Toro 74261, 74262, 74263 Operator's Manual

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Form No. 3354-305 Rev B

Z500 Z Master, With 52in, 60in or 72in Turbo Force® Side Discharge Mower

Model No. 74261 —Serial No. 260000001 and Up Model No. 74262 —Serial No. 260000001 and Up Model No. 74263 —Serial No. 260000001 and Up

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Warning

CALIFORNIA

Pr oposition 65 W ar ning

T he engine exhaust fr om this pr oduct contains chemicals kno wn to the State of Calif or nia to cause cancer , bir th defects, or other r epr oducti v e har m.

Important: T his engine is not equipped with a spar k ar r ester muf ﬂer . It is a violation of Calif or nia Public R esource Code Section 4442 to use or operate the engine on an y f or est-co v er ed, br ush-co v er ed, or g rass-co v er ed land. Other states or federal ar eas may ha v e similar la ws.

Figure 1

1. Model and serial number location

T his spark ignition system complies with Canadian ICES-002

T he enclosed Engine Owner’ s Man ual is supplied f or inf or mation r egarding the US En vir onmental Pr otection Agency (EP A) and the Calif or nia Emission Contr ol R egulation of emission systems, maintenance, and w ar ranty . R eplacements may be order ed thr ough the engine man uf actur er .

Introduction

R ead this infor mation carefully to lear n ho w to operate and maintain y our product properly and to a v oid injur y and product damag e . Y ou are responsible for operating the product properly and safely .

Y ou ma y contact T oro directly at www .T oro .com for product and accessor y infor mation, help ﬁnding a dealer , or to register y our product.

Model No.

Serial No.

T his man ual identiﬁes potential hazards and has safety messag es identiﬁed b y the safety aler t symbol ( Figure 2 ), whic h signals a hazard that ma y cause serious injur y or death if y ou do not follo w the recommended precautions .

Figure 2

1. Safety alert symbol

T his man ual uses 2 other w ords to highlight infor mation. Impor tant calls attention to special mec hanical infor mation and Note emphasizes g eneral infor mation w or th y of special attention.

W henev er y ou need ser vice , g en uine T oro par ts , or additional infor mation, contact an A uthorized Ser vice Dealer or T oro Customer Ser vice and ha v e the model and serial n umbers of y our product ready . Figure 1 identiﬁes the location of the model and serial n umbers on the product. W rite the n umbers in the space pro vided.

Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safe Operating Practices . . . . . . . . . . . . . . . . . . . . . . 4

Slope Char t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Safety and Instr uctional Decals . . . . . . . . . . . . 8

Product Ov er view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Adding Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Chec king the Engine Oil Lev el . . . . . . . . . . . 15

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Using the R ollo v er Protection

System (R OPS) . . . . . . . . . . . . . . . . . . 15

T hink Safety First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Operating the P arking Brak e . . . . . . . . . . . . . . 17

Star ting and Stopping the

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Operating the P o w er T ak e Off

(PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

T he Safety Interloc k System . . . . . . . . . . . . . . . 19

Dri ving F orw ard or Bac kw ard . . . . . . . . . . . . 20

Stopping the Mac hine . . . . . . . . . . . . . . . . . . . . . . . . 21

Adjusting the Height-of-Cut . . . . . . . . . . . . . . 21

Adjusting the Anti-Scalp

R ollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Adjusting the Flo w Bafﬂe . . . . . . . . . . . . . . . . . . . 22

P ositioning the Flo w Bafﬂe . . . . . . . . . . . . . . . . 23

Using the Lift Assist Lev er . . . . . . . . . . . . . . . . . 24

P ositioning the Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Unlatc hing the Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Pushing the Mac hine b y Hand . . . . . . . . . . . . 24

Using the Side Disc harg e . . . . . . . . . . . . . . . . . . . 25

Breaking In a New Mac hine . . . . . . . . . . . . . . . 25

T ranspor ting Mac hines . . . . . . . . . . . . . . . . . . . . . . 25

Loading Mac hines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Operating Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

R ecommended Maintenance

Sc hedule(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Greasing and Lubrication . . . . . . . . . . . . . . . . . . . 28

Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Ser vicing the Air Cleaner . . . . . . . . . . . . . . . . . . . 30

Ser vicing the Engine Oil . . . . . . . . . . . . . . . . . . . . 31

Ser vicing the Spark Plugs . . . . . . . . . . . . . . . . . . . 32

Fuel System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 33

R e placing the Fuel Filter . . . . . . . . . . . . . . . . . . . . 33

Ser vicing the Fuel T ank . . . . . . . . . . . . . . . . . . . . . . 34

Electrical System Maintenance . . . . . . . . . . . . . . . . . . . 34

Ser vicing the Batter y . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Ser vicing the Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Dri v e System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 37

Adjusting the T rac king . . . . . . . . . . . . . . . . . . . . . . . 37

Chec king the Tire Pressure . . . . . . . . . . . . . . . . . 37

Chec king the W heel Hub Slotted

Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Adjusting the Caster Pi v ot

Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Cooling System Maintenance . . . . . . . . . . . . . . . . . . . . . 38

Cleaning the Engine Screen and the

Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . 38

Cleaning the Engine Fins . . . . . . . . . . . . . . . . . . . 39

Brak e Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Adjusting the P arking Brak e . . . . . . . . . . . . . . . 39

Belt Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Inspecting the Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

R e placing the Mo w er Belt . . . . . . . . . . . . . . . . . . 39

Adjusting the Mo w er Belt

T ension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

R e placing the Pump Dri v e

Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Controls System Maintenance . . . . . . . . . . . . . . . . . . . . 42

Adjusting the Control Handle

Neutral P osition . . . . . . . . . . . . . . . . 42

Hy draulic System Maintenance . . . . . . . . . . . . . . . . . . 43

Chec king the Hy draulic Fluid . . . . . . . . . . . . . 43

R e placing the Hy draulic Filter and

Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Bleeding the Hy draulic System . . . . . . . . . . . 45

Chec king the Hy draulic Hoses . . . . . . . . . . . 45

Setting the Hy draulic Pump

Neutral P osition . . . . . . . . . . . . . . . . 46

Mo w er Dec k Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 48

Lev eling the Mo w er at T hree

P ositions . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Ser vicing the Cutting Blades . . . . . . . . . . . . . . . 50

R e placing the Grass Deﬂector . . . . . . . . . . . . 52

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Cleaning Under the Mo w er . . . . . . . . . . . . . . . . 53

W aste Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Storag e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

T roubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Sc hematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

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Safety

hair , loose clothing or jew elr y ma y g et tangled in mo ving par ts .

Improper use or maintenance b y the operator or o wner can result in injur y . T o reduce the potential for injur y , comply with these safety instr uctions and alw a ys pa y attention to the safety aler t symbol, whic h means CA UTION , W ARNING , or D ANGER -“personal safety instr uction." F ailure to comply with the instr uction ma y result in personal injur y or death.

T his product is capable of amputating hands and feet and thro wing objects . Alw a ys follo w all safety instr uctions to a v oid serious injur y or death.

T his product is designed for cutting and recycling g rass or , when equipped with a g rass bag g er , for catc hing cut g rass . Any use for pur poses other than these could pro v e dang erous to user and b ystanders .

Safe Operating Practices

T he follo wing instr uctions are from ANSI standard B71.4-2004.

Training

• R ead the Operator’ s Man ual and other training material. If the operator(s) or mec hanic(s) can not read English it is the o wner’ 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 mec hanics should be trained. T he o wner is responsible for training the users .

• Nev er let c hildren or untrained people operate or ser vice the equipment. Local regulations ma y restrict the ag e of the operator .

• T he o wner/user can prev ent and is responsible for accidents or injuries occur ring to himself or herself , other people or proper ty .

• Inspect the area where the equipment is to be used and remo v e all objects suc h as roc ks , to ys and wire whic h can be thro wn b y the mac hine .

• Use extra care when handling g asoline and other fuels . T hey are ﬂammable and v apors are explosi v e .

– Use only an appro v ed container

– Nev er refuel or drain the mac hine indoors .

– Nev er remo v e g as cap or add fuel with

engine r unning . Allo w engine to cool before refueling . Do not smok e .

• Chec k that operator’ s presence controls , safety switc hes and shields are attac hed and functioning properly . Do not operate unless they are functioning properly .

Operation

• Nev er r un an engine in an enclosed area.

• Only operate in g ood light, k ee ping a w a y from

holes and hidden hazards .

• Be sure all dri v es are in neutral and parking brak e is eng ag ed before star ting engine . Star t the engine only from the operator’ s position. Use seat belts .

• Nev er raise mo w er with the blades r unning .

• Nev er operate without the PTO shield, or

other guards securely in place . Be sure all interloc ks are attac hed, adjusted properly , and functioning properly .

• Nev er operate with the disc harg e deﬂector raised, remo v ed or altered, unless using a g rass catc her .

• Do not c hang e the engine g o v er nor setting or o v erspeed the engine .

Preparation

• Ev aluate the ter rain to deter mine what accessories and attac hments are needed to properly and safely perfor m the job . Only use accessories and attac hments appro v ed b y the man ufacturer .

• W ear appropriate clothing including hard hat, safety glasses and hearing protection. Long

• Stop on lev el g round, lo w er implements , diseng ag e dri v es , eng ag e parking brak e , shut off engine before lea ving the operator’ s position for any reason including emptying the catc hers or unclog ging the c hute .

• Stop equipment and inspect blades after striking objects or if an abnor mal vibration occurs . Mak e necessar y re pairs before resuming operations .

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• K ee p hands and feet a w a y from the cutting units .

• Nev er car r y passeng ers and k ee p pets and b ystanders a w a y .

• Be aler t, slo w do wn and use caution when making tur ns . Look behind and to the side before c hanging directions .

• Slo w do wn and use caution when crossing roads and sidew alks . Stop blades if not mo wing .

• Be a w are of the mo w er disc harg e direction and do not point it at any one .

• Do not operate the mo w er under the inﬂuence of alcohol or dr ugs .

• Use extreme care when loading or unloading the mac hine into a trailer or tr uc k.

• Use care when approac hing blind cor ners , shr ubs , trees , or other objects that ma y obscure vision.

• Alw a ys a v oid sudden star ting or stopping on a slope . If tires lose traction, diseng ag e the blades and proceed slo wly off the slope .

• F ollo w the man ufacturer’ s recommendations for wheel w eights or counterw eights to impro v e stability .

• Use extreme care with g rass catc hers or other attac hments . T hese can c hang e the stability of the mac hine and cause loss of control.

Using the Rollover Protection System (ROPS)

• K ee p the roll bar in the raised and loc k ed position and use the seat belt when operating the mac hine .

• Be cer tain that the seat belt can be released quic kly in the ev ent of an emerg ency .

• Be a w are there is no rollo v er protection when the roll bar is do wn.

