Toro 74258 Operator's Manual

Download

Page 1

Form No. 3329–599

Z288E

Z Master with 62 SFS Side Discharge Mower

Model No. 74258—230000001 & Up

Operator ’s Manual

Pour obtenir gratuitement une version en français de ce manuel, écrivez à l’adresse ci-dessous. N’oubliez pas d’indiquer les numéros de modèle et de série de votre produit.

The Toro Company, Attn: Parts Dept., 8111 Lyndale Ave S, Bloomington, MN 55420–1196

English (EN)

Page 2

Warning

CALIFORNIA

Proposition 65 Warning

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

Because in some areas there are local, state, or federal regulations requiring that a spark arrester be used on the engine of this mower, a spark arrester is incorporated with the muffler assembly.

Important This engine is equipped with a spark

arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate this engine without a spark arrester muffler 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 4. . . . . . . . . . . . . . . . . . .

Toro Mower Safety 5. . . . . . . . . . . . . . . . . . . . . . .

Slope Chart 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety and Instruction Decals 9. . . . . . . . . . . . . . .

Gasoline and Oil 14. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Gasoline 14. . . . . . . . . . . . . . . . . . .

Using Stabilizer/Conditioner 14. . . . . . . . . . . . . . . .

Filling the Fuel Tank 14. . . . . . . . . . . . . . . . . . . . . .

Checking the Engine Oil Level 14. . . . . . . . . . . . . .

Setup 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loose Parts 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

 2003 by The Toro Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196

Installing the Drive Wheels 16. . . . . . . . . . . . . . . . .

Checking the Tire Pressure 16. . . . . . . . . . . . . . . . .

Installing the Motion Control Levers 17. . . . . . . . .

Installing the Seat 18. . . . . . . . . . . . . . . . . . . . . . . . .

Activating the Battery 18. . . . . . . . . . . . . . . . . . . . .

Installing the Air Cleaner 19. . . . . . . . . . . . . . . . . . .

Checking the Hydraulic Fluid 20. . . . . . . . . . . . . . .

Greasing the Bearings 20. . . . . . . . . . . . . . . . . . . . .

Checking the Side Discharge Chute 20. . . . . . . . . .

Check the Level of the Mower Deck 21. . . . . . . . . .

Checking the Engine Oil Level 21. . . . . . . . . . . . . .

Operation 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Think Safety First 22. . . . . . . . . . . . . . . . . . . . . . . .

Controls 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating the Parking Brake 23. . . . . . . . . . . . . . . .

Starting and Stopping the Engine 23. . . . . . . . . . . .

Operating the Power Take Off (PTO) 24. . . . . . . . .

The Safety Interlock System 25. . . . . . . . . . . . . . . .

Driving Forward or Backward 25. . . . . . . . . . . . . . .

Stopping the Machine 26. . . . . . . . . . . . . . . . . . . . .

Adjusting the Height-of-Cut 26. . . . . . . . . . . . . . . .

Using the Lift Assist Lever 26. . . . . . . . . . . . . . . . .

Adjusting the Anti-Scalp Rollers 27. . . . . . . . . . . . .

Positioning the Seat 27. . . . . . . . . . . . . . . . . . . . . . .

Pushing the Machine by Hand 27. . . . . . . . . . . . . . .

Using a Rollover Protection System 28. . . . . . . . . .

Using the Side Discharge 28. . . . . . . . . . . . . . . . . . .

Transporting Machines 28. . . . . . . . . . . . . . . . . . . .

Loading Machines 28. . . . . . . . . . . . . . . . . . . . . . . .

Using the Z Standt 29. . . . . . . . . . . . . . . . . . . . . . . .

Tips for Mowing Grass 30. . . . . . . . . . . . . . . . . . . .

Maintenance 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Maintenance Schedule 32. . . . . . . .

Servicing the Cutting Blades 33. . . . . . . . . . . . . . . .

Servicing the Air Cleaner 35. . . . . . . . . . . . . . . . . .

Servicing the Engine Oil 36. . . . . . . . . . . . . . . . . . .

Servicing the Spark Plug 37. . . . . . . . . . . . . . . . . . .

Servicing the Electronic Fuel Injection System 38.

Servicing the Fuel Filters 38. . . . . . . . . . . . . . . . . . .

Servicing the Fuel Tank 39. . . . . . . . . . . . . . . . . . . .

Servicing the Spark Arrester 40. . . . . . . . . . . . . . . .

Cleaning the Cooling Systems 40. . . . . . . . . . . . . . .

Greasing and Lubrication 40. . . . . . . . . . . . . . . . . . .

Greasing the Bearings 41. . . . . . . . . . . . . . . . . . . . .

Checking the Tire Pressure 41. . . . . . . . . . . . . . . . .

Adjusting the Wheel Hub Slotted Nut 42. . . . . . . . .

Adjusting the Caster Pivot Bearing 42. . . . . . . . . . .

Servicing the Hydraulic System 42. . . . . . . . . . . . .

Adjusting the Handle Neutral 44. . . . . . . . . . . . . . .

Page

Page 3

Page

Setting the Hydraulic Pump Neutral 45. . . . . . . . . .

Adjusting the Tracking 46. . . . . . . . . . . . . . . . . . . .

Replacing the Pump Drive Belt 47. . . . . . . . . . . . . .

Adjusting the Parking Brake 47. . . . . . . . . . . . . . . .

Servicing the Fuse 48. . . . . . . . . . . . . . . . . . . . . . . .

Servicing the Battery 48. . . . . . . . . . . . . . . . . . . . . .

Adjusting the Mower Level 50. . . . . . . . . . . . . . . . .

