts at the ball joints on pump control
rod (Fig. 55).
2. Start the engine, open throttle 1/2 way and release
parking brake. Refer to Starting and Stopping the
Engine, page 19.
Note: Motion control lever must be in neutral while
making any adjustments.
Note: The front nut on the pump rod has left–hand
threads.
3. Adjust pump rod length by rotating double nuts on rod,
in the appropriate direction, until wheel is still or
slightly creeps in reverse (Fig. 55).
4. Move motion control lever forward and reverse, then
back to neutral. Wheel must stop turning or slightly
creep in reverse.
9. Reinstall prop rod and lower the seat into position.
Adjusting the Tracking
The right hand pump has a knob for adjusting the
tracking.
Important Adjust the handle neutral and hydraulic
pump neutral before adjusting the tracking. Refer to
Adjusting the Handle Neutral on page 39 and Adjusting
the Hydraulic Pump Neutral on page 40.
1. Push both control levers forward the same distance.
2. Check if the machine pulls to one side. If it does, stop
the machine and set the parking brake.
3. Tip the seat up to access the tracking knob.
Note: Determine the left and right sides of the machine
from the normal operating position.
4. To make the machine go right, turn the knob towards
the rightside of the machine. Refer to figure 57.
5. To make the machine go left, turn the knob towards
the leftside of the machine. Refer to figure 57.
6. Repeat adjustment until the tracking is correct.
5. Open throttle to fast. Make sure wheel remains
stopped or slightly creeps in reverse, re-adjust if
necessary.
6. Tighten the locknuts at the ball joints (Fig. 55).
41
Page 42
2
3
4
1
m–6280
Figure 57
1. Pump rod
2. Turn this way to track left
3. Tracking knob
4. Turn this way to track right
Replacing the Pump Drive Belt
2. Measure the length of the spring. Measurement should
be 2-3/4 inch (70 mm) between washers (Fig. 59).
3. If adjustment is necessary, loosen the jam nut below
the spring and tighten the nut directly below the yoke
(Fig. 59). Turn the nut until the correct measurement is
obtained. Tighten the two nuts together and repeat on
opposite side of unit.
4. Turn nuts clockwise to shorten spring length and turn
counter–clockwise to lengthen the spring.
5. Engage parking brake, lever up.
6. Measure the distance between the trunnion roller and
the collar on brake rod. Measurement should be
3/16–1/4 inch (5–7 mm) (Fig. 59).
7. If adjustment is necessary, loosen the jam nut directly
below the yoke. Turn the bottom rod until the correct
measurement is obtained (Fig. 59). Tighten jam nut at
yoke.
4
5
Check pump drive belt for wear after every 50 hours of
operation.
1. Pull spring loaded idler down and remove traction belt
from the engine and hydro pump pulleys (Fig. 58).
Remove belt between pulleys.
2. Install new belt around engine and hydro pump pulleys
(Fig. 58).
3. Pull spring loaded idler down and align below traction
belt. Release pressure on spring loaded idler (Fig. 58).
Figure 58
6
1
2
3
m–3788
Figure 59
1. Brake lever
2. Spring, 2.75 inch (70 mm)
3. Adjusting nuts
4. Collar on brake rod
5. 3/16–1/4 inch (5–7 mm)
6. Jam nut and yoke
Servicing the Fuse
Service Interval/Specification
The electrical system is protected by fuses. It requires no
maintenance, however, if a fuse blows check
component/circuit for malfunction or short.
Adjustment Parking Brake
Check parking brake for proper adjustment.
1. Disengage brake lever (lever down).
Fuse: Main F1–20 amp, blade-type
Alternator F2–20 amp, blade-type
1. Raise the seat to gain access to fuse holder (Fig. 60).
2. To replace fuses pull out on the fuse to remove it
(Fig. 60).
42
Page 43
2
1
1
m–3653
Figure 60
1. Main-20 a m p 2. Alternator-20 amp
Servicing the Battery
Warning
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.