Slope Operation

• Do not mo w slopes g reater than 15 deg rees .

• Do not mo w near drop-offs , ditc hes , stee p

banks or w ater . W heels dropping o v er edg es can cause rollo v ers , whic h ma y result in serious injur y , death or dro wning .

• Do not mo w slopes when g rass is w et. Slipper y conditions reduce traction and could cause sliding and loss of control.

• Do not mak e sudden tur ns or rapid speed c hang es .

• Use a w alk behind mo w er and/or a hand trimmer near drop-offs , ditc hes , stee p banks or w ater .

• R educe speed and use extreme caution on slopes .

• R emo v e or mark obstacles suc h as roc ks , tree limbs , etc . from the mo wing area. T all g rass can hide obstacles .

• W atc h for ditc hes , holes , roc ks , dips , and rises that c hang e the operating angle , as rough ter rain could o v er tur n the mac hine .

• A v oid sudden star ts when mo wing uphill because the mo w er ma y tip bac kw ards .

• Be a w are that loss of traction ma y occur g oing do wnhill. W eight transfer to the front wheels ma y cause dri v e wheels to slip and cause loss of braking and steering .

• Chec k the area to be mo w ed and nev er fold the R OPS in areas where there are slopes , drop offs or w ater .

• Lo w er the rollbar only when absolutely necessar y . Do not w ear the seat belt with the roll bar folded do wn.

• Chec k carefully for o v erhead clearances (i.e . branc hes , doorw a ys , electrical wires) before dri ving under any objects and do not contact them.

Maintenance and storage

• Diseng ag e dri v es , lo w er implement, set parking brak e , stop engine and remo v e k ey or disconnect spark plug wire . W ait for all mo v ement to stop before adjusting, cleaning or re pairing .

• Clean g rass and debris from cutting units , dri v es , m ufﬂers , and engine to help prev ent ﬁres . Clean up oil or fuel spillag e .

• Let engine cool before storing and do not store near ﬂame .

• Shut off fuel while storing or transpor ting . Do not store fuel near ﬂames or drain indoors .

• P ark mac hine on lev el g round. Nev er allo w untrained personnel to ser vice mac hine .

• Use jac k stands to suppor t components when required.

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• Carefully release pressure from components with stored energ y .

• Disconnect batter y or remo v e spark plug wire before making any re pairs . Disconnect the neg ati v e ter minal ﬁrst and the positi v e last. R econnect positi v e ﬁrst and neg ati v e last.

• Use care when c hec king blades . W rap the blade(s) or w ear glo v es , and use caution when ser vicing them. Only re place blades . Nev er straighten or w eld them.

• K ee p hands and feet a w a y from mo ving par ts . If possible , do not mak e adjustments with the engine r unning .

• Charg e batteries in an open w ell v entilated area, a w a y from spark and ﬂames . Unplug c harg er before connecting or disconnecting from batter y . W ear protecti v e clothing and use insulated tools .

• K ee p all par ts in g ood w orking condition and all hardw are tightened. R e place all w or n or damag ed decals .

• Use only T oro appro v ed attac hments . W ar ranty ma y be v oided if used with unappro v ed attac hments .

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Slope Chart

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Safety and Instructional Decals

Safety decals and instr uctions are easily visible to the operator and are located near any area of potential dang er . R e place any decal that is damag ed or lost.

1-403005

54-9220

1-523552

58-6520

1. Grease

1-633462

66-1340

1-643339

68-8340

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1. Warning—wear hearing protection.

98-4387

98-5954

110-5721

1. Engine—stop

2. Engine—run

3. Engine—start

4. Power take-off (PTO)

5. Fast

6. Continuous variable setting

7. Slow

8. Choke

103-5881

105-7798

107-1621

105-7797

Page 10

107-1622

107-1860

107-1857

107-2112

107-1861

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107-1864

Battery Symbols

Some or all of these symbols are on your battery

1. Explosion hazard 6. Keep bystanders a safe

2. No re, open ame, or smoking.

3. Caustic liquid/chemical burn hazard

4. Wear eye protection

5. Read the Operator’s

Manual.

distance from the battery.

7. Wear eye protection; explosive gases can cause blindness and other injuries

8. Battery acid can cause blindness or severe burns.

9. Flush eyes immediately with water and get medical help fast.

10. Contains lead; do not discard.

108-5278

1. Read the Operator’s Manual .

Manufacturer’s Mark

1. Indicates the blade is identied as a part from the original machine manufacturer.

107-2102

107-1613

Page 12

106-7492

106-9989

107-8076

1. Fast

2. Slow 3. Neutral

4. Reverse

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Product Overview

Figure 3

1. Motion control lever 5. Controls

2. Parking brake lever 6. Seat belt

3. Height-of-cut lever 7. Roll bar

4. Fuel cap (both sides)

Controls

Become familiar with all the controls before y ou star t the engine and operate the mac hine ( Figure 3 and Figure 4 ).

Figure 4

1. Ignition switch

2. Throttle

3. Choke

Hour Meter

4. Power take off (PTO)

5. Hour meter

6. Gas cap

T he hour meter records the n umber of hours the engine has operated. It operates when the engine is r unning . Use these times for sc heduling regular maintenance ( Figure 4 ).

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Operation

Note: Deter mine the left and right sides of the

mac hine from the nor mal operating position.

Adding Fuel

Use unleaded regular g asoline suitable for automoti v e use (85 pump octane minim um). Leaded regular g asoline ma y be used if unleaded regular is not a v ailable .

Important: Nev er use methanol, gasoline containing methanol, or gasohol containing mor e than 10% ethanol because the fuel system could be dama ged. Do not mix oil with gasoline.

In cer tain conditions, gasoline is extr emel y ﬂamma ble and highl y explosi v e. A ﬁr e or explosion fr om gasoline can bur n y ou and other s and can dama ge pr oper ty .

• Fill the fuel tank outdoor s, in an open ar ea, when the engine is cold. W ipe up an y gasoline that spills.

• Nev er ﬁll the fuel tank inside an enclosed trailer .

In cer tain conditions during fueling , static electricity can be r eleased causing a spar k which can ignite the gasoline v apor s. A ﬁr e or explosion fr om gasoline can bur n y ou and other s and can dama ge pr oper ty .

• Al w ays place gasoline container s on the g r ound a w ay fr om y our v ehicle bef or e ﬁlling .

• Do not ﬁll gasoline container s inside a v ehicle or on a tr uck or trailer bed because interior car pets or plastic tr uck bed liner s may insulate the container and slo w the loss of an y static charge.

• W hen practical, r emo v e gas-po w er ed equipment fr om the tr uck or trailer and r efuel the equipment with its wheels on the g r ound.

• If this is not possible, then r efuel such equipment on a tr uck or trailer fr om a por ta ble container , rather than fr om a gasoline dispenser nozzle.

• If a gasoline dispenser nozzle must be used, k eep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete.

• Do not ﬁll the fuel tank completel y full. Add gasoline to the fuel tank until the lev el is 1/4 to 1/2 inch (6 to 13 mm) belo w the bottom of the ﬁller neck. T his empty space in the tank allo ws gasoline to expand.

• Nev er smok e when handling gasoline, and stay a w ay fr om an open ﬂame or wher e gasoline fumes may be ignited by a spar k.

• Stor e gasoline in an appr o v ed container and k eep it out of the r each of childr en. Nev er buy mor e than a 30-day suppl y of gasoline.

• Do not operate without entir e exhaust system in place and in pr oper w or king condition.

Gasoline is har mful or f atal if s w allo w ed. Long-ter m exposur e to v apor s can cause serious injur y and illness.

• A v oid pr olonged br eathing of v apor s.

• K eep f ace a w ay fr om nozzle and gas tank or conditioner opening .

• K eep gas a w ay fr om ey es and skin.

Using Stabilizer/Conditioner

Use a fuel stabilizer/conditioner in the mac hine to pro vide the follo wing beneﬁts:

• K ee ps g asoline fresh during storag e of 90 da ys or less . F or long er storag e it is recommended that the fuel tank be drained.

Page 15

• Cleans the engine while it r uns

• Eliminates gum-lik e v ar nish buildup in the fuel

system, whic h causes hard star ting

Important: Do not use fuel additi v es containing methanol or ethanol.

Add the cor rect amount of g as stabilizer/conditioner to the g as .

Note: A fuel stabilizer/conditioner is most effecti v e when mix ed with fresh g asoline . T o minimize the c hance of v ar nish de posits in the fuel system, use fuel stabilizer at all times .

Filling the Fuel Tank

1. Shut the engine off and set the parking brak e .

2. Clean around eac h fuel tank cap and remo v e the cap .

3. Add unleaded regular g asoline to both fuel tanks , until the lev el is 1/4 to 1/2 inc h (6 mm to 13 mm) belo w the bottom of the ﬁller nec k.

T his space in the tank allo ws g asoline to expand. Do not ﬁll the fuel tanks completely full.

4. Install fuel tank caps securely .

5. Wipe up any g asoline that ma y ha v e spilled.

Checking the Engine Oil

T her e is no r ollo v er pr otection when the r oll bar is in the do wn position.

• Lo w er the r oll bar onl y when a bsolutel y necessar y .

• Do not w ear the seat belt when the r oll bar is in the do wn position.

• Dri v e slo wl y and car efull y .

• R aise the r oll bar as soon as clearance per mits.

• Check car efull y f or o v erhead clearances (i.e. branches, doorw ays, electrical wir es) bef or e dri ving under an y objects and do not contact them.

Important: Lo w er the r oll bar onl y when a bsolutel y necessar y .

1. T o lo w er the roll bar , loosen the front knobs ( Figure 7 ).

2. R emo v e the hair pin cotter pins and remo v e the tw o pins ( Figure 6 ).

3. Lo w er the roll bar to the do wn position. T here are tw o do wn positions . See Figure 5 for the positions .

4. Install the tw o pins and secure them with the hair pin cotter pins ( Figure 6 ).

Level

Before y ou star t the engine and use the mac hine , c hec k the oil lev el in the engine crankcase; refer to Chec king the Oil Lev el in Engine Maintenance , pag e 30

Using the Rollover Protection System (ROPS)

T o a v oid injur y or death fr om r ollo v er : k eep the r oll bar in the raised lock ed position and use the seat belt.

Ensur e that the r ear par t of the seat is secur ed with the seat latch.

Figure 5

1. Full down position 2. Down position with bagger installed

Important: Ensur e that the r ear par t of the seat is secur ed with the seat latch.

Page 16

5. T o raise the roll bar , remo v e the hair pin cotter pins and remo v e the tw o pins ( Figure 6 ).

6. Raise the roll bar to the upright position and install the tw o pins and secure them with the hair pin cotter pins ( Figure 6 ).

Important: Al w ays use the seat belt with the r oll bar in the raised position.