Cleaning Under the Deck 51. . . . . . . . . . . . . . . . . . .

Inspecting the Belts 51. . . . . . . . . . . . . . . . . . . . . . .

Replacing the Deck Belt 51. . . . . . . . . . . . . . . . . . .

Replacing the PTO Drive Belt 52. . . . . . . . . . . . . . .

Replacing the Grass Deflector 53. . . . . . . . . . . . . . .

Waste Disposal 54. . . . . . . . . . . . . . . . . . . . . . . . . . .

Mercury Tilt Switch 54. . . . . . . . . . . . . . . . . . . . . . .

Mercury Tilt Switch Disposal 54. . . . . . . . . . . . . . .

Wiring Diagram 55. . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning and Storage 56. . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The Toro Total Coverage Guarantee 60. . . . . . . . . . . . .

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.

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.

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.

Figure 1

1. Location o f the model and serial numbers

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.

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.

Page 4

Safe Operating Practices

The following instructions are from ANSI standard B71.4—1999.

• 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.

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.

• 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 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

• 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.

• 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.

Page 5

• 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.

• 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.

• 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.

• 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.

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.

• 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.

Page 6

Page 7

Slope Chart

Page 8

Page 9

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

103-2750

1-643288

1-633706

1-633462

1-643339

1-643401

1-633818

Page 10

1-523552

98-4387

1. Warning—wear hearing protection.

98-5954

43-8480

1-633766

98-3798

93-1122

Page 11

66-1340

67-5360

99-4686

103-0261

93-7818

1. Warning—read the

torquing the blade bolt/nut to 115–149 N⋅m (85–110 ft.-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

Manual.

Operator’s

distance from the battery.

Page 12

104-7759

104-8172

104-8569

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

Page 13

106-6570

106-6571

Page 14

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.

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 the Engine Oil Level, page 36.

Page 15

Setup

Loose Parts

Note: Use the chart below to verify all parts have been shipped.

Step Description Qty. Use

1 2

3 4

5 6 7

Rear Wheels 2 Installing the wheels to traction unit

No parts needed Checking the Tire Pressure

Control lever–right Control lever–left Bolt 3/8 x 1 inch Spring washer 3/8 inch

No parts needed Checking the Engine Oil Level

Suspension Seat Nuts

No parts needed Activating the battery

Air Filter Hose Clamp

1 1 4 4

1 4

1 1

Installing the motion control levers

Installing the seat

Installing the air filter

8 9 10

No parts needed Checking the Hydraulic Fluid

No parts needed Greasing the Bearings

No parts needed Checking the Side Discharge Chute

Page 16

Step UseQty.Description

11 12

Step

No parts needed Checking the Level of the Mower Deck

Key Operator’s Manual Engine Operator’s Manual Parts Catalog Registration card

Parts needed for this step:

• 2 Rear Wheels

2 1 1 1 1

Step

Read before operating machine Read before operating machine

Fill out and return to Toro

No parts needed for this step.

Checking the Tire Pressure

Installing the Drive Wheels

1. Uncrate mower.

2. Remove wheel nuts from rear wheel hubs.

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-lbs

(128 NM).

Important Make sure that wheel nuts are torqued to

95 ft–lb (128 NM).

Check the air pressure in the front and rear tires (Fig. 2). Pressure: 13 psi (90 kPa)

m–1872

Figure 2

1. Valve stem

Page 17

Step

4. Align the front\rear position of the levers, with each

other, in the neutral position. Loosen the hardware and adjust by sliding/tilting the lever(s) forward or backward until they are properly aligned (Fig. 3).

Parts needed for this step:

• 1 Control lever–right

• 1 Control lever–left

• 4 Bolt 3/8 x 1 inch

• 4 Spring washer 3/8 inch

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.

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. 3).

5. If the ends of the levers hit against each other, while in

the drive position (Fig 4) (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.

Figure 4

Step

1. Mounting plate

2. Bolt, 3/8 x 1 inch

3. Spring washer, 3/8 inch

2. Place the levers (with the mounting plate toward the

rear) on the outside of the control arm shaft and secure them with 4 bolts (3/8 x 1 inch) and 4 spring washers (3/8 in.) (Fig. 3).

3. Position the levers so that the bolts are in the center of

the slots on the lever mounting plate and tighten until snug.

4 5 6

m–5596

Figure 3

4. Top hole

5. Middle hole

6. Bottom hole

No parts needed for this step.

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 36.

Page 18

Step

Parts needed for this step:

• 1 Suspension Seat

• 4 Nuts

Installing the Seat

1. Remove seat from crate.

2. Position seat on the studs in the adjustable tracks

(Fig. 5).

3. Install nuts onto studs (Fig 5).

No parts needed for this step.

Activating the Battery

Bulk electrolyte with 1.265 specific gravity must be purchased from a local battery supply outlet.

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. Seat

2. Studs

Figure 5

3. Adjustable track

4. Nuts

m–4817

1. Remove the battery from the machine. Refer to

Removing the Battery on page 48.

2. Clean the top of the battery with a paper towel. 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).

Page 19

Step

Figure 6

1. Filler caps

2. Upper line

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.

3. Lower line

m–5004

Warning

Parts needed for this step:

• 1 Air Filter

• 1 Hose Clamp

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).

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 49.

8. Install the battery into the machine. Refer to Installing the Battery on page 48.

Note: Do not run the machine with the battery disconnected, electrical damage may occur to the engine computer.

Note: Do not jump start the machine.

m–4810

Figure 7

1. Air cleaner

2. Valve cover mounting screws

3. Air cleaner bracket

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).

Important Tighten the valve cover screws to 70 in–lb

(5 Nm) 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).