Checking the Electrolyte Level
1. With the engine off, locate the battery under the seat.
2
3
Figure 61
1. Filler caps
2. Upper line
3. Lower line
Danger
Battery electrolyte contains sulfuric acid which is
a deadly poison and causes severe burns.
• Do not drink electrolyte and avoid contact with
skin, eyes or clothing. Wear safety glasses to
shield your eyes and robber gloves to protect
your hands.
• Fill the battery where clean water is always
available for flushing the skin.
• Follow all instructions and comply with all
safety messages on the electrolyte container.
m–5004
2. Look at the side of the battery. The electrolyte must be
up to the upper line (Fig. 61). Do not allow the
electrolyte to get below the lower line (Fig. 61).
3. If the electrolyte is low, add the required amount of
distilled water; refer to Adding Water to the Battery,
page 44.
Installing the Battery
1. Position battery in tray with terminal posts toward the
engine (Fig. 62).
2. First, install the positive (red) battery cable to positive
(+) battery terminal.
3. Then install negative battery cable and ground wire to
the negative (–) battery terminal.
4. Secure cables with 2 bolts (1/4 x 3/4 inch), 2 washers
(1/4 inch), and 2 locknuts (1/4 inch) (Fig. 62).
43
Page 44
5. Slide the red terminal boot onto the positive (red)
6
7
3
8
battery post.
Warning
6. Secure battery with J-bolts, hold down clamp and 2
washers (1/4 inch), and 2 wing nuts (1/4 inch)
(Fig. 62).
9 5
4
11
7
10
1
m–5598
Figure 62
1. Battery
2. Terminal boot
3. Positive battery cable
4. Negative battery cable
5. Ground wire
6. Bolt, 1/4 x 3/4 inch
7. Washer, 1/4 inch
8. Locknut, 1/4 inch
9. Battery clamp
10. J-bolts
11. Wing nut, 1/4 inch
Incorrect battery cable routing could damage the
machine and cables causing sparks. Sparks can
cause the battery gasses to explode, resulting in
personal injury.
2
• Always Disconnect the negative (black) battery
cable before disconnecting the positive (red)
cable.
• Always Reconnect the positive (red) battery
cable before reconnecting the negative (black)
cable.
1. Disengage the power take off (PTO), set the parking
brake, and turn the ignition key to off. Remove the
key.
2. Tilt seat up.
3. First disconnect the negative battery cable and ground
wire from the negative (–) battery terminal (Fig. 62).
4. Slide the red terminal boot off the positive (red)
battery terminal. Then remove positive (red) battery
cable (Fig. 62).
5. Remove both wing nuts (1/4 inch) securing the battery
clamp (Fig. 62).
6. Remove the battery.
Adding Water to the Battery
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.
The best time to add distilled water to the battery is just
before you operate the machine. This lets the water mix
thoroughly with the electrolyte solution.
1. Remove the battery from the machine.
2. Clean the top of the battery with a paper towel.
Note: Never fill the battery with distilled water while the
battery installed in the machine. Electrolyte could be
spilled on other parts and cause corrosion.
3. Remove the vent caps from the battery (Fig. 61).
4. Slowly pour distilled water into each battery cell until
the level is up to the upper line (Fig. 61) on the
battery case.
Important Do not overfill the battery because
electrolyte (sulfuric acid) can cause severe corrosion and
damage to the chassis.
5. Wait five to ten minutes after filling the battery cells.
Add distilled water, if necessary, until the electrolyte
level is up to the upper line (Fig. 61) on the battery
case.
44
Page 45
6. Reinstall battery vent caps.
Leveling the Mower
Charging the Battery
Warning
Charging the battery produces gasses that can
explode.
Never smoke near the battery and keep sparks
and flames away from battery.
Important Always keep the battery fully charged
(1.265 specific gravity). This is especially important to
prevent battery damage when the temperature is below
32°F (0°C).