Think Safety First

Please read all safety instr uctions and symbols in the safety section. Kno wing this infor mation could help y ou or b ystanders a v oid injur y .

Operating on w et g rass or steep slopes can cause sliding and loss of contr ol.

W heels dr opping o v er edges can cause r ollo v er s, which may r esult in serious injur y , death or dr o wning .

T her e is no r ollo v er pr otection when the r oll bar is do wn.

Al w ays k eep the r oll bar in the raised and lock ed position and use the seat belt.

R ead and f ollo w the r ollo v er pr otection instr uctions and w ar nings.

T o a v oid loss of contr ol and possibility of r ollo v er :

Figure 6

1. Roll bar

2. Raised position

3. Pin

4. Hairpin cotter pin

Important: Tighten the fr ont knobs a gainst the center r oll bar ends ( Figur e 7 ).

• Do not operate near dr op-of fs or near w ater .

• Do not operate on slopes g r eater than 15 deg r ees.

• R educe speed and use extr eme caution on slopes.

• A v oid sudden tur ns or rapid speed changes.

1. Front handle

Figure 7

Page 17

Setting the Parking Brake

1. Mo v e the motion control lev ers ( Figure 16 ) out to the neutral loc k position.

2. Pull up and bac k on the parking brak e lev er to set the parking brak e ( Figure 10 ). T he parking brak e lev er should sta y ﬁr mly in the eng ag ed position.

P ar king brak e may not hold machine par k ed on a slope and could cause per sonal injur y or pr oper ty dama ge.

Figure 8

1. Safe Zone-use the Z Master here on slopes less than 15 degrees or at areas.

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

3. Water

T his machine pr oduces sound lev els in ex cess of 85 dB A at the operator s ear and can cause hearing loss thr ough extended periods of exposur e.

W ear hearing pr otection when operating this machine.

W ear protecti v e equipment for y our eyes , ears , feet, and head when using this mac hine .

Do not par k on slopes unless wheels ar e chock ed or block ed

Releasing the Parking Brake

Push forw ard and do wn on the parking brak e lev er to release the parking brak e ( Figure 10 ). T he parking brak e is diseng ag ed and the lev er will rest ag ainst the brak e stop .

Figure 9

1. Warning— wear hearing protection

Operating the Parking Brake

Alw a ys set the parking brak e when y ou stop the mac hine or lea v e it unattended.

Figure 10

1. Parking brake-ON 3. Brake Stop

2. Parking brake-OFF

Starting and Stopping the Engine

Starting the Engine

1. Sit on the seat and mo v e the motion controls to neutral loc k ed position.

2. Set the parking brak e; refer to Setting the P arking Brak e .

Page 18

3. Mo v e the PTO (po w er tak e off) switc h to the Off position ( Figure 11 ).

Figure 11

1. PTO—on

2. PTO—off

4. Mo v e the c hok e control to the on position before star ting a cold engine ( Figure 12 ).

Note: A w ar m or hot engine ma y not require c hoking . After engine star ts , mo v e c hok e control to R un position.

Figure 13

1. Throttle—fast 2. Throttle—slow

6. T ur n the ignition k ey to Star t ( Figure 14 ). W hen the engines star ts , release the k ey .

Important: Do not enga ge star ter f or mor e than 10 seconds at a time. If engine f ails to star t allo w 30 second cool-do wn period betw een attempts. F ailur e to f ollo w these instr uctions can bur n out star ter motor .

Figure 14

1. Off

2. Run

3. Start

Figure 12

1. Choke—on 2. Choke—off

5. Mo v e the throttle control to the F ast position before star ting a cold engine ( Figure 13 ).

7. After the engine star ts , mo v e the c hok e to off ( Figure 12 ). If the engine stalls or hesitates , mo v e the c hok e bac k to on for a few seconds , then mo v e the throttle lev er to desired setting . R e peat this as required.

Stopping the Engine

1. Push the PTO to the off position ( Figure 11 ).

2. Mo v e the throttle lev er midw a y betw een the slo w and fast positions ( Figure 13 ).

3. Let the engine idle for 60 seconds .

Page 19

4. T ur n the ignition k ey to the off position and remo v e the k ey ( Figure 14 ).

5. Close the fuel shut off v alv e before transpor ting or storing the mac hine . R efer to Fuel System Maintenance , pag e 33 .

Important: Mak e sur e that the fuel shut of f v alv e is closed bef or e transpor ting or storing the machine, as fuel leaka ge may occur . Set the par king brak e bef or e transpor ting . Mak e sur e to r emo v e the k ey as the fuel pump may r un and cause the batter y to lose charge.

Childr en or bystander s may be injur ed if they mo v e or attempt to operate the tractor while it is unattended.

1. PTO-On

Disengaging the PTO

Figure 15

2. PTO-Off

Al w ays r emo v e the ignition k ey and set the par king brak e when lea ving the machine unattended, ev en if just f or a few min utes.

Operating the Power Take Off (PTO)

T he po w er tak e off (PTO) switc h star ts and stops the mo w er blades and any po w ered attac hments .

Engaging the PTO

1. If the engine is cold, allo w the engine to w ar m up 5 to 10 min utes before eng aging the PTO .

2. W hile seated in the seat, release the pressure on the traction control lev ers and place in neutral.

3. Place the throttle in the fast position. Note: Eng aging the PTO with the throttle

at the half or less position will cause ex cessi v e w ear to the dri v e belts .

4. Pull out on the po w er tak e off (PTO) switc h to eng ag e it ( Figure 15 ).

T o diseng ag e , push the PTO switc h to the Off position ( Figure 15 ).

The Safety Interlock System

If safety inter lock s witches ar e disconnected or dama ged the machine could operate unexpectedl y causing per sonal injur y .

• Do not tamper with the inter lock s witches.

• Check the operation of the inter lock s witches dail y and r eplace an y dama ged s witches bef or e operating the machine.

Understanding the Safety Interlock System

T he safety interloc k system is designed to prev ent the engine from star ting unless:

• Y ou are sitting on the seat.

• T he parking brak e is eng ag ed.

• T he po w er tak e off (PTO) is diseng ag ed.

• T he motion control lev ers are in the neutral

loc k ed position

T he safety interloc k system also is designed to stop the engine when the traction controls are mo v ed from the loc k ed position with the parking brak e

Page 20

eng ag ed or if y ou rise from the seat when the PTO is eng ag ed.

Testing the Safety Interlock System

T est the safety interloc k system before y ou use the mac hine eac h time . If the safety system does not operate as described belo w , ha v e an A uthorized Ser vice Dealer re pair the safety system immediately .

Machine can spin v er y rapidl y . Operator may lose contr ol of machine and cause per sonal injur y or dama ge to machine.

• Use caution when making tur ns.

• Slo w the machine do wn bef or e making shar p tur ns.

1. Sitting on the seat, eng ag e the parking brak e and mo v e the PTO to on. T r y star ting the engine; the engine should not crank.

2. Sitting on the seat, eng ag e the parking brak e and mo v e the PTO to off . Mo v e either motion control lev er (out of neutral loc k ed position). T r y star ting the engine; the engine should not crank. R e peat for other control lev er .

3. Sitting on the seat, eng ag e the parking brak e , mo v e the PTO switc h to off and mo v e the motion control lev ers to neutral loc k position. No w star t the engine . W hile the engine is r unning, release the parking brak e , eng ag e the PTO and rise slightly from the seat; the engine should stop .

4. Sitting on the seat, eng ag e the parking brak e , mo v e the PTO switc h to off and mo v e the motion control lev ers to neutral loc k position. No w star t the engine . W hile the engine is r unning, center either motion control and mo v e (forw ard or rev erse); the engine should stop . R e peat for other motion control.

5. Sitting on the seat, diseng ag e the parking brak e , mo v e the PTO switc h to off and mo v e the motion control lev ers to neutral loc k position. T r y star ting the engine; the engine should not crank.

Driving Forward

1. R elease the parking brak e; refer to R eleasing the P arking Brak e .

2. Mo v e the lev ers to the center , un-loc k ed position.

3. T o g o forw ard, slo wly push the motion control lev ers forw ard ( Figure 16 ).

Note: T he engine will kill if the traction control lev ers are mo v ed with the parking brak e eng ag ed.

T o g o straight, apply equal pressure to both motion control lev ers ( Figure 16 ).

T o tur n, mo v e the motion control lev er to w ard neutral in the direction y ou w ant to tur n ( Figure 16 ).

T he far ther y ou mo v e the traction control lev ers in either direction, the faster the mac hine will mo v e in that direction.

T o stop , pull the motion control lev ers to the neutral position.

Driving Forward or Backward

T he throttle control regulates the engine speed as measured in r pm (rev olutions per min ute). Place the throttle control in the fast position for best perfor mance . Alw a ys operate in the full throttle position when mo wing .

1. Motion control lever-neutral lock position

2. Center un-lock position 4. Backward

Figure 16

3. Forward

Page 21

Driving Backward

1. Mo v e the lev ers to the center , un-loc k ed position.

2. T o g o bac kw ard, slo wly pull the motion control lev ers rearw ard ( Figure 16 ).

T o g o straight, apply equal pressure to both motion control lev ers ( Figure 16 ).

T o tur n, release pressure on the motion control lev er to w ard the direction y ou w ant to tur n ( Figure 16 ).

T o stop , push the motion control lev ers to the neutral position.

Stopping the Machine

T o stop the mac hine , mo v e the traction control lev ers to neutral and mo v e to loc k ed position, diseng ag e the po w er tak e off (PTO), and tur n the ignition k ey to off .

Set the parking brak e when y ou lea v e the mac hine; refer to Setting the P arking Brak e . R emember to remo v e the k ey from the ignition switc h.

Childr en or bystander s may be injur ed if they mo v e or attempt to operate the tractor while it is unattended.

Al w ays r emo v e the ignition k ey and set the par king brak e when lea ving the machine unattended, ev en if just f or a few min utes.

Adjusting the Height-of-Cut

T he height-of-cut is adjusted from 1-1/2 to 5 inc h (38 to 127 mm) in 1/4 inc h (6 mm) increments b y relocating the clevis pin into different hole locations .

1. Raise the height-of-cut lev er to the transpor t position (also the 5 inc h (127 mm) cutting height position) ( Figure 17 ).

Figure 17

1. Height of cut lever 2. Clevis Pin

2. T o adjust, remo v e the clevis pin from the height-of-cut brac k et ( Figure 17 ).

3. Select a hole in the height-of-cut brac k et cor responding to the height-of-cut desired and, inser t the clevis pin ( Figure 17 ).

4. Mo v e the lev er to the selected height.

Adjusting the Anti-Scalp Rollers

W henev er y ou c hang e the height-of-cut, it is recommended to adjust the height of the anti-scalp rollers .