4. Air intake elbow

5. Air cleaner hose

6. Hose clamp

Page 20

Step

No parts needed for this step.

Checking the Hydraulic Fluid

Check the hydraulic fluid level before the engine is first started.

Refer to Checking the Hydraulic Fluid on page 42.

Step

No parts needed for this step.

Checking the Side Discharge Chute

Remove plastic tie holding side discharge chute up and lower into place.

Step

No parts needed for this step.

Greasing the Bearings

Make sure cutting unit spindles are full of grease before engine is first started.

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).

M–5035

Figure 8

1. Spindles

Checking the Level of the Mower

Check the level of the deck before the machine is first put in use.

Refer to Mower Leveling and Compression Spring Adjustment in the Maintenance section on page 49.

Page 21

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 85dBA 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. Caution 2. Wear hearing protection

1. Safe Zone—use the Z Master here on slopes less than 15 degrees or flat areas.

The use of protective equipment for eyes, ears, feet and head is recommended.

m–6478

Figure 9

2. Use walk behind mower and/or hand trimmer near drop–offs and water.

3. Water

Page 22

Controls

Become familiar with all the controls (Fig. 11) before you start the engine and operate the machine.

M–4821

1. Ignition switch

2. Motion control lever

3. Parking brake lever

4. Throttle

5. MIL (Malfunction Indicator Light)

Figure 11

6. Power take off (PTO)

7. Height-of-Cut lever

8. Fuel cap

9. Fuel shut off lever

10. Hour meter

11. Deck lift assist

Once the MIL illuminates, initial trouble shooting checks should be made. Refer to Troubleshooting on page 58 under the MIL section.

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

Switching the Fuel Tanks

The unit has two fuel tanks. One tank is on the left side and one on the right side. 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 a 1/4 turn to the left from the off location. This uses fuel from the right hand tank only. When the right hand fuel tank is empty, move the fuel shut off valve 1/4 turn to the left from the right hand tank position. This uses fuel from the left hand tank.

Close fuel shut off valve, on front panel before transporting or storing machine.

Figure 13

1. Shut-off valve

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.

m–3077

Figure 12

1. Hour meter

Using the Malfunction Indicator Light

The malfunction indicator light lets the user know there is a problem with the fuel injection system.

If the malfunction indicator light (MIL) illuminates, during operation, the electronic control unit (ECU) has detected a problem or fault in the electronic fuel injection (EFI) system.

Note: If the machine runs out of fuel, the fuel injection system may need the air bled out of the system. Contact an Authorized Service Dealer for this procedure.

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.

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.

Page 23

m–4163

Figure 14

1. Parking brake—ON

2. Parking brake—OFF

3. Brake stop

Starting and Stopping the Engine

4. Move the throttle control midway between the slow

and fast positions (Fig. 16).

m–2720

Figure 16

1. Throttle–Fast 2. Throttle–Slow

5. Turn ignition key to the start position. When engines

starts, release key (Fig. 17).

Starting the Engine

Note: This machine does not have a manual choke. This machine is equipped with a electronic fuel injection (EFI) system.

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 22.

3. Move the PTO (power take off) switch to off (Fig. 15).

Figure 15

1. PTO—Off 2. PTO—On

m–4201

M–4268

Figure 17

1. Off

2. Run

3. Start

Important Do not engage starter for more than 10

seconds at a time. If engine fails to start allow 60 second cool-down period between attempts. Failure to follow these instructions can burn out starter motor.

Stopping the Engine

1. Push the PTO to off (Fig. 15).

2. Move the throttle lever midway between the slow and

fast positions (Fig. 16).

3. Let the engine idle for 60 seconds.

4. Turn the ignition key to off (Fig. 17).

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.

Page 24

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.

Caution

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.

The Safety Interlock System

Caution

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

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. 18).

m–4201

Figure 18

1. PTO—Off 2. PTO—On

Disengaging the PTO

1. To disengage push the PTO switch to the off position (Fig. 18).

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 or 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

the PTO to on. Try starting the engine; the engine should not crank.

2. Sitting on the seat, engage the parking brake and move

the PTO to on. 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 the

PTO switch to off and move the motion control levers to neutral lock position. Now start the engine. While 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 the

PTO switch to off, and move the motion control levers to neutral lock position. Now start the engine. While

Page 25

the engine is running, center either motion control and move (forward or reverse); the engine should stop. Repeat for other motion control.

5. Sitting on the seat, disengage the parking brake, move

the 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 22.

2. Move levers to the center, unlocked position.

3. To go forward, slowly push the motion control levers

forward (Fig. 19).

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. 19).

To turn, move the motion control lever toward neutral in the direction you want to turn (Fig. 19).

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.

m–2715

Figure 19

1. Motion control lever—neutral lock position

2. Center unlock position

3. Forward

4. Backward

Driving Backward

1. Move levers to the center, unlocked position.

2. To go backward, slowly pull the motion control levers

rearward (Fig. 19).

To go straight, apply equal pressure to both motion control levers (Fig. 19).

To turn, release pressure on the motion control lever toward the direction you want to turn (Fig. 19).

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 22. Remember to remove the key from the ignition switch.

Caution

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.

Page 26

Note: Press on lift assist pedal when raising deck. This will help in lifting the deck (Fig. 22).

1. Press your foot on the lift assist pedal while raising the

height-of-cut lever to the transport position (also the 5 in. (127 mm) cutting height position) (Fig. 20).

2. To adjust, remove hairpin cotter and clevis pin from

height-of-cut bracket (Fig. 20).

3. Select hole in height-of-cut bracket corresponding to

the height-of-cut desired, and insert clevis pin (Fig. 20).