1. Remove the battery from the chassis; refer to
Removing the Battery, page 44.
2. Check the electrolyte level; refer to Checking
Electrolyte Level, page 43.
3. Make sure the filler caps are installed in battery.
Charge battery for 10 to 15 minutes at 25 to 30 amps
or 30 minutes at 4–6 amps.
4. When the battery is fully charged, unplug the charger
from the electrical outlet, then disconnect the charger
leads from the battery posts (Fig. 63).
4
2
3
1
1. Position mower on a flat surface. Stop the engine, set
the parking brake, remove the key and disconnect the
spark plug wire(s) from the spark plug(s).
2. Check tire pressure of all four (4) tires. If needed,
adjust to 13 psi (90 kPa)
3. Set anti–scalp rollers to top holes or remove them
completely for this adjustment.
4. Raise the deck to the transport position and take all
force off of the two large deck lift springs by loosening
nut in front of each spring (Fig. 65).
5. Place two 1-1/2 inch (38 mm) thick blocks under rear
left and right lower edge of mower. Place one
2–1/4 inch (57 mm) block under front center lower
edge of mower. Lower mower to the 2 inch (51 mm)
height-of-cut position (Fig. 64).
1
2
m–4164
Figure 64
1. Transport position 2. 2 inch (51 mm)
height-of-cut
Figure 63
1. Positive Battery Post
2. Negative Battery Post
3. Red (+) Charger Lead
4. Black (–) Charger Lead
5. Install the battery in the machine and connect the
battery cables; refer to Installing the Battery on
page 43.
Note: Do not run the machine with the battery
disconnected, electrical damage may occur.
m–4970
6. Loosen the four top chain bolts in slots. Check the
length of the rod/swivel assemblies. Distance from
outside of rear swivel to outside of front swivel should
be 19–17/32 inch (496 mm) (Fig. 65). Make sure that
all four swivels move freely in holes.
7. If measurement is not 19–17/32 inch (496 mm) on
each side, adjust by turning nuts on either side of front
swivels.
8. Lift up on the four top chain attachment bolts, in the
slots, to take slack out of chains and tighten flange
lock nuts. (Deck is still supported by two rear and a
front block under mower.)
9. If bolts contact the end of slots, shorten or lengthen
rod/swivel assemblies as required, for extra clearance,
adjust each side same amount.
45
Page 46
Note: When properly adjusted, the front blade tip will be
slightly lower than the rear blade tip. See Checking for
Bent Blades on page 29 to measure.
1
2. Raise the deck to the transport position.
3. Raise the front of the machine by using the Z Stand;
refer to Using the Z Stand, page 25.
Warning
Unit could fall onto someone and cause serious
injury or death.
3
2
Figure 65
1. 19–17/32 inch (496 mm)
outside swivels
2. T op chain bolt
10.Recheck that blocks just fit just under the mower and
that tension on all four chains is approximately equal.
Tighten chain attachment bolts securely.
11. Measure height of cut. This can be checked with the
same procedure as Checking for Bent Blades on page
29.
12.Install anti–scalp rollers for proper height-of-cut and
tighten securely.
3. Front swivel
4. 10–1/4 inch (260 mm)
4
spring compressed
2
m–3747
Compression Spring Adjustment
1. Raise deck lift lever to the transport position, (Fig. 64).
2. Springs are compressed so the distance between the
two large washers should be 10–1/4 inch (260 mm)
(Fig. 65).
3. Adjust by turning nut in front of each spring (Fig. 65).
Clockwise will shorten spring, counter–clockwise will
lengthen spring.
• Use extreme caution when operating unit on
Z Stand.
• Use only for cleaning deck and removing
blades.
• Do not keep unit on Z Stand for extended
periods of time.
• Always shut engine off and set parking brake
before performing any maintenance to deck.
Belt Inspection
Inspect all belts every 100 hours.
1. Check belts for cracks, frayed edges, burn marks or
any other damage. Replace damaged belts.