Adjusting the Outer Roller

1. Diseng ag e the PTO , mo v e the motion control lev ers to the neutral loc k ed position, and set the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. After adjusting the height-of-cut, remo v e the ﬂang e n ut, bushing, spacer , and bolt ( Figure 18 ).

Page 22

Figure 18

1. Outer roller 4. Bolt

2. Spacer

3. Bushing

5. Nut

4. Select a hole so that the outer roller is positioned to the nearest cor responding height-of-cut desired ( Figure 18 ).

5. Install the outer roller , bushing, spacer , bolt, and n ut ( Figure 18 ).

6. T or que the bolt to 40 to 45 ft-lb (54 to 61 N ⋅ m).

Figure 19

1. Outer roller 4. Bolt

2. Spacer

3. Bushing

5. Nut

4. Select a hole so that the center rollers are positioned to the nearest cor responding height-of-cut desired ( Figure 19 ).

Note: Do not adjust the rollers to suppor t the mo w er housing .

5. Install the center rollers , bushing, spacer , bolt, and n ut ( Figure 19 ).

6. T or que the bolt to 40 to 45 ft-lb (54 to 61 N ⋅ m).

Adjusting the Center Rollers

1. Diseng ag e the PTO , mo v e the motion control lev ers to the neutral loc k ed position, and set the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. After adjusting the height-of-cut, remo v e the ﬂang e n ut, bushing, and bolt ( Figure 19 ).

Adjusting the Flow Bafe

T he mo w er disc harg e ﬂo w can be adjusted for different types of mo wing conditions . P osition the cam loc ks and bafﬂe to gi v e the best quality of cut.

1. Diseng ag e the PTO , mo v e the motion control lev ers to the neutral loc k ed position and set the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. T o adjust the cam loc ks , swing the lev er up to loosen the cam loc k ( Figure 20 ).

4. Adjust the bafﬂe and cam loc ks in the slots to the desired disc harg e ﬂo w .

5. Swing the lev er bac k o v er to tighten the bafﬂe and cam loc ks ( Figure 20 ).

6. If the cams do not loc k the bafﬂe into place or it is too tight, loosen the lev er and then rotate

Page 23

the cam loc k. Adjust the cam loc k until the desired loc king pressure is ac hiev ed.

Figure 20

1. Cam lock

2. Lever

3. Rotate cam to increase or decrease locking pressure

4. Slot

Positioning the Flow Bafe

T he follo wing ﬁgures are only recommendations for use . Adjustments will v ar y b y g rass type , moisture content, and height of g rass .

Note: If the engine po w er dra ws do wn and the mo w er g round speed is the same , open up the bafﬂe .

Position B

Use this position when bag ging .

Figure 22

Position C

T his is the full open position. T he sug g ested use for this position is as follo ws .

• Use in tall, dense g rass mo wing conditions .

Position A

T his is the full rear position. T he sug g ested use for this position is a follo ws .

• Use for shor t, light g rass mo wing conditions .

• Use in dr y conditions .

• F or smaller g rass clippings .

• Propels g rass clippings far ther a w a y from the

mo w er .

Figure 21

• Use in w et conditions .

• Lo w ers the engine po w er consumption.

• Allo ws increased g round speed in hea vy

conditions .

• T his position is similar to the beneﬁts of the T oro SFS mo w er .

Page 24

1. Adjustment lever

Figure 25

Figure 23

Using the Lift Assist Lever

T he lift assist lev er is used along with the height-of-cut lev er for raising the mo w er . T his allo ws for easier raising of the mo w er .

1. Place y our foot onto lift assist lev er .

2. Press on the lift assist lev er while pulling up on the height-of-cut lev er ( Figure 24 ).

Unlatching the Seat

Push the seat latc h rearw ard to unlatc h the seat. T his will allo w access to the mac hine under the seat ( Figure 26 ).

Figure 26

1. Seat latch

2. Fuel cap

3. Seat

Figure 24

1. Lift Assist Lever

Positioning the Seat

T he seat can mo v e forw ard and bac kw ard. P osition the seat where y ou ha v e the best control of the mac hine and are most comfor table .

Important: T o adjust, mo v e the lev er sidew ays to unlock seat ( Figur e 25 ).

Slide the seat to the desired position and release lev er to loc k in position.

Pushing the Machine by Hand

Important: Al w ays push the machine

by hand. Nev er to w the machine because h y draulic dama ge may occur .

Pushing the Machine

1. Diseng ag e the po w er tak e off (PTO) and tur n the ignition k ey to off . Mo v e the lev ers to neutral loc k ed position and apply parking brak e . R emo v e the k ey .

2. R otate the b y-pass v alv es countercloc kwise 1 tur n to push. T his allo ws h y draulic ﬂuid to

Page 25

b y-pass the pump enabling the wheels to tur n ( Figure 27 ).

Important: Do not r otate by-pass v alv es mor e than 1 tur n. T his pr ev ents v alv es fr om coming out of the body and causing ﬂuid to r un out.

W ithout the g rass deﬂector , discharge co v er , or complete g rass catcher assembl y mounted in place, y ou and other s ar e exposed to blade contact and thr o wn de bris. Contact with r otating mo w er blade(s) and thr o wn de bris will cause injur y or death.

• Nev er r emo v e the g rass deﬂector fr om the mo w er because the g rass deﬂector r outes material do wn to w ard the turf. If the g rass deﬂector is ev er dama ged, r eplace it immediatel y .

• Nev er put y our hands or feet under the mo w er .

• Nev er tr y to clear the discharge ar ea or mo w er blades unless y ou mo v e the po w er tak e of f (PT O) to the of f position, r otate the ignition k ey to of f and r emo v e the k ey .

Figure 27

1. By-pass valve 2. Hydraulic tank

3. Diseng ag e parking brak e before pushing .

Changing to Machine Operation

R otate the b y-pass v alv es cloc kwise 1 tur n to operate mac hine ( Figure 27 ).

Note: Do not o v er tighten the b y-pass v alv es .

T he mac hine will not dri v e unless b y-pass v alv es are tur ned in.

Using the Side Discharge

T he mo w er has a hing ed g rass deﬂector that disperses clippings to the side and do wn to w ard the turf .

• Mak e sur e the g rass deﬂector is in the do wn position.

Breaking In a New Machine

New engines tak e time to dev elop full po w er . Mo w er dec ks and dri v e systems ha v e higher friction when new , placing additional load on the engine . Allo w 40 to 50 hours of break-in time for new mac hines to dev elop full po w er and best perfor mance .

Transporting Machines

Use a hea vy-duty trailer or tr uc k to transpor t the mac hine . Ensure that the trailer or tr uc k has all necessar y lighting and marking as required b y la w . Please carefully read all the safety instr uctions . Kno wing this infor mation could help y ou, y our family , pets or b ystanders a v oid injur y .

T o transpor t the mac hine:

• Loc k the brak e and bloc k the wheels .

• Securely fasten the mac hine to the trailer or

tr uc k with straps , c hains , cable , or ropes .

Page 26

Important: Do not use the motion contr ol lev er s as anchor s f or tieing the machine do wn.

• Secure a trailer to the to wing v ehicle with

safety c hains .

Dri ving on the str eet or r oad w ay without tur n signals, lights, r eﬂecti v e mar kings, or a slo w mo ving v ehicle emblem is danger ous and can lead to accidents causing per sonal injur y .

Do not dri v e machine on a public str eet or r oad w ay .

Loading Machines

Loading a unit onto a trailer or tr uck incr eases the possibility of backw ard tip-o v er and could cause serious injur y or death.

• Use extr eme caution when operating a unit on a ramp .

• Use onl y a sing le, full width ramp; Do Not use indi vidual ramps f or each side of the unit.

• If indi vidual ramps must be used, use enough ramps to cr eate an unbr ok en ramp surf ace wider than the unit.

• Do not ex ceed a 15 deg r ee ang le betw een ramp and g r ound or betw een ramp and trailer or tr uck.

Use extreme caution when loading units on trailers or tr uc ks . One full width ramp that is wide enough to extend bey ond the rear tires is recommended instead of indi vidual ramps for eac h side of the unit ( Figure 28 ). T he lo w er rear section of the tractor frame extends bac k betw een the rear wheels and ser v es as a stop for tipping bac kw ard. Ha ving a full width ramp pro vides a surface for the frame members to contact if the unit star ts to tip bac kw ard. If it is not possible to use one full width ramp , use enough indi vidual ramps to sim ulate a full width contin uous ramp .

T he ramp should be long enough so that the angles do not ex ceed 15 deg rees ( Figure 28 ). A stee per angle ma y cause mo w er components to g et caught as the unit mo v es from ramp to trailer or tr uc k. Stee per angles ma y also cause the unit to tip bac kw ard. If loading on or near a slope , position the trailer or tr uc k so it is on the do wn side of the slope and the ramp extends up the slope . T his will minimize the ramp angle . T he trailer or tr uc k should be as lev el as possible .

• A v oid sudden acceleration while dri ving unit up a ramp to a v oid tipping backw ard.

• A v oid sudden deceleration while backing unit do wn a ramp to a v oid tipping backw ard.

Important: Do not attempt to tur n the unit while on the ramp; y ou may lose contr ol and dri v e of f the side.

A v oid sudden acceleration when dri ving up a ramp and sudden deceleration when bac king do wn a ramp . Both maneuv ers can cause the unit to tip bac kw ard.

Figure 28

1. Trailer 3. Not greater than 15 degrees

2. Full width ramp 4. Full width ramp—side view

Page 27

Operating Tips

Long Grass

Fast Throttle Setting

F or best mo wing and maxim um air circulation, operate the engine at the fast throttle position. Air is required to thoroughly cut g rass clippings , so do not set the height-of-cut so lo w as to totally sur round the mo w er b y uncut g rass . Alw a ys tr y to ha v e one side of the mo w er free from uncut g rass , whic h allo ws air to be dra wn into the mo w er .

Cutting a Lawn for the First Time

Cut g rass slightly long er than nor mal to ensure the cutting height of the mo w er does not scalp any unev en g round. Ho w ev er , the cutting height used in the past is g enerally the best one to use . W hen cutting g rass long er than six inc hes tall, y ou ma y w ant to cut the la wn twice to ensure an acce ptable quality of cut.

Cut 1/3 of the Grass Blade

It is best to cut only about 1/3 of the g rass blade . Cutting more than that is not recommended unless g rass is sparse , or it is late fall when g rass g ro ws more slo wly .

Mowing Direction

Alter nate mo wing direction to k ee p the g rass standing straight. T his also helps disperse clippings whic h enhances decomposition and fer tilization.