4. Secure clevis pin with hairpin cotter (Fig. 20).

5. Move lever to selected height.

M–4164

Figure 20

1. Height-of-cut lever

2. Clevis pin

3. Hairpin cotter

m–5028

Figure 21

1. Lift Assist Lever

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. 22).

Note: Do not remove the wheel nut and washer (Fig. 22).

3. Select hole so gage wheel is positioned to the nearest

corresponding height-of-cut desired (Fig. 22).

4. Reinstall the flange nut and spring disk. Torque to

40–45 ft-lbs. (54.2–61.0 Nm) (Fig. 22).

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. 21).

5. Repeat adjustment on other gage wheels.

Figure 22

1. Gage wheel

2. Stud

3. Spring disk

4. Flange nut

5. Wheel nut and washer. Do not remove.

m–4161

Page 27

Positioning the Seat

Setting the Seat Position

The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable.

1. To adjust, move the lever sideways to unlock seat

(Fig. 23).

2. Slide the seat to the desired position and release lever

to lock in position.

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. 24).

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.

Changing to Machine Operation

1. Rotate the by-pass valves clockwise 1 turn to operate

machine (Fig. 24).

Setting the Seat Suspension

The seat can be adjusted to provide a smooth and comfortable ride. Position the seat where you are most comfortable.

1. To adjust, turn the knob in front either direction to

provide the best comfort (Fig. 23).

m–4818

Figure 23

1. Seat suspen s i o n k n o b 2. Seat position adjustment

Note: Do not over tighten the by–pass valves. Note: The machine will not drive unless by-pass valves

are turned in. Do not over tighten.

m–6124

Figure 24

1. By-pass valve

Using a Rollover Protection

Pushing the Machine by Hand

Important Always push the machine by hand. Never

tow the machine because hydraulic damage may occur.

Pushing 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.

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.

Page 28

Using the Side Discharge

The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf.

Danger

Warning

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.

Without the grass deflector, discharge cover, or complete grass catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris. Contact with rotating mower blade(s) and thrown debris will cause injury or death.

• Never remove the grass deflector from the

mower because the grass deflector routes material down toward the turf. If the grass deflector is ever damaged, replace it immediately.

• Never put your hands or feet under the mower.

• Never try to clear discharge area or mower

blades unless you move the power take off (PTO) to off and rotate the ignition key to off. Also remove the key and pull the wire off the spark plug(s).

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. Knowing this information could help you, your family, pets or bystanders avoid injury.

To transport the machine:

• Lock brake and block wheels.

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. 25). 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. 25). 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.

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.

• Securely fasten the machine to the trailer or truck with

straps, chains, cable, or ropes.

• Secure a trailer to towing vehicle with safety chains.

Page 29

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.

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.

m–6841

1. Trailer

2. Full width ramp

3. Not greater than 15 degrees

Figure 25

4. Full width ramp—side view

Driving up onto the Z Stand

Important Use the Z Stand on a level surface.

1. Raise deck to transport position.

2. Remove bracket pin (Fig. 26).

m–5599

Figure 26

1. Z Stand

2. Latch

3. Bracket

4. Bracket Pin

5. Bottom of slot

Page 30

m–5600

Figure 27

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. 26 and 27).

4. Set foot of stand on the ground and rest latch on pivot tab (Fig. 27).

5. Start engine and put at half throttle.

Note: For best results, place foot of stand into seams in

sidewalks or into turf (Fig. 27).

6. Drive onto stand. Stop when latch drops over tab into locked position (Fig. 27). Once onto stand, engage parking brake. Shut off engine.

1. Z Stand

2. Latch

m–5601

Figure 28

3. Locked position

4. Unlocked position

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. 28).

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. 26).

Page 31

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.

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.

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.

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 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.

Page 32

Maintenance

Recommended Maintenance Schedule

Maintenance Service

Interval

After First Use

Each Use

Every 5 Hours

Every 25 Hours

Every 50 Hours

Every 100 Hours

Every 200 Hours

Maintenance Procedure

• Change engine oil

• Check hydraulic fluid level

• Change hydraulic filter

• Check engine oil level

• Check safety system

• Air cleaner filter minder

• Clean cooling systems

• Clean mower housing

• Check cutting blades

• Grease blade spindle bearings

• Check hydraulic fluid level

• Grease chassis

• Oil linkage bushings

• Check battery electrolyte

• Check belts for wear/cracks

• Check tire pressure

• Service the spark arrester

• Change engine oil

• Check hydraulic lines

• Change engine oil filter

• Change hydraulic filter

• Service primary air cleaner

• Check spark plug(s)

• Replace low pressure fuel filter

Every 500 Hours or at

Storage

Every 600 Hours or at

Storage

Every 1500 Hours or at

Storage

• Adjust caster pivot

• Adjust Wheel Hub Slotted Nut

• Replace safety air cleaner

• Replace high pressure fuel filter

• Perform all maintenance procedures listed above before storage

Before Storage

• Drain gasoline

• Charge battery, disconnect cables

• Paint chipped surfaces

More often in dusty, dirty conditions

Important Refer to your engine operator’s manual for additional maintenance procedures.

Page 33

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. Cutting edge

2. Curved area

Figure 29

3. Wear/slot forming

Checking for Bent Blades

1. Rotate the blades until the ends face forward and

backward (Fig. 30). Measure from a level surface to the cutting edge of the blades (Fig. 31). Note this dimension.

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 29). If the edges are not

sharp or have nicks, remove and sharpen the blades. Refer to Sharpening the Blades on page 34.

2. Inspect the blades, especially the curved area (Fig. 29).

If you notice any damage, wear, or a slot forming in this area (item 3 in Fig. 29), immediately install a new blade.