Replacing the Deck Belt
Squealing when the belt is rotating, blades slipping when
cutting grass, frayed belt edges, burn marks and cracks are
signs of a worn deck belt. Replace the deck belt if any of
these conditions are evident.
1. Stop the engine, set the parking brake, remove the key
and disconnect the spark plug wire(s) from the spark
plug(s).
2. Remove the PTO drive belt. Refer to Replacing the
PTO Drive Belt, on page 47.
3. Loosen two nuts securing idler plate and move the
idler arm to relieve belt tension on the idler pulley,
then remove the worn deck belt (Fig. 66).
Cleaning Under the Deck
Remove grass buildup under the deck daily.
1. Position the mower on a flat surface. Stop the engine,
set the parking brake, remove the key, and disconnect
the spark plug wire(s) from the spark plug(s).
4. Install the new deck belt around the spindle pulleys,
belt guide, the idler pulley, and in the lower groove of
the center spindle pulley (Fig. 66).
5. Using a socket and torque wrench, rotate the idler
adjusting nut until torque is 25–30 ft–lb (34–41 Nm).
Tighten two nuts.
46
Page 47
1
4
2
3
M–4312
Figure 66
Top View
1. Deck Belt
2. Idler Arm
3. Idler nuts
4. Idler adjusting nut
6. Install the PTO drive belt. Refer to Replacing the PTO
Drive Belt, page 47.
Replacing the PTO Drive Belt
Squealing when the belt is rotating, blades slipping when
cutting grass, frayed belt edges, burn marks and cracks are
signs of a worn drive belt. Replace the PTO drive belt if
any of these conditions are evident.
1. Stop the engine, set the parking brake, remove the key
and disconnect the spark plug wire(s) from the spark
plug(s).
Note: Idler belt has to be installed between spacer and
PTO belt idler pulley.
7. Install clutch retaining strap and plug clutch terminal
into main wire harness (Fig. 67).
4
5
3
m–3748
2
1
M–4373
Figure 67
1. Clutch
2. Clutch retaining strap
3. clutch Terminal
5
4
4. PTO belt
5. Machine Frame
1
2
3
2. Remove the clutch retaining strap from machine frame
and unplug clutch terminal from wire harness
(Fig. 67).
3. Remove PTO drive belt from clutch, around rear idler
pulleys and off of mower top center pulley (Fig. 68).
4. Remove bolt, nut, washer and spacer from idler pulley
bracket assembly. Remove belt from bracket assembly
(Fig. 68).
5. Install new PTO drive belt over clutch, around rear
idler pulleys and onto mower top center pulley.
Note: Check that belt has only 1/4 twist between each
pulley and idler.
6. Install belt into idler pulley bracket assembly. Install
bolt, nut, washer and spacer into assembly (Fig. 68).
m–4311
Figure 68
1. Clutch Pulley
2. PTO Drive Belt
3. Drive Belt Idler Pulley
4. Idler Bracket Assembly
5. Spacer, Bolt, Nut and
washer (Remove)
8. Check belt tension. The center bolt of spring loaded
idler must be between the two alignment holes in left
support plate (Fig 69).
47
Page 48
Note: Increase belt tension by lengthening the push arms
and decrease belt tension by shortening push arms.
Important If the push arm lengths are changed, then
the mower deck must be leveled. See Leveling the Mower
on page 45.
2
1
3
4
1
m–3744
Figure 69
1. Center bolt, spring loaded
idler
9. If adjustment is required, loosen the fixed idler on
right support plate and move up or down in adjustment
slot (Fig. 70). To relieve belt tension lift up on spring
2. Alignment hole
1. Push arm
2. 15–5/16 inch (389 mm)
nominal
loaded idler.
Replacing the Grass Deflector
12
An uncovered discharge opening could allow the
lawn mower to throw objects in the operator’s or
bystander’s direction and result in serious injury.