Mow at Correct Intervals

Nor mally , mo w ev er y four da ys . But remember , g rass g ro ws at different rates at different times . So to maintain the same cutting height, whic h is a g ood practice , mo w more often in early spring . As the g rass g ro wth rate slo ws in mid summer , mo w less frequently . If y ou cannot mo w for an extended period, ﬁrst mo w at a high cutting height; then mo w ag ain tw o da ys later at a lo w er height setting .

If the g rass is ev er allo w ed to g ro w slightly long er than nor mal, or if it contains a high deg ree of moisture , raise the cutting height higher than usual and cut the g rass at this setting . T hen cut the g rass ag ain using the lo w er , nor mal setting .

When Stopping

If the mac hine’ s forw ard motion m ust be stopped while mo wing, a clump of g rass clippings ma y drop onto y our la wn. T o a v oid this , mo v e onto a previously cut area with the blades eng ag ed.

Keep the Underside of the Mower Clean

Clean clippings and dir t from the underside of the mo w er after eac h use . If g rass and dir t build up inside the mo w er , cutting quality will ev entually become unsatisfactor y .

Blade Maintenance

Maintain a shar p blade throughout the cutting season because a shar p blade cuts cleanly without tearing or shredding the g rass blades . T earing and shredding tur ns g rass bro wn at the edg es , whic h slo ws g ro wth and increases the c hance of disease . Chec k the cutter blades daily for shar pness , and for any w ear or damag e . File do wn any nic ks and shar pen the blades as necessar y . If a blade is damag ed or w or n, re place it immediately with a g en uine TOR O re placement blade .

Cutting Speed

T o impro v e cut quality , use a slo w er g round speed in cer tain conditions .

Avoid Cutting Too Low

If the cutting width of the mo w er is wider than the mo w er y ou previously used, raise the cutting height to ensure that unev en turf is not cut too shor t.

Page 28

Maintenance

Recommended Maintenance Schedule(s)

Maintenance Service

Interval

After the rst 8 operating

hours

After the rst 25

operating hours

Before each use or daily

Every 25 hours

Every 50 hours

Every 100 hours

Every 150 hours

Every 200 hours

Maintenance Procedure

• Check the hydraulic uid level.

• Change the hydraulic lter and oil.

• Check the safety interlock system.

• Check the engine oil level.

• Check the mower blades.

• Clean the mower deck.

• Check the hydraulic uid level.

• Grease the mower bearings.

• Check the tire pressure.

• Check the pump drive belt.

• Change the engine oil.

• Clean the engine cylinder and cylinder head cooling ns

• Inspect the belts for cracks and wear.

• Check the hydraulic hoses.

• Lubricate the machine with light oil.

• Check and/or replace the primary air lter.

• Replace the oil lter.

• Check the spark plugs.

• Replace the fuel lter.

• Grease the brake pivot and lever.

Every 500 hours

Every 600 hours

Yearly

• Check the wheel hub slotted nut.

• Adjust the caster pivot bearing.

• Replace the safety lter.

• Grease the front caster pivots (more often in dirty or dusty conditions).

• Change the hydraulic lter and oil.

Important: R efer to y our Engine Operator’ s Man ual f or additional maintenance pr ocedur es.

If y ou lea v e the k ey in the ignition s witch, someone could accidentl y star t the engine and seriousl y injur e y ou or other bystander s.

R emo v e the k ey fr om the ignition and disconnect the wir e fr om the spar k plug(s) bef or e y ou do an y maintenance. Set the wir e aside so that it does not accidentall y contact the spar k plug .

Lubrication

more frequently when operating conditions are extremely dusty or sandy .

Greasing and Lubrication

Grease T ype: General-pur pose g rease .

Lubricate the mac hine when sho wn on the Chec k Ser vice Ref er ence Aid decal ( Figure 29 ). Grease

Page 29

How to Grease

1. Diseng ag e the PTO , mo v e the motion control lev ers to the neutral loc k ed position and set the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. Clean the g rease ﬁttings with a rag . Mak e sure to scrape any paint off the front of the ﬁtting(s).

4. Connect a g rease gun to the ﬁtting . Pump g rease into the ﬁttings until g rease begins to ooze out of the bearings .

5. Wipe up any ex cess g rease .

Greasing the Front Caster Pivots

Lubricate the front caster pi v ots once a year .

1. R emo v e the dust cap and adjust the caster pi v ots . K ee p the dust cap off until g reasing is done . R efer to Adjusting the Caster Pi v ot Bearing in Dri v e System Maintenance , pag e 37 .

2. R emo v e the hex plug . T hread a g rease zerk into the hole .

3. Pump g rease into the zerk until it oozes out around the top bearing .

4. R emo v e the g rease zerk in the hole . Install the hex plug and cap .

Where to Add Grease

Lubricate the g rease ﬁttings as sho wn on the Chec k Ser vice R eference Aid decal ( Figure 29 ).

Figure 29

Where to Add Light Oil or Spray Lubrication

Lubricate the mac hine in the follo wing areas with spra y type lubricant or light oil. Lubricate ev er y 150 hours .

• Seat switc h actuator .

• Brak e handle pi v ot.

• Brak e rod bushings .

• Motion control bronze bushings .

Greasing the Bearings

Lubricate the cutting mac hine after ev er y 50 operating hours . Grease with No . 2 g eneral-pur pose lithium-base or molybden um-base g rease .

1. Diseng ag e the PTO , mo v e the motion control lev ers to the neutral loc k ed position, and set the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. Grease the ﬁttings on the 3 spindle bearings (Fig . 38).

Page 30

Figure 30

4. Grease the idler pulley pi v ot (Fig . 38).

Engine Maintenance

Servicing the Air Cleaner

Primar y Filter : Chec k and/or re place it after ev er y 200 operating hours or more often in dusty conditions .

Safety Filter : R e place it after ev er y 600 operating hours .

Note: Chec k the ﬁlters more frequently if the operating conditions are extremely dusty or sandy .

Removing the Filters

Figure 31

1. Air cleaner body 4. Air cleaner cover

2. Primary lter 5. Safety lter

3. Latch

4. Clean the inside of the air cleaner co v er with compressed air .

5. Gently slide the primar y ﬁlter out of the air cleaner body ( Figure 31 ).

Note: A v oid knoc king the ﬁlter into the side of the body .

6. R emo v e the safety ﬁlter only if y ou intend to re place it.

Important: Nev er attempt to clean the safety ﬁlter . If the safety ﬁlter is dir ty , then the primar y ﬁlter is dama ged. R eplace both ﬁlter s.

7. Inspect the primar y ﬁlter for damag e b y 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 damag ed, discard it.

1. Diseng ag e the PTO , mo v e the motion control lev ers to the neutral loc k ed position, and set the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. R elease the latc hes on the air cleaner and pull the air cleaner co v er off the air cleaner body ( Figure 31 ).

Servicing the Primary Filter

• Chec k and/or re place the primar y ﬁlter after 200 operating hours .

• If the primar y ﬁlter is dir ty , bent, or damag ed, re place it.

• Do not clean the primar y ﬁlter .

Servicing the Safety Filter

R e place the safety ﬁlter after 600 operating hours .

Important: Nev er attempt to clean the safety ﬁlter . If the safety ﬁlter is dir ty , then the primar y ﬁlter is dama ged. R eplace both ﬁlter s.

Page 31

Installing the Filters Important: T o pr ev ent engine dama ge,

al w ays operate the engine with both air ﬁlter s and co v er installed.

1. If installing new ﬁlters , c hec k eac h ﬁlter for shipping damag e . Do not use a damag ed ﬁlter .

2. If the safety ﬁlter is being re placed, carefully slide it into the ﬁlter body ( Figure 31 ).

3. Carefully slide the primar y ﬁlter o v er the safety ﬁlter ( Figure 31 ).

Note: Ensure that the primar y ﬁlter is fully seated b y pushing on its outer rim while installing it.

Important: Do not pr ess on the soft inside ar ea of the ﬁlter .

4. Install the air cleaner co v er with the side indicated as up facing upw ard and secure the latc hes ( Figure 31 ).

Servicing the Engine Oil

2. Diseng ag e the PTO , tur n the ignition k ey to off , and remo v e the k ey .

3. W ait for all mo ving par ts to stop before lea ving the operating position and then c hoc k or bloc k tires .

4. Clean around the oil dipstic k ( Figure 33 ) so that dir t cannot fall into the ﬁller hole and damag e the engine .

Figure 33

1. Oil dipstick 2. Filler tube

Chang e the engine oil after ev er y 100 operating hours .

Note: Chang e the oil more frequently when the operating conditions are extremely dusty or sandy .

Oil T ype: Deterg ent oil (API ser vice SF , SG or SH)

Crankcase Capacity: w/ﬁlter , 67 oz. (2 l)

Viscosity: See the table belo w .

Figure 32

Checking the Engine Oil Level

1. P ark the mac hine on a lev el surface .

5. Unscrew the oil dipstic k and wipe the end clean ( Figure 33 ).

6. Slide the oil dipstic k fully into the ﬁller tube , but do not thread onto tube ( Figure 33 ).

7. Pull the dipstic k out and look at the metal end. If the oil lev el is lo w , slo wly pour only enough oil into the ﬁller tube to raise the lev el to the Full mark.

Important: Do not o v erﬁll the crankcase with oil and r un the engine; engine dama ge can r esult.

Changing the Oil

1. Star t the engine and let it r un ﬁv e min utes . T his w ar ms the oil so it drains better .

2. P ark the mac hine so that the drain side is slightly lo w er than the opposite side to ensure the oil drains completely .

3. Diseng ag e the PTO and set the parking brak e .

4. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

5. Place a pan belo w the drain. R otate oil drain v alv e to allo w oil to drain ( Figure 34 ).

Page 32

6. W hen oil has drained completely , close the drain v alv e .

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

Figure 34

1. Oil drain valve 2. Oil drain hose

Figure 35

1. Oil lter 3. Adapter

2. Adapter gasket

3. P our new oil in through the center hole of the ﬁlter . Fill it up to the bottom of the threads inside .

4. Allo w the ﬁlter material to absorb the new oil for 1 to 2 min utes .

7. Slo wly pour appro ximately 80% of the speciﬁed oil into the ﬁller tube ( Figure 33 ).

8. Chec k the oil lev el; refer to Chec king the Engine Oil Lev el.

9. Slo wly add the additional oil to bring it to the Full mark.

Changing the Oil Filter

R e place the oil ﬁlter ev er y 200 operating hours or ev er y other oil c hang e .

Note: Chang e the oil ﬁlter more frequently when the operating conditions are extremely dusty or sandy .

1. Drain the oil from the engine; refer to Changing the Engine Oil.

2. R emo v e the old ﬁlter and wipe the ﬁller adapter g ask et surface ( Figure 35 ).

5. Apply a thin coat of new oil to the r ubber g ask et on the re placement ﬁlter ( Figure 35 ).

6. Install the re placement oil ﬁlter to the ﬁlter adapter , tur n the oil ﬁlter cloc kwise until the r ubber g ask et contacts the ﬁlter adapter , then tighten the ﬁlter an additional 2/3 to 1 tur n ( Figure 35 ).