Front

m–1078

Figure 30

Page 34

Sharpening the Blades

Warning

MEASURE FROM CUT-

TING EDGE TO A LEV-

EL SURFACE

m–2539

Figure 31

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 34.

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. 32). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges.

m–1854

Figure 32

1. Sharpen a t original angle

2. Check the balance of the blade by putting it on a blade

balancer (Fig. 33). 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. 34). 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. 34).

m–1855

Figure 33

1. Blade 2. Balancer

Installing the Blades

1. Install the blade onto the spindle shaft (Fig. 34).

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. 34). Torque

the blade bolt to 85–110 ft-lb (115–150 Nm).

Important Make sure blade is torqued to 85–110 ft-lb

(115–150 Nm).

Page 35

3 5

1. Sail area of blade

2. Blade

3. Spring disk

Figure 34

4. Blade bolt

5. Cone toward bolt head

3. Test run the engine and recheck the gauge. If the

plunger changes to red, the primary element is restricted and must be replaced, even though it may

not appear to be dirty.

4. The gauge may be reset at any time, however it will

return to red if correct filter servicing has not been performed.

Removing the Air Cleaner

M–4226

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).

Servicing the Air Cleaner

Primary Filter: Clean or replace every 200 operating hours or when Filter Minder reaches Change Filter level.

Safety Filter: Replace after every 600 operating hours. Note: Service the air cleaner more frequently if operating

conditions are extremely dusty or sandy.

Using the Filter Minder

This machine contains an air cleaner Filter Minder gauge.

Filter Minder: Check this daily. The plunger inside the gauge canister will change to red

when the air cleaner element becomes dirty and restricted. When it changes red, air cleaner maintenance is required.

1. Start by visually checking the condition of the primary

element. If the element is visually dirty, replace the primary element. Do not attempt to clean it.

2. Reset the gauge by depressing the button in the bottom

of the canister until the plunger returns to the lowest point (Fig. 35).

m–4815

Figure 36

1. Latches

2. Air cleaner cover

3. Air filter body

4. Primary filter

5. Safety filter

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. Do not remove the safety filter, unless you intend to replace it as well.

5. 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.

Figure 35

1. Filter minder 2. Button (push to reset)

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.

M–4824

Page 36

Cleaning the Primary Filter

Blow compressed air from the inside to the outside of the primary filter.

Important Do not exceed 100 psi and keep the hose at

least 2 inches from the filter. Replace air filters if they are damaged or cannot be cleaned.

USE THESE SAE VISCOSITY OILS

10W–30

5W–20, 5W–30

Servicing the Safety Filter

Do not clean 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).

–20 0 20

F

–30 –20 –10

C

40 60

01020

80 100

30 40

Checking the 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.

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, SH, SJ or higher) Crankcase Capacity: w/filter, 67 oz. (2.0 l) Viscosity: See table below

m–3219m–4811

Figure 37

1. Oil dipstick

2. Filler cap

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.

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.

3. Metal end

Changing the Engine Oil

1. Start the engine and let it run five minutes. This warms

the oil so it drains better.

Page 37

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).

5. When oil has drained completely, close the drain valve

(Fig. 38).

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

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).

m–5624

Figure 38

1. Oil drain valve

6. Slowly pour approximately 80% of the specified oil,

on page 36, into the filler cap (Fig. 37). Now check the oil level; refer to Checking Oil Level, page 36. Slowly add additional oil to bring it to the full mark.

Change the Oil Filter

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 36.

2. Remove the old filter and wipe the filter adapter

(Fig. 39) gasket surface.

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 Engine Oil on page 36.

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 Premium Gold 2071 (or equivalent) Air Gap: 0.030 inch (0.76 mm)

Removing the Spark Plug(s)

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.

Page 38

3. Remove the spark plug(s) and metal washer.

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).

m–4811

Figure 40

1. Spark plug wire 2. Spark plug

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 (Fig. 41) if the gap is not correct.

0.030 inch (0.76 mm )

Servicing the Electronic Fuel Injection System

This machine contains an electronic fuel injection system. It controls the fuel flow under different operating conditions.

Checking the Malfunction Indicator Light

If the malfunction indicator light (MIL) illuminates, during operation, the electronic control unit (ECU) has detected a problem or fault in the electronic fuel injection (EFI) system.

Once the MIL illuminates, initial trouble shooting checks should be made. Refer to Troubleshooting on page 58, under the MIL section.

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

Servicing the Fuel Filter

Replace the high pressure fuel filter after every 1500 operating hours or more frequently under extremely dusty or dirty conditions.

Ensure that an Authorized Service Dealer replaces the fuel filter and any components for the fuel system.

1. Center electrode insulator

2. Side electrode

Figure 41

3. Air gap (not to scale)

m–3215

Warning

Fuel system components are under high pressure. Use of improper components can result in system failure, gasoline leakage and possible explosion.

• Ensure that an Authorized Service Dealer

replace the fuel filter and any components for the fuel system.

• Use only approved fuel lines, hose clamps and

fuel filters for high pressure systems.

Page 39

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.

Important Removal of hose clamps requires special

pliers. Contact an Authorized Kohler Service Dealer for ordering pliers.

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. 42).

3. Loosen the hose clamp at the low pressure fuel filter

and slide it up the fuel line away from the fuel filter (Fig. 42).

4. Pull the fuel line off low pressure fuel filter (Fig. 42).

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.

1. Fuel shut-off valve

2. Low pressure fuel filter

Figure 42

3. Hose clamp

4. Fuel line

m–4814

Servicing the Spark Arrester

Inspect the spark arrester every 50 hours for damage, such as holes in the screen, and for build-up on the screen. If it is damaged, replace it with a new spark arrester. If it is dirty, remove it and clean the screen with a wire brush and/or soak it in solvent.