Also, contact with the blade could occur.
m–3746
Figure 70
1. Fixed Idler 2. Adjustment slot
10.Check belt tension again. The center bolt of spring
loaded idler must be between the two alignment holes
in left support plate (Fig. 69). Adjust, if necessary, and
tighten all hardware securely.
11. If the fixed idler contacts the end of the adjustment
slot and more belt tension is required, a small change
to lengthen the push arms can be made (Fig. 71).
12.To adjust push arms, loosen jam nut and rotate ball
joint counterclockwise, one turn at a time. Adjust each
side the same amount (Fig. 71).
Never operate the lawn mower unless you install a
cover plate, a mulch plate, or a grass chute and
catcher.
1. Remove the locknut, bolt, spring and spacer holding
the deflector to the pivot brackets (Fig. 72). Remove
damaged or worn grass deflector.
2. Place spacer and spring onto grass deflector. Place the
L end of spring behind deck edge.
Note: Make sure the L end of spring is installed behind
deck edge before installing the bolt as shown in figure 72.
3. Install bolt and nut. Place J hook end of spring around
grass deflector (Fig. 72).
Important The grass deflector must be able to lower
down into position. Lift the deflector up to test that it
lowers into the full down position.
2
m–6273
Figure 71
3. Jam nut
4. Ball joint
Warning
48
Page 49
8
6
1
4
2
3
5
7
that these sealed devices contain mercury and should not
be placed in the garbage until the mercury is removed and
reused, recycled or otherwise managed to insure that it
does not become part of solid waste or waters.
Management and disposal practices must be within
relevant federal, state or local laws.
Return the switch to your Toro dealer if it is faulty and is
being replaced or if the unit containing the switch is no
longer operating and is being scrapped. If the switch is
damaged or broken open use extreme caution in handling.
Call your local waste management authority or Toro
Customer Service for instructions.
m–5037
Figure 72
1. Bolt
2. Spacer
3. Locknut
4. Spring
5. Spring installed
6. Grass Deflector
7. L end of spring, place
behind deck edge before
installing bolt
8. J hook end of spring
Waste Disposal
Engine oil, hydraulic oil and engine coolant are pollutants
to the environment. Dispose of these according to your
state and local regulations.
Mercury Tilt Switch
The tilt switch on this unit contains mercury, a hazardous
material. Mercury that is outside a sealed container
vaporizes at room temperature. The vapors are harmful.
Mercury can be absorbed through the skin. Do not attempt
to open or repair this switch.
A very small amount of mercury is contained in a
hermetically sealed body. The steel switch is then potted
in a hard epoxy in a plastic case. It is unlikely that the
mercury will ever escape from the enclosure. These high
performance and reliable inexpensive switches are
recyclable.
Caution
The mercury contained in the tilt switch is
poisonous and exposure to mercury can cause
severe illness.
• Never attempt to open or repair the tilt
switch.
• Avoid contact with the mercury.
Mercury is an important and beneficial compound but
requires special care in handling and disposal. When used
and managed properly, mercury is not a threat to people or
the environment. This information is presented to users so
that they are aware that these switches contain mercury
and will apply sound disposal practices when these
devices reach their normal end of life or are damaged.