7. Fill the crankcase with the proper type of new oil; refer to Ser vicing the Engine Oil.

8. R un the engine for about 3 min utes , stop the engine , and c hec k for oil leaks around the oil ﬁlter .

9. Chec k the engine oil lev el and add oil if needed.

Servicing the Spark Plugs

Chec k the spark plugs after ev er y 200 operating hours .

Ensure that the air g ap betw een the center and side electrodes is cor rect before installing the spark plug . Use a spark plug wrenc h for remo ving and installing the spark plugs and a g apping tool/feeler g aug e to c hec k and adjust the air g ap . Install a new spark plugs if necessar y .

T ype: Champion® R C12Y C , Champion® Platin um 3071 or equi v alent

Air Gap: 0.030 inc h (0.76 mm)

Page 33

Checking the Spark Plugs

1. Look at the center of the spark plugs ( Figure 36 ). If y ou see light bro wn or g ra y on the insulator , the engine is operating properly . A blac k coating on the insulator usually means that the air cleaner is dir ty .

Figure 36

1. Center electrode insulator

2. Side electrode

3. Air gap (not to scale)

Figure 37

1. Spark-plug wire/spark plug

4. Clean around the spark plugs to prev ent dir t from falling into the engine and potentially causing damag e .

5. R emo v e the spark plugs and the metal w ashers .

Installing the Spark Plugs

Important: Al w ays r eplace the spar k

plugs when it has a black coating , w or n electr odes, an oil y ﬁlm, or cracks.

2. Chec k the g ap betw een the center and side electrodes ( Figure 36 ). Bend the side electrode ( Figure 36 ) if the g ap is not cor rect.

Removing the Spark Plugs

1. Diseng ag e the PTO and set the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. Disconnect the wires from the spark plugs ( Figure 37 ).

1. Install the spark plugs and the metal w asher . Ensure that the air g ap is set cor rectly .

2. Tighten the spark plugs to 18 to 22 ft-lb (24.4 to 29.8 N ⋅ m).

3. Connect the wires to the spark plugs ( Figure 36 ).

Fuel System Maintenance

Replacing the Fuel Filter

R e place the fuel ﬁlter after ev er y 200 operating hours or yearly , whic hev er occurs ﬁrst.

Nev er install a dir ty ﬁlter if it is remo v ed from the fuel line .

1. Diseng ag e the PTO , mo v e the motion control lev ers to the neutral loc k ed position, and set the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. Allo w the mac hine to cool do wn.

4. Close the fuel shutoff v alv e ( Figure 38 ).

Page 34

Figure 38

1. Fuel lter 3. Fuel shutoff valve

2. Hose clamp

4. Loosen the hose clamp at the fuel ﬁlter and slide it up the fuel line a w a y from the fuel ﬁlter ( Figure 38 ).

5. Disconnect the fuel line from the fuel ﬁlter ( Figure 38 ).

6. Open the fuel shutoff v alv e . Note: Allo w g asoline to drain into a fuel

container can or drain pan ( Figure 38 ). Note: No w is the best time to install a new

fuel ﬁlter because the fuel tank is empty .

7. Install the fuel line onto the fuel ﬁlter . Slide the hose clamp close to the fuel ﬁlter to secure the fuel line ( Figure 38 ).

5. Squeeze the ends of the hose clamps tog ether and slide them a w a y from the ﬁlter ( Figure 38 ).

6. R emo v e the ﬁlter from the fuel lines .

7. Install a new ﬁlter and mo v e the hose clamps close to the ﬁlter ( Figure 38 ).

8. Open the fuel shutoff v alv e .

Servicing the Fuel Tank

In cer tain conditions, gasoline is extr emel y ﬂamma ble and highl y explosi v e. A ﬁr e or explosion fr om gasoline can bur n y ou and other s and can dama ge pr oper ty .

• Drain gasoline fr om the fuel tank when the engine is cold. Do this outdoor s in an open ar ea. W ipe up an y gasoline that spills.

• Nev er smok e when draining gasoline, and stay a w ay fr om an open ﬂame or wher e a spar k may ignite the gasoline fumes.

Electrical System Maintenance

Servicing the Battery

Warning

CALIFORNIA

Pr oposition 65 W ar ning

Batter y posts, ter minals, and r elated accessories contain lead and lead compounds, chemicals kno wn to the State of Calif or nia to cause cancer and r epr oducti v e har m. W ash hands after handling .

Batter y electr ol yte contains sulfuric acid which is a deadl y poison and causes sev er e bur ns.

Do not drink electr ol yte and a v oid contact with skin, ey es or clothing . W ear safety g lasses to shield y our ey es and r ub ber g lo v es to pr otect y our hands.

1. P ark the mac hine on a lev el surface to ensure that the fuel tanks drain completely .

2. Diseng ag e the po w er tak eoff (PTO), set the parking brak e , stop the engine , and remo v e the k ey .

3. Close the fuel shutoff v alv e ( Figure 38 ).

Page 35

Removing the Battery

Batter y ter minals or metal tools could shor t a gainst metal machine components causing spar ks. Spar ks can cause the batter y gasses to explode, r esulting in per sonal injur y .

• W hen r emo ving or installing the batter y , do not allo w the batter y ter minals to touch an y metal par ts of the machine.

• Do not allo w metal tools to shor t betw een the batter y ter minals and metal par ts of the machine.

Incor r ect batter y ca ble r outing could dama ge the machine and ca bles causing spar ks. Spar ks can cause the batter y gasses to explode, r esulting in per sonal injur y .

Figure 39

1. Battery

2. Terminal boot

3. Positive battery cable 9. Battery clamp

4. Negative battery cable 10. J-bolts

5. Ground wire

6. Bolt (1/4 x 3/4 inch)

7. Washer (1/4 inch)

8. Locknut (1/4 inch)

11. Wingnut (1/4 inch)

• Al w ays Disconnect the negati v e (black) batter y ca ble bef or e disconnecting the positi v e (r ed) ca ble.

• Al w ays R econnect the positi v e (r ed) batter y ca ble bef or e r econnecting the negati v e (black) ca ble.

1. Diseng ag e the PTO , mo v e the motion control lev ers to the neutral loc k ed position, and set the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. Unlatc h the seat and tilt the seat up .

4. First disconnect the neg ati v e batter y cable and g round wire from the neg ati v e (-) batter y ter minal ( Figure 39 ).

5. Slide the red ter minal boot off the positi v e (red) batter y ter minal. T hen remo v e the positi v e (red) batter y cable ( Figure 39 ).

6. R emo v e both wing n uts (1/4 inc h) securing the batter y clamp ( Figure 39 ).

7. R emo v e the batter y .

Installing the Battery

1. P osition batter y in the tra y with the ter minal posts to w ard the engine ( Figure 39 ).

2. First, install the positi v e (red) batter y cable to positi v e (+) batter y ter minal.

3. T hen install the neg ati v e batter y cable and g round wire to the neg ati v e (-) batter y ter minal.

4. Secure the cables with 2 bolts (1/4 x 3/4 inc h), 2 w ashers (1/4 inc h), and 2 loc kn uts (1/4 inc h) ( Figure 39 ).

5. Slide the red ter minal boot onto the positi v e (red) batter y post.

6. Secure batter y with J-bolts , hold do wn clamp and 2 w ashers (1/4 inc h), and 2 wing n uts (1/4 inc h) ( Figure 39 ).

Page 36

Charging the Battery

T he fuses are as follo ws:

• Main F1-30 amp , blade-type

Charging the batter y pr oduces gasses that can explode.

Nev er smok e near the batter y and k eep spar ks and ﬂames a w ay fr om batter y .

Important: Al w ays k eep the batter y full y charged (1.265 speciﬁc g ra vity). T his is especiall y impor tant to pr ev ent batter y dama ge when the temperatur e is belo w 32°F (0°C).

1. R emo v e the batter y from the c hassis .

2. Charg e batter y for 10 to 15 min utes at 25 to 30 amps or 30 min utes at 4-6 amps .

3. W hen the batter y is fully c harg ed, unplug the c harg er from the electrical outlet, then disconnect the c harg er leads from the batter y posts (Fig . 67).

• Alter nator F2-25 amp , blade-type

1. Unlatc h the seat and raise the seat to g ain access to fuse holder ( Figure 41 ).

Figure 41

1. Main F1-30 amp

2. Alternator F2-25 amp

2. T o re place the fuses , pull out on the fuse to remo v e it.

3. Install a new fuse ( Figure 41 ).

Figure 40

4. Install the batter y in the mac hine and connect the batter y cables; refer to Installing the Batter y .

Note: Do not r un the mac hine with the batter y disconnected, electrical damag e ma y occur .

Servicing the Fuses

T he electrical system is protected b y fuses . It requires no maintenance , ho w ev er , if a fuse blo ws c hec k component/circuit for malfunction or shor t.

Page 37

Drive System

Checking the Tire Pressure

Maintenance

Adjusting the Tracking

Note: Deter mine the left and right sides of the

mac hine from the nor mal operating position.

T he right hand pump has a knob for adjusting the trac king .

Important: Adjust the handle neutral and h y draulic pump neutral bef or e adjusting the tracking . R efer to Adjusting the Handle Neutral and Adjusting the Hy draulic Pump Neutral.

1. Push both control lev ers forw ard the same distance .

2. Chec k if the mac hine pulls to one side . If it does , stop the mac hine and set the parking brak e .

3. Unlatc h the seat and tip the seat up to access the trac king knob .

Chec k the pressure at the v alv e stem after ev er y 50 operating hours or monthly , whic hev er occurs ﬁrst ( Figure 43 ).

Maintain the air pressure in the front and rear tires at 13 psi (90 kP a). Unev en tire pressure can cause unev en cut. Chec k the tires when they are cold to g et the most accurate pressure reading .

Figure 43

4. Adjust the trac king as follo ws ( Figure 42 ):

• T o mak e the mac hine g o right, tur n the knob to w ards the right side of the mac hine .

• T o mak e the mac hine g o left, tur n the knob to w ards the left side of the mac hine .

Figure 42

1. Pump rod 3. Tracking knob

2. Turn this way to track left 4. Turn this way to track right

Checking the Wheel Hub Slotted Nut

Chec k after ev er y 500 operating hours .

T he slotted n ut needs to be tor qued to 125 ft-lb (170 N ⋅ m).

1. Diseng ag e the PTO , mo v e the motion control lev ers to the neutral loc k ed position and set the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. R emo v e the cotter pin.