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. 43).

5. Install the fuel line onto the fuel filter. Install hose

clamp close to the fuel filter to secure the fuel line (Fig. 42).

Figure 43

1. Engine screen 2. Oil cooler

Page 40

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.

3. Pump grease into zerk until it oozes out around top

bearing.

4. Remove grease zerk in hole. Reinstall hex plug and

dust cap.

Where to Add Grease

Lubricate the grease fittings as shown on the Check Service Reference Aid decal (Fig. 45).

1. Panel

2. Engine shroud

Figure 44

3. Screws

m–5766

Greasing and Lubrication

Lubricate the machine when shown on the Check Service Reference Aid decal (Fig. 45). 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 45

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. Refer to Adjusting the Caster Pivot Bearing, page 42.

2. Remove hex plug and dust cap. Thread a grease zerk into hole.

Greasing the Bearings

The cutting unit must be lubricated daily; refer to the Recommended Maintenance Schedule, page 32. Grease with No. 2 general purpose lithium base or molybdenum base grease.

Important Make sure cutting unit spindles are full of

grease daily.

Page 41

1. Stop the engine, set the parking brake, remove the key

and disconnect the spark plug wire(s) from the spark plug(s).

Adjusting the Wheel Hub Slotted Nut

2. Grease the fittings on the three spindle bearings until

grease comes out lower seals (Fig. 46).

3. Grease the fittings on the push arms (Fig. 46).

M–5035

Figure 46

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. 47). Check the tires when they are cold to get the most accurate pressure reading.

Check after every 500 operating hours. The slotted nut needs to be torqued to 125 ft-lbs

(169.5 Nm).

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 125 ft-lbs (169.5 Nm) (Fig. 48).

4. Check the distance from bottom of slot in nut to inside

edge of hole. Two threads or less should be showing (Fig. 48).

5. If more than two threads are showing remove nut and

install washer between hub and nut (Fig. 48).

6. Torque the slotted nut to 125 ft-lbs (169.5 Nm)

(Fig. 48).

7. Tighten nut until the next set of slots line up with the

hole in the shaft (Fig. 48).

8. Replace cotter pin.

Pressure: 13 psi (90 kPa) drive wheels and caster wheels.

m–1872

Figure 47

1. Valve stem

Figure 48

1. Slotted n u 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).

2. Remove dust cap from caster and tighten lock nut (Fig. 49).

m–4638

Page 42

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. 49).

4. Grease caster pivot. Refer to Grease Front Caster

Pivots on page 40.

4. If there is no fluid, add fluid to the reservoir until it reaches the cold level of the baffle.

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 23.

Important Make sure spring washers are installed

correctly as shown in figure 49.

M–4640

Figure 49

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.

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. 50).

3. Remove cap from filler neck. Look inside to check if

there is fluid in the reservoir. (Fig. 50).

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. 50).

7. Install cap on filler neck.

m–5615

Figure 50

1. Cap

2. Baffle

3. Cold fluid level—full

4. Hot fluid level—full

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.

Replacing the Hydraulic Filter

Change the hydraulic filter:

After the first 8 operating hours.

Page 43

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 a drain pan under filter, remove the old filter and

wipe the filter adapter gasket surface clean (Fig. 51).

10.Start engine and let run for about two minutes at low

idle. This will purge air from the system. Stop the engine and check for leaks. If one or both wheels will not drive, refer Bleeding Hydraulic System, page 43.

11. Check fluid level in hydraulic tank while fluid is

warm. Add fluid to raise level to top of the baffle, if required. Do not overfill.

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.

M–4763

Figure 51

1. Hydraulic filter

4. Apply a thin coat hydro fluid to the rubber gasket on

the replacement filter (Fig. 52).

m–1256

Figure 52

1. Hydraulic filter

2. Gasket

3. Adapter

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. 52).

8. Clean up any spilled fluid.

9. If there is no fluid or it is low, add fluid to reservoir

approximately a 1/4 inch (6mm) below the top of baffle.

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.

Note: Keep areas around hydraulic system clean from grass and debris build up.

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.

Page 44

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 17.

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. 53).

m–6282

1011

1. Clevis pin in slot

2. Nut against yoke

3. Adjustment bolt

4. Pump rod

5. Double nuts

6. Jam Nut

Figure 54

7. Spring

8. Pivot shaft

9. Yoke

10. Locknut

11. Ball joint

M–6278

Figure 53

1. Neutral locked position

2. Control lever

3. Neutral position

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. 54).

5. Check where the control lever is relative to notch in

console (Fig. 53). It should be centered allowing lever to pivot outward to the neutral lock position.

6. If adjustment is needed, loosen the nut and jam nut

against the yoke (Fig. 54).

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. 54).

9. Repeat on the opposite side of unit.

Setting the Hydraulic Pump Neutral

Note: Adjust handle neutral first. That has to be correct before the following adjustment can be made.

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.

Page 45

2. Disconnect electrical connector from the seat safety switch. Temporarily install a jumper wire across terminals in the wiring harness connector.

2. Start the engine, open throttle 1/2 way and release

parking brake. Refer to Starting and Stopping the Engine, page 23.

3. Slide seat forward, disconnect prop rod and tilt seat fully forward.

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 Engine, page 23.

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. 55).

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.

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. 54).

4. Move motion control lever forward and reverse, then

back to neutral. Wheel must stop turning or slightly creep in reverse.

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. 54).

Warning

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.

m–6281

Figure 55

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. 54).

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.

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 44 and Adjusting the Hydraulic Pump Neutral on page 44.

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.