Disposing the Mercury Tilt
Switch
Several states have passed laws concerning the disposal of
devices containing mercury. In all the remaining states it
is advisable to follow similar procedures. The laws state
49
Page 50
Wiring Diagram
TAN
RED
PINK
T
R
PK
WIRE COLOR CODES
SW1
(IGNITION)
I A
Y B
SX
BLACK
BK
BLUE
BROWN
BU
BN
WHITE
VIOLET
VIO
W
GREY
GREEN
GN
GY
YELLOW
Y
ORANGE
OR
VIO
PK
PK R
BNOR
IGNITION
SPARK PLUG SPARK PLUG
F2
20A
F1
20A
MODULES
MAG
2
W
R
PK
AC
3
REG
VIO
HOUR
AC
METER
GY
FUEL
SOLINIOD
FUEL
4
PK
–+
GN
GND
–+
BATTERY
ST
B
BU
STARTER
3
1
4
GYW
Y
3
BU
4
5
GY
2
5
BK
K1
(KILL RELAY)
OIL
SWITCH
R
OIL
1
GN
1
BN
2
Y
I
S
X
Y
KEY SWITCH PN 88–9830
OFF NO CONNECTION
ON B I A AND X Y
START B I S
B
A
KEY SW
SW2
SW7
TERMINAL VIEW FROM
BACK OF SWITCH
PK
(PTO)
SHOWN IN
BN
(TILT SW)
SWITCH OPENS
WHEN TILTED
PAST 60 DEGREES
FROM VERTICAL
OFF POSITION
GY
OR
Y
SW6
SW3
(BRAKE)
(SEAT SW)
SHOWN WITH
OPERATOR
IN SEAT
P1–A
DISENGAGED
SHOWN WITH
PARK BRAKE
BN
T
P2–C
DELAY MODULE
100–6186
P1–C
VIO
VIO
PTO
P1–B
CLUTCH
BK
SHOWN WITH
LEVER IN
NEUTRAL
POSITION
SW4
(NEUTRAL)
BK
W
K2
(START RELAY)
SHOWN WITH
LEVER IN
SW5
Y
NEUTRAL
POSITION
(NEUTRAL)
GND
BK
50
Page 51
Cleaning and Storage
1. Disengage the power take off (PTO), set the parking
brake and turn the ignition key to off. Remove spark
plug wire. Remove the key.
2. 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’s 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.
3. Service the air cleaner; refer to Servicing the Air
Cleaner, page 31.
A. Add a petroleum based stabilizer/conditioner to
fuel in the tank. Follow mixing instructions from
stabilizer manufacture. Do not use an alcohol
based stabilizer (ethanol or methanol).
Note: A fuel stabilizer/conditioner is most effective when
mixed with fresh gasoline and used at all times.
B. Run engine to distribute conditioned fuel through
the fuel system (5 minutes).
C. Stop engine, allow to cool and drain the fuel tank;
refer to Servicing the Fuel Tank, page 34.
D. Restart engine and run it until it stops.
E. Choke or prime the engine. Start and run engine
until it will not start. Operate primer, if equipped
on machine, several times to ensure fuel remains in
primer system.
4. Grease and oil the machine; refer to Greasing and
Lubrication, page 35.
5. Change the crankcase oil; refer to Servicing the
Engine Oil, page 32.
6. Change the hydraulic filter; refer to Servicing the
Hydraulic System, page 37.
7. Check the tire pressure; refer to Checking the Tire
Pressure, page 36.
8. Charge the battery; refer to Servicing the Battery
page 43.
9. Scrape any heavy buildup of grass and dirt from the
underside of the mower, then wash the mower with a
garden hose.
10.Check the condition of the blades. Refer to Servicing
the Cutting Blades on page 29.
11. Prepare the machine for storage when non–use occurs
over 30 days. Prepare machine for storage as follows.
F. Dispose of fuel properly. Recycle as per local
codes.
Important Do not store stabilizer/conditioned gasoline
over 90 days.
12.Remove the spark plug(s) and check its condition;
refer to Servicing the Spark Plug, page 33. With the
spark plug(s) removed from the engine, pour two
tablespoons of engine oil into the spark plug hole.
Now 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).
13.Check and tighten all bolts, nuts, and screws. Repair or
replace any part that is damaged or defective.
14.Paint all scratched or bare metal surfaces. Paint is
available from your Authorized Service Dealer.
15.Store the machine in a clean, dry garage or storage
area. Remove the key from the ignition switch and
keep it in a memorable place out of reach of children
or other unauthorized users. Cover the machine to
protect it and keep it clean.
51
Page 52
Troubleshooting
g,,
g
g
Problem Possible Causes Corrective Action
Starter does not crank
Engine will not start, starts hard, or
fails to keep running.