4. T or que the slotted n ut to 125 ft-lb (170 N ⋅ m) ( Figure 44 ).

5. R e peat this adjustment until the trac king is cor rect.

Page 38

Figure 44

1. Slotted Nut 3. Hole in threaded shaft

2. Two threads or less showing

4. Washer (if needed)

5. Chec k the distance from bottom of slot in n ut to inside edg e of hole . T w o threads or less should be sho wing ( Figure 44 ).

6. If more than tw o threads are sho wing remo v e n ut and install w asher betw een hub and n ut.

7. T or que the slotted n ut to 125 ft-lb . (170 N ⋅ m) ( Figure 44 ).

8. Tighten the n ut until the next set of slots line up with the hole in the shaft ( Figure 44 ).

9. R e place the cotter pin.

Figure 45

1. Spring Washers

2. Lock Nut

3. Dust Cap

4. Tighten the loc kn ut until the spring w ashers are ﬂat and then bac k off a 1/4 tur n to properly set the pre-load on the bearings ( Figure 45 ).

Adjusting the Caster Pivot Bearing

Chec k after ev er y 500 operating hours or at storag e , whic h ev er comes ﬁrst.

1. Diseng ag e the PTO , mo v e the motion control lev ers to the neutral loc k ed position and set the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. R emo v e the dust cap from caster and tighten loc k n ut ( Figure 45 ).

Important: Mak e sur e spring w asher s ar e installed cor r ectl y as sho wn in Figur e 45 .

5. Install the dust cap ( Figure 45 ).

Cooling System Maintenance

Cleaning the Engine Screen and the Oil Cooler

Before eac h use , c hec k and clean the engine screen and oil cooler . R emo v e any build-up of g rass , dir t or other debris from the oil cooler screen and engine screen ( Figure 46 and Figure 47 ).

Page 39

Figure 46

1. Engine screen

2. Oil cooler

Cleaning the Engine Fins

Ev er y 100 hours clean the engine cylinder and cylinder head cooling ﬁns . Also clean around carburetor , g o v er nor lev ers and linkag e . T his will mak e sure adequate cooling to h y draulic pumps , motors and engine and will reduce the possibility of o v erheating and mec hanical damag e .

1. R emo v e the engine shroud.

2. Clean the engine cooling ﬁns .

3. Install the engine shroud.

Figure 48

1. Brake lever 4. Collar on brake rod

2. Spring (2-3/4 inches/70 mm)

3. Adjusting nuts 6. Jam nut and yoke

5. 3/16–1/4 inch (5–7 mm)

3. If adjustment is necessar y , loosen the jam n ut belo w the spring and tighten the n ut directly belo w the y ok e ( Figure 48 ). T ur n the n ut until the cor rect measurement is obtained. Tighten the tw o n uts tog ether and re peat on opposite side of unit.

4. T ur n n uts cloc kwise to shor ten spring length and tur n counter -cloc kwise to lengthen the spring .

5. Eng ag e parking brak e , lev er up .

6. Measure the distance betw een the tr unnion roller and the collar on brak e rod.

Figure 47

1. Panel

2. Engine shroud

3. Screws

Brake Maintenance

Adjusting the Parking Brake

Chec k the parking brak e for proper adjustment.

1. Diseng ag e brak e lev er (lev er do wn).

2. Measure the length of the spring .

T he measurement should be 2-3/4 inc h (70 mm) betw een w ashers ( Figure 48 ).

T he measurement should be 3/16-1/4 inc h (5-7 mm) ( Figure 48 ).

7. If adjustment is necessar y , loosen the jam n ut directly belo w the y ok e . T ur n the bottom rod until the cor rect measurement is obtained ( Figure 48 ). Tighten jam n ut at y ok e

Belt Maintenance

Inspecting the Belts

Inspect all belts ev er y 100 hours .

Chec k belts for crac ks , fra yed edg es , bur n marks or any other damag e . R e place damag ed belts .

Replacing the Mower Belt

Squealing when the belt is rotating, blades slipping when cutting g rass , fra yed belt edg es , bur n marks and crac ks are signs of a w or n mo w er belt. R e place

Page 40

the mo w er belt if any of these conditions are evident.

1. Diseng ag e the PTO , mo v e the motion control lev ers to the neutral loc k ed position, and set the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. R emo v e the belt co v ers .

4. Loosen the n ut securing the idler plate and mo v e the idler plate to reliev e the belt tension on the idler pulley ( Figure 49 ).

5. R emo v e the n ut, w asher and belt guide from the rear leftside pulley .

6. R emo v e the mo w er belt from the belt guides and remo v e the belt ( Figure 49 ).

7. Install the new mo w er belt around the mo w er spindle pulleys , mo w er idler pulley , into the belt guides , into rear idler ar m assembly , and the clutc h ( Figure 49 ).

8. Install the belt guide with a w asher and n ut onto the rear leftside pulley .

Note: Chec k the amount of twist in the belt betw een the pulleys . Ensure it is only what is speciﬁed in Figure 49 .

Figure 49

1. Clutch 4. Belt guide 7. Belt guide

2. Mower belt

3. 1/4 trun belt twist

5. Mower spindle pulley

6. Mower idler pulley

8. Nut

9. Washer

installed

10. Rear left side pulley

9. Adjust the belt tension, refer to Adjusting the Mo w er Belt T ension

10. Install the belt co v ers and close the latc hes ( Figure 50 ).

Page 41

Figure 51

1. Center bolt 3. Left support plate

2. Alignment hole 4. Spring loaded idler

Figure 50

1. Belt cover 3. Insert slot into the tab

2. Latch

Adjusting the Mower Belt Tension

1. Diseng ag e the PTO , mo v e the motion control lev ers to the neutral loc k ed position, and set the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. Raise the mo w er to the transpor t position.

Important: Check the amount of twist in the belt betw een the pulleys. Mak e sur e it is onl y what is speciﬁed in Figur e 49 .

Important: Check and mak e sur e the belt is installed into both the fr ont and r ear belt guides ( Figur e 51 ).

5. If adjustment is required, loosen the mo w er idler plate and adjust it ( Figure 52 ).

6. Inser t a ratc het or break er bar into the square hole in the mo w er idler plate to adjust the tension ( Figure 52 ).

7. T o increase belt tension, rotate the mo w er idler plate until resistance is felt and rotation stops . Do not g o past when it stops ( Figure 52 ).

8. Tighten the idler plate bolts ( Figure 52 ).

4. Chec k the belt tension. T he spring loaded idler center bolt needs to be near the top alignment hole in left suppor t plate ( Figure 51 ).

Figure 52

1. Mower idler plate 3. Ratchet or breaker bar

2. Square hole 4. Idler plate bolt

9. Chec k the distance from the r ubber stop and the ar m of the spring loaded idler pulley when the idler plate is tightened. It needs to be 0 to 1/4 inc h (0 to 6 mm) from the r ubber stop ( Figure 53 ).

Page 42

Figure 53

1. Spring loaded idler pulley 4. Idler pulley arm

2. Top alignment hole 5. Belt

3. 0 to 1/4 inch gap (0 to 6 mm)

6. Rubber bumper

10. Adjust the belt tension and the idler plate , if necessar y , and tighten all hardw are securely ( Figure 52 ).

pulleys ( Figure 55 ). R emo v e belt betw een pulleys .

Figure 55

2. Install new belt around engine and h y dro pump pulleys ( Figure 55 ).

3. Pull spring loaded idler do wn and align belo w traction belt. R elease the pressure on the spring loaded idler ( Figure 55 ).

11. If the mo w er idler plate contacts the end of the adjustment slot and more belt tension is required, a small c hang e to the right side ﬁx ed idler can create more belt tension adjustment ( Figure 54 ).

Figure 54

1. Fixed idler 2. Adjustment slot

Replacing the Pump Drive Belt

Chec k pump dri v e belt for w ear after ev er y 50 hours of operation.

1. Pull the spring loaded idler do wn and remo v e traction belt from the engine and h y dro pump

Controls System Maintenance

Adjusting the Control Handle Neutral Position

If motion control lev ers do not align, or mo v e easily into the console notc h, adjustment is required. Adjust eac h lev er , spring and rod se parately .

Note: Motion control lev ers m ust be installed cor rectly . See Installing the Motion Control Lev ers in the set up instr uctions .

1. Diseng ag e the PTO , mo v e the motion control lev ers to the neutral loc k ed position and set the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. Unlatc h the seat and tilt the seat forw ard.

4. Begin with either the left or right motion control lev er .

5. Mo v e the lev er to the neutral position but not loc k ed ( Figure 56 ).

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Figure 56

1. Neutral locked position 3. Neutral potion

2. Control lever

6. Pull the lev er bac k until the clevis pin (on ar m belo w pi v ot shaft) contacts the end of the slot (just beginning to put pressure on the spring) ( Figure 56 ).

7. Chec k where the control lev er is relati v e to notc h in console ( Figure 56 ). It should be centered allo wing lev er to pi v ot outw ard to the neutral loc k position.

8. If adjustment is needed, loosen the n ut and jam n ut ag ainst the y ok e ( Figure 57 ).

9. Apply slight rearw ard pressure on the motion control lev er , tur n the head of the adjustment bolt in the appropriate direction until the control lev er is centered in the neutral loc k position ( Figure 57 ).

Note: K ee ping rearw ard pressure on the lev er will k ee p the pin at the end of the slot and allo w the adjustment bolt to mo v e the lev er to the appropriate position.

10. Tighten the n ut and jam n ut ( Figure 57 ).

11. R e peat for the opposite side of the mac hine .

Figure 57

1. Clevis pin in slot

2. Nut against yoke 8. Pivot shaft

3. Adjustment bolt 9. Yoke

4. Pump rod 10. Locknut

5. Double nuts 11. Ball joint

6. Jam nut

7. Spring

Hydraulic System Maintenance

Checking the Hydraulic Fluid

Chec k the h y draulic ﬂuid lev el:

• Before the engine is ﬁrst star ted.

• After the ﬁrst 8 operating hours .

• After ev er y 25 operating hours .

Fluid T ype: Mobil 1 15W -50 synthetic motor oil or equi v alent synthetic oil.

Important: Use oil speciﬁed or equi v alent. Other ﬂuids could cause system dama ge.

Hy draulic System Oil Capacity: 67 oz. (2.0 l) Note: T here are tw o w a ys of c hec king the

h y draulic oil. One is when the oil is w ar m and one is when the oil is cold. T he bafﬂe inside the tank has tw o lev els de pending if the oil is w ar m or cold.

1. P osition the mac hine on a lev el surface and set the parking brak e .

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2. Clean the area around ﬁller nec k of h y draulic tank ( Figure 58 ).