Page 46

4. To make the machine go right, turn the knob towards

the right side of the machine. Refer to figure 56.

5. To make the machine go left, turn the knob towards

the left side of the machine. Refer to figure 56.

6. Repeat adjustment until the tracking is correct.

Adjusting the Parking Brake

Check parking brake for proper adjustment.

1. Disengage brake lever (lever down).

2. Measure the length of the spring. Measurement should

be 2.75 inch (70 mm) between washers (Fig. 58).

m–6280

Figure 56

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

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. 57). Remove belt between pulleys.

2. Install new belt around engine and hydro pump pulleys

(Fig. 57).

3. Pull spring loaded idler down and align below traction

belt. Release pressure on spring loaded idler (Fig. 57).

Important Spring loaded idler is under high tension.

m–3788

Figure 58

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

3. If adjustment is necessary, loosen the jam nut below

the spring and tighten the nut directly below the yoke (Fig. 58). 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

counterclockwise to lengthen the spring.

5. Engage parking brake, lever up.

A. 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. 58).

6. If adjustment is necessary, loosen the jam nut directly

below the yoke. Turn the bottom rod until the correct measurement is obtained (Fig. 58). Tighten jam nut at yoke

Figure 57

Servicing the Fuse

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

Fuse: Main F1—30 amp, blade-type (Fig. 59)

1. Raise the seat to gain access to fuse holder (Fig. 59).

Page 47

2. To replace fuses pull out on the fuse to remove it (Fig. 59).

Figure 59

1. Main—30 amp

Fuse: Fuel Pump 10 amp, blade-type (Fig. 60) Fuse: Engine Fuse 20 amp, blade-type (Fig. 60)

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 49.

m–3653

1. Locate fuses in the left rear of machine. Pull plastic

clip out and down to gain access to fuses in holders (Fig. 60).

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

60).

2 3

m–4823

Figure 60

1. Engine-20 amp

2. Fuel Pump-10 amp

3. Plastic clip

Servicing the Battery

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

Warning

CALIFORNIA

Proposition 65 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 Electrolyte Level

1. With the engine off, locate the battery under the seat.

Page 48

Installing the Battery

6 7

1. Position battery in tray with terminal posts toward the

engine (Fig. 62).

Removing the Battery

Warning

9 5

1. Battery

2. Terminal boot

3. Positive battery cable

4. Negative battery cable

5. Ground wire

6. Bolt, 1/4 x 3/4 inch

Figure 62

7. Washer, 1/4 inch

8. Locknut, 1/4 inch

9. Battery clamp

10. J-bolts

11. Wing nut, 1/4 inch

Battery terminals or metal tools could short against metal machine components causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury.

• When removing or installing the battery, do not

allow the battery terminals to touch any metal parts of the machine.

• Do not allow metal tools to short between the

battery terminals and metal parts of the machine.

Warning

Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can

m–5598

cause the battery gasses to explode, resulting in personal injury.

• 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.

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).

5. Slide the red terminal boot onto the positive (red)

battery post.

6. Secure battery with J-bolts, hold down clamp and 2

washers (1/4 inch), and 2 wing nuts (1/4 inch) (Fig.

62).

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. Note: When the battery is removed, the electronic control

unit (ECU) will loose its memory. The machine may run different for the first few hours while it recalibrates.

Page 49

Adding Water to the Battery

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.

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 48.

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

m–4970

6. Reinstall battery vent caps.

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 48.

2. Check the electrolyte level; refer to Checking

Electrolyte Level, page 47.

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).

Adjusting the Mower Level

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. 64).

m–4164

Figure 64

1. Transport position 2. 2 inch (51 mm)

height-of-cut

Page 50

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).

6. Loosen 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 four (4) 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 one front blocks 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.

2. Springs are compressed so the distance between the

two large washers should be 11 inch (279 mm) (Fig. 65).

3. Adjust by turning nut in front of each spring (Fig. 65).

Clockwise will shorten spring; counterclockwise will lengthen spring.

Cleaning Under the Deck

Remove grass build up under deck daily.

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. Raise deck to the transport position.

3. Raise front of machine by using the Z–Stand. Refer to

Z–Stand operation on page 29.

Danger

Note: When properly adjusted, the front blade tip will be slightly lower than the rear blade tip. See Checking for Bent Blades on page 33 to measure.

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 33.

12.Install anti-scalp rollers for proper height-of-cut and tighten securely.

3. Front swivel

4. 11 inch (279 mm) spring

m–3747

compressed

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.

Inspecting the Belts

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 51.

Adjusting the Compression Spring

1. Raise deck lift lever to the transport position, (Fig. 64).

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).

Page 51

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 Nm). Tighten two nuts.

5. Install clutch retaining strap and plug clutch terminal

into main wire harness (Fig. 67).

M–4312

Figure 66

Top View

1. Deck belt

2. Idler arm

3. Idler nuts

4. Idler adjusting nut

6. Reinstall the PTO drive belt. Refer to Replacing the

PTO Drive Belt, page 51.

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.

-4451

M-4373

Figure 67

1. Clutch

2. Clutch retaining strap

3. Clutch terminal

4. PTO belt

5. Machine frame

6. 1/4 inch belt twist

7. 1/8 inch belt twist

6. Check belt tension. The center bolt of spring loaded

idler must be between the two alignment holes in left support plate (Fig 68).

Note: Check position of center bolt in Low Height of Cut. The center bolt must be at or below the top alignment hole.

Check position of center bolt in a High Height of Cut. The center bolt must be at or above the lower adjustment hole (Fig 68).

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 clutch retaining strap from machine frame

and unplug clutch terminal from wire harness (Fig. 67).