1. Blade control (PTO) is
engaged.
2. Parking brake is not on. 2. Set parking brake.
3. Operator is not seated.
4. Battery is dead.
5. Electrical connections are
corroded or loose.
6. Fuse is blown. 6. Replace fuse.
7. Relay or switch is defective. 7. Contact Authorized Service
1. Fuel tank is empty. 1. Fill fuel tank with gasoline.
2. Choke is not on. 2. Move choke lever to on.
3. Air cleaner is dirty. 3. Clean or replace air cleaner
4. Spark plug wires is loose or
disconnected.
5. Spark plugs are pitted, fouled,
or gap is incorrect.
6. Dirt in fuel filter. 6. Replace fuel filter.
1. Move blade control (PTO) to
disengaged.
3. Sit on the seat.
4. Charge the battery.
5. Check electrical connections
for good contact.
Dealer.
element.
4. Install wires on spark plug.
5. Install new, correctly gapped
spark plugs.
Engine loses power.
Engine overheats.
7. Dirt, water, or stale fuel is in
fuel system.
1. Engine load is excessive. 1. Reduce ground speed.
2. Air cleaner is dirty. 2. Clean air cleaner element.
3. Oil level in crankcase is low. 3. Add oil to crankcase.
4. Cooling fins and air passages
under engine blower housing
are plugged.
5. Spark plugs are pitted, fouled,
or gap is incorrect.
6. Vent in fuel cap is closed. 6. Open vent in fuel cap.
7. Dirt in fuel filter. 7. Replace fuel filter.
8. Dirt, water, or stale fuel is in
fuel system.
1. Engine load is excessive. 1. Reduce ground speed.
2. Oil level in crankcase is low. 2. Add oil to crankcase.
3. Cooling fins and air passages
under engine blower housing
are plugged.
7. Contact Authorized Service
Dealer.
4. Remove obstruction from
cooling fins and air passages.
5. Install new, correctly gapped
spark plugs.
8. Contact Authorized Service
Dealer.
3. Remove obstruction from
cooling fins and air passages.
52
Page 53
Problem Corrective ActionPossible Causes
gg
Machine does not drive.
Abnormal vibration.
Uneven cutting height.
1. Traction belt is worn, loose or
broken.
2. Traction belt is off pulley. 2. Contact Authorized Service
3. Hydro fluid level low. 3. Add hydro fluid to reservoir.
1. Cutting blade(s) is/are bent or
unbalanced.
2. Blade mounting bolt is loose. 2. Tighten blade mounting bolt.
3. Engine mounting bolts are
loose.
4. Loose engine pulley, idler
pulley, or blade pulley.
5. Engine pulley is damaged. 5. Contact Authorized Service
6. Blade spindle bent. 6. Contact Authorized Service
1. Blade(s) not sharp. 1. Sharpen blade(s).
2. Cutting blade(s) is/are bent. 2. Install new cutting blade(s).
3. Mower is not level. 3. Level mower from side-to-side
1. Contact Authorized Service
Dealer.
Dealer.
1. Install new cutting blade(s).
3. Tighten engine mounting bolts.
4. Tighten the appropriate pulley.
Dealer.
Dealer.
and front-to-rear.
Blades do not rotate.
4. Gage wheel not set correctly.
5. Underside of mower is dirty.
6. Tire pressure is incorrect. 6. Adjust tire pressure.
7. Blade spindle bent. 7. Contact Authorized Service
1. Drive belt is worn, loose or
broken.
2. Drive belt is off pulley. 2. Install drive belt and check
3. Deck belt is worn, loose or
broken.
4. Deck belt is off pulley. 4. Install deck pulley and check
4. Adjust gage wheel height.
5. Clean the underside of the
mower.
Dealer.
1. Install new drive belt.
adjusting shafts and belt guides
for correct position.
3. Install new deck belt.
the idler pulley, idler arm and
spring for correct position and
function.
53
Page 54
54
Page 55
55
Page 56
LCE
The Toro Total Coverage Guarantee
A Limited Warranty
Conditions and Products Covered
The Toro Company and its affiliate, Toro Warranty Company,
pursuant to an agreement between them, jointly promise to repair
the listed Toro Products if defective in materials or workmanship.
The following time periods apply from the date of purchase:
Products
• All Products 1 year
• All Spindles 2 years parts and labor;
• Engines/Hydraulic Systems* on
the following:
Outfront and Mid-Mount Z’s
ProLine Mid-Size Mowers
Groundsmaster
Backpack Blowers
• Deck Shells (36″–72″) on the
following:
ProLine Mid-Size Mowers
Mid-Mount Z’s
• Electric Clutch on 200 Series
Mid-Mount Z’s
This warranty includes the cost of parts and labor, but you must
pay transportation costs.
This warranty applies to:
• Outfront and Mid-Mount Z’s
• ProLine Mid-Size Mowers
• Groundsmaster Riding Mowers
• Turf Maintenance Equipment
• Debris Management Equipment
* Some engines used on Toro LCE Products are warranted by the
engine manufacturer.
Riding Mowers
Warranty Period
third year, parts only
2 years
2 years
2 years
Instructions for Obtaining Warranty Service
If you think that your T oro Product contains a defect in materials or
workmanship, follow this procedure:
1. Contact any Toro Authorized or Master Service Dealer to
arrange service at their dealership. To locate a dealer
convenient to you, access our website at www.Toro.com. U.S.
Customers may also call 800-348-2424.
2. Bring the product and your proof of purchase (sales receipt) to
the Service Dealer.
If for any reason you are dissatisfied with the Service Dealer’s
analysis or with the assistance provided, contact us at:
LCB Customer Service Department
Toro Warranty Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
888-577-7466 (U.S. customers)
877-484-9255 (Canada customers)
You must maintain your Toro Product by following the maintenance
procedures described in the operator’s manual. Such routine
maintenance, whether performed by a dealer or by you, is at your
expense.
There is no other express warranty except for special emission
system coverage on some products. This express warranty does
not cover the following:
• Cost of regular maintenance service or parts, such as filters,
fuel, lubricants, tune-up parts, blade sharpening, brake and
clutch adjustments.
• Any product or part which has been altered or misused or
required replacement or repair due to normal wear, accidents,
or lack of proper maintenance.
• Repairs necessary due to improper fuel, contaminants in the
fuel system, or failure to properly prepare the fuel system prior
to any period of non-use over three months.
• Pickup and delivery charges.
All repairs covered by this warranty must be performed by an
Authorized T oro Service Dealer using Toro approved replacement
parts.
Repair by an Authorized Toro Service Dealer is your sole remedy
under this warranty.
Neither The Toro Company nor Toro Warranty Company is liable
for indirect, incidental or consequential damages in connection
with the use of the Toro Products covered by this warranty,
including any cost or expense of providing substitute equipment or
service during reasonable periods of malfunction or non-use
pending completion of repairs under this warranty.
Some states do not allow exclusions of incidental or consequential
damages, or limitations on how long an implied warranty lasts, so
the above exclusions and limitations may not apply to you.
All implied warranties of merchantability (that the product is fit for
ordinary use) and fitness for use (that the product is fit for a
particular purpose) are limited to the duration of the express
warranty.
This warranty gives you specific legal rights, and you may also
have other rights which vary from state to state.
Owner Responsibilities
Items and Conditions Not Covered
General Conditions
Countries Other than the United States or Canada
Customers who have purchased Toro products exported from the United States or Canada should contact their Toro Distributor (Dealer)
to obtain guarantee policies for your country, province, or state. If for any reason you are dissatisfied with your Distributor’s service or
have difficulty obtaining guarantee information, contact the Toro importer. If all other remedies fail, you may contact us at Toro Warranty
Company.
Part No. 374-0037 Rev. C
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