3. Remove PTO drive belt from rear idler arm and front

idler pulley assembly. Remove the PTO drive belt (Fig. 67).

4. Place new drive belt over clutch, around rear idler

pulley, installed into rear idler arm assembly, installed into front idler pulley assembly and onto top center pulley (Fig. 67).

Important Check the amount of twist in belt between

pulleys. Make sure it is only what is specified in figure 67.

Figure 68

1. Center bolt, spring loaded idler

2. Alignment hole

7. If adjustment is required, loosen the fixed idler on right support plate and move up or down in adjustment slot. To relieve belt tension lift up on spring loaded idler.

M–4417

Page 52

m–3746

Figure 69

1. Fixed Idler 2. Adjustment slot

8. Check belt tension again. The center bolt of spring

loaded idler must be between the two alignment holes in left support plate (Fig 68). Adjust, if necessary, and tighten all hardware securely.

9. 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. 70).

10.To lengthen, loosen jam nut and rotate ball joint

counterclockwise, one turn at a time. Adjust each side the same amount (Fig. 70).

M–4374

Figure 71

1. Belt guide

2. PTO drive belt

3. 1/8–1/4 inch (3–7 mm)

Replacing the Grass Deflector

Warning

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.

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.

m–6273

Figure 70

1. Push arm

2. 15 inches (381 mm) nominal

3. Jam nut

4. Ball joint

11. Rotate the belt guide, on rear of the mower, so it is 1/8–1/4 inch (3–7 mm) away from the vertical side of the PTO belt (Fig. 71).

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.

Page 53

1. Bolt

2. Spacer

3. Locknut

4. Spring

5. Spring installed

Figure 72

6. Grass Deflector

7. L end of spring, place

8. J hook end of spring

m–5037

behind deck edge before installing bolt

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 Disposal

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 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.

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 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.

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.

Page 54

Wiring Diagram

WHITE

VIOLET

PINK

RED

TAN

YELLOW

WIRE COLOR CODES

SW1

SXY B

(IGNITION)

KEY SWITCH PN 88–9830

BLUE

BLACK

BROWN

OFF NO CONNECTION

ON B I A AND X Y

START B I S

VIO

GREEN

GREY

RPK

BNOR

ORANGE

KEY SW

GND

–+

SW7

(TILT SW)

TERMINAL VIEW FROM

BACK OF SWITCH

VIOLET – ALTERNATOR

BATTERY

SWITCH OPENS

WHEN TILTED

PAST 60 DEGREES

FROM VERTICAL

RED – FUSE (ECU & FUEL PUMP POWER)

SW6

(SEAT SW)

SHOWN WITH

OPERATOR

30A

IN SEAT

P1–A

DELAY MODULE

STARTER

P2–C

100–6186

P1–C

P1–B

HOUR

METER

–+

NOTE: SOME COLORS CHANGE AT THE

3 4

GREEN – OIL PRESSURE

ENGINE CONNECTOR

(START RELAY)

RED/YELLOW – ECU & PUMP RELAY

RED/YELLOW – FUEL PUMP RELAY

BLUE – ENGINE MODULE (ECU)

FUEL

PUMP

LAMP

(Safety Relay)

RED/BLUE – FUEL PUMP FUSE

ECU SAFETY

SW2

(PTO)

SHOWN IN

OFF POSITION

VIO

SW3

(BRAKE)

DISENGAGED

SHOWN WITH

PARK BRAKE

PTO

CLUTCH

SHOWN WITH

LEVER IN

NEUTRAL

POSITION

SW4

(NEUTRAL)

W GN

SHOWN WITH

SW5

LEVER IN

NEUTRAL

POSITION

(NEUTRAL)

GND

Page 55

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 35.

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 39. 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 40.

5. Change the crankcase oil and filter; refer to Servicing

the Engine Oil, page 36.

6. Change the hydraulic filter; refer to Servicing the

Hydraulic System, page 42.

7. Check the tire pressure; refer to Checking the Tire

Pressure, page 41.

8. Charge the battery; refer to Servicing the Battery

page 47.

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 33.

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 37. 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.

Page 56

Troubleshooting

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. Air cleaner is dirty. 2. Clean or replace air cleaner

3. Spark plug wires is loose or disconnected.

4. Spark plugs are pitted, fouled, or gap is incorrect.

5. Dirt in fuel filter. 5. Replace fuel filter.

6. Dirt, water, or stale fuel is in fuel system.

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.

3. Install wires on spark plug.

4. Install new, correctly gapped spark plugs.

6. Contact Authorized Service Dealer.

Engine loses power.

Engine overheats.

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.

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.

Page 57

Problem Corrective ActionPossible Causes

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.

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.

Page 58

Problem Corrective ActionPossible Causes

Malfunction Indicator Light (MIL) comes on.

1. Old gas in gas tank or fuel shut off valve not open completely.

2. Fuel tank vent cap is blocked. 2. Make sure fuel tank vent cap is

3. Air cleaner is dirty. 3. Make sure air cleaner and

4. Incorrect fuel filters used or dirty fuel filters.

5. Connections to sensors, electronic control unit (ECU), and fuel injectors are not secured properly.

6. 12 volt battery being used is not fully charged.

1. Use new gas and ensure shut off valve is open.

not blocked and working properly.

precleaner is clean. Replace if necessary.

4. Install correct fuel and ensure that it is clean.

5. Ensure all connections to sensors are properly secured.

6. Ensure a good 12 volt battery is being used and fully charged.

Page 59

Page 60

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

Instructions for Obtaining Warranty Service

If you think that your Toro 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)

Y ou 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 Toro 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 d o n o t a l l o w 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 W arranty Company.

Part No. 374-0037 Rev. C