Figure 58

1. Cap

2. Bafe 4. Hot uid level-full

3. Cold uid level-full

3. R emo v e the cap from the ﬁller nec k. Look inside to c hec k if there is ﬂuid in the reser v oir ( Figure 58 ).

4. If there is no ﬂuid, add ﬂuid to the reser v oir until it reac hes the cold lev el of the bafﬂe .

5. R un the mac hine at lo w idle for 15 min utes to allo w any air to purg e out of the system and w ar m the ﬂuid. R efer to Star ting and Stopping the Engine in Operation , pag e 14 .

Hy draulic ﬂuid escaping under pr essur e can penetrate skin and cause injur y .

• If h y draulic ﬂuid is injected into the skin it must be surgicall y r emo v ed within a few hour s by a doctor f amiliar with this type of injur y . Gang r ene may r esult if this is not done.

• K eep body and hands a w ay fr om pin hole leaks or nozzles that eject high pr essur e h y draulic ﬂuid.

• Use cardboard or paper to ﬁnd h y draulic leaks.

• Safel y r eliev e all pr essur e in the h y draulic system bef or e perf or ming an y w or k on the h y draulic system.

• Mak e sur e all h y draulic ﬂuid hoses and lines ar e in good condition and all h y draulic connections and ﬁttings ar e tight bef or e appl ying pr essur e to h y draulic system.

Replacing the Hydraulic

6. R ec hec k the ﬂuid lev el while the ﬂuid is w ar m. T he ﬂuid should be betw een cold and hot.

7. If required, add ﬂuid to the h y draulic tank. Note: T he ﬂuid lev el should be to the top

of the hot lev el of the bafﬂe , when the ﬂuid is hot ( Figure 58 ).

8. Install cap on ﬁller nec k.

Filter and Oil

Chang e the h y draulic ﬁlter and oil:

• After the ﬁrst 25 operating hours .

• Chang e yearly after the ﬁrst 25 operating hours .

Use summer ﬁlter abo v e 32°F (0°C)

Use winter ﬁlter belo w 32°F (0°C)

1. Diseng ag e the PTO , mo v e the motion control lev ers to the neutral loc k ed position and set the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

Important: Do not substitute automoti v e oil ﬁlter or sev er e h y draulic system dama ge may r esult.

3. Place drain pan under ﬁlter , remo v e the old ﬁlter and wipe the ﬁlter adapter g ask et surface clean ( Figure 59 ).

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Figure 59

1. Hydraulic lter

4. Apply a thin coat h y dro ﬂuid to the r ubber g ask et on the re placement ﬁlter ( Figure 60 ).

Bleeding the Hydraulic System

T he traction system is self bleeding, ho w ev er , it ma y be necessar y to bleed the system if ﬂuid is c hang ed or after w ork is perfor med on the system.

1. Raise rear of the mac hine so wheels are off the g round and suppor t with jac k stands .

2. Star t the engine and r un at lo w idle speed. Eng ag e the lev er and traction on one side and spin the wheel b y hand.

3. W hen the wheel begins to spin on its o wn, k ee p it eng ag ed until wheel dri v es smoothly . (minim um 2 min utes)

4. Chec k h y draulic ﬂuid lev el and add as required to maintain proper lev el.

5. R e peat this procedure on the opposite wheel.

Checking the Hydraulic

Figure 60

1. Hydraulic lter 3. Adapter

2. Gasket

5. Install the re placement h y draulic ﬁlter onto the ﬁlter adapter . Do not tighten.

6. Fill the h y draulic tank with h y draulic ﬂuid until the ﬂuid o v erﬂo ws the ﬁlter and then tur n the oil ﬁlter cloc kwise until the r ubber g ask et contacts the ﬁlter adapter , then tighten the ﬁlter an additional 1/2 tur n ( Figure 60 ).

7. Clean up any spilled ﬂuid.

8. Add ﬂuid to the cold lev el of the bafﬂe in the h y draulic tank.

9. Star t the engine and let it r un for about tw o min utes to purg e air from the system. Stop the engine and c hec k for leaks . If one or both wheels will not dri v e , refer Bleeding Hy draulic System.

Hoses

After ev er y 100 operating hours , c hec k the h y draulic hoses for leaks , loose ﬁttings , kink ed lines , loose mounting suppor ts , w ear , w eather and c hemical deterioration. Mak e necessar y re pairs before operating .

Note: K ee p areas around the h y draulic system clean from g rass and debris build up .

10. R ec hec k the ﬂuid lev el while the ﬂuid is w ar m. T he ﬂuid should be betw een cold and hot.

11. If required, add ﬂuid to the h y draulic tank. Do not o v erﬁll.

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Hy draulic ﬂuid escaping under pr essur e can penetrate skin and cause injur y .

• If h y draulic ﬂuid is injected into the skin it must be surgicall y r emo v ed within a few hour s by a doctor f amiliar with this type of injur y . Gang r ene may r esult if this is not done.

• K eep body and hands a w ay fr om pin hole leaks or nozzles that eject high pr essur e h y draulic ﬂuid.

T his adjustment m ust be made with dri v e wheels tur ning .

1. Raise the frame and use jac k stands to hold up the mac hine so dri v e wheels can rotate freely .

2. Unlatc h the seat, tilt the seat forw ard and disconnect electrical connector from the seat safety switc h.

3. T emporaril y install a jumper wire across ter minals in the wiring har ness connector .

4. Slide the seat forw ard, disconnect the prop rod and tilt the seat fully forw ard.

• Use cardboard or paper to ﬁnd h y draulic leaks.

• Safel y r eliev e all pr essur e in the h y draulic system bef or e perf or ming an y w or k on the h y draulic system.

• Mak e sur e all h y draulic ﬂuid hoses and lines ar e in good condition and all h y draulic connections and ﬁttings ar e tight bef or e appl ying pr essur e to h y draulic system.

Setting the Hydraulic Pump Neutral Position

Note: Adjust the handle neutral ﬁrst. T hat needs

to be cor rect before the follo wing adjustment can be made .

Mechanical or h y draulic jacks may f ail to suppor t machine and cause a serious injur y .

Setting the Right-hand Hydraulic Pump Neutral Position

1. Star t the engine , open the throttle 1/2 w a y and release parking brak e . R efer to Star ting and Stopping the Engine in Operation , pag e 14 .

Note: T he motion control lev er m ust be in neutral while making any adjustments .

2. Adjust the pump rod length b y rotating the knob , in the appropriate direction, until the wheel is still or slightly cree ping in rev erse ( Figure 61 ).

• Use jack stand when suppor ting machine.

• Do not use h y draulic jacks.

Engine must be r unning so motion contr ol adjustment can be perf or med. Contact with mo ving par ts or hot surf aces may cause per sonal injur y .

K eep hands, feet, f ace, clothing and other body par ts a w ay fr om r otating par ts, muf ﬂer and other hot surf aces.

Page 47

Figure 61

1. Tracking knob 3. Adjustment bolt

2. Pump rod 4. Yoke

3. Mo v e the motion control lev er forw ard and rev erse , then bac k to neutral. T he wheel m ust stop tur ning or slightly cree p in rev erse .

Figure 62

1. Clevis pin in slot

2. Nut against yoke 8. Pivot shaft

3. Adjustment bolt 9. Yoke

4. Pump rod 10. Locknut

5. Double nuts 11. Ball joint

6. Jam nut

7. Spring

4. Open the throttle to fast. Mak e sure wheel remains stopped or slightly cree ps in rev erse , adjust if necessar y .

Setting the Left-hand Hydraulic Pump Neutral Position

1. Loosen the loc kn uts at the ball joints on the pump control rod ( Figure 62 ).

2. Star t the engine , open throttle 1/2 w a y , and release parking brak e . R efer to Star ting and Stopping the Engine in Operation , pag e 14 .

Note: T he motion control lev er m ust be in neutral while making any adjustments .

Note: T he front n ut on the pump rod has left-hand threads .

3. Adjust the pump rod length b y rotating double n uts on rod, in the appropriate direction, until wheel is still or slightly cree ps in rev erse ( Figure 62 ).

4. Mo v e the motion control lev er forw ard and rev erse , then bac k to neutral. T he wheel m ust stop tur ning or slightly cree p in rev erse .

5. Open the throttle to fast. Mak e sure the wheel remains stopped or slightly cree ps in rev erse , adjust if necessar y .

6. Tighten the loc kn uts at the ball joints ( Figure 62 ).

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Electrical system will not perf or m pr oper safety shut of f with jumper wir e installed.

• If one rear c hain is loose , lo w er (loosen) the

front suppor t ar m on the same side . R efer to Adjusting the F ront-to-R ear Mo w er Pitc h.

• R emo v e jumper wir e fr om wir e har ness connector and plug connector into seat s witch when adjustment is completed.

• Nev er operate this unit with jumper installed and seat s witch bypassed.

7. After both pump neutrals are set, shut off the mac hine .

8. R emo v e the jumper wire from the wire har ness connector and plug the connector into the seat switc h.

9. Install the seat rod and lo w er the seat into position.

10. R emo v e the jac k stands .

Mower Deck Maintenance

• If one front c hain is loose , raise (tighten) the front suppor t ar m for that c hain. R efer to Adjusting the F ront-to-R ear Mo w er Pitc h.

Leveling the Mower Side-to-Side

1. P osition the right blade front-to-rear ( Figure 63 ).

Leveling the Mower at Three Positions

Important: T her e ar e onl y thr ee measuring

positions needed to lev el the mo w er .

Setting Up the Machine

1. P osition mo w er on a ﬂat surface .

2. Diseng ag e the PTO , mo v e the motion control lev ers to the neutral loc k ed position and set the parking brak e .

3. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

4. Chec k tire pressure of all four tires . If needed, adjust to 13 psi (90 kP a)

5. Lo w er the mo w er to the 3 inc h (76 mm) height-of-cut position.

6. Inspect the four c hains . T he c hains need to ha v e tension.

Figure 63

1. Measure here from blade to hard surface

2. Measure the right blade at the B location, from a lev el surface to the cutting edg e of the blade tip ( Figure 63 ).

3. R ecord this measurement. T his measurement needs to be 3-1/8 to 3-1/4 inc hes .

4. P osition the left blade front-to-rear ( Figure 63 ).

5. Measure the left blade at the C location ( Figure 63 ), from a lev el surface to the cutting edg e of the blade tip .

6. R ecord this measurement. T his measurement needs to be 3-1/8 to 3-1/4 inc hes .

7. If the measurements at positions B or C are not cor rect, loosen the bolt attac hing the rear c hain to the rear suppor t ar m ( Figure 64 ).

2. Measure at B and C

Note: Adjust the rear c hains to the top of the slot, where they are attac hed to the mo w er .

Page 49

Figure 64

1. Rear chain 5. Adjustment bolt

2. Rear support arm

3. Bolt

4. Jam Nut

6. Front swivel

7. Front support arm

1. Measure here from blade to hard surface

Figure 65

2. Measure at A and B

8. Loosen the jam n ut under the rear suppor t ar m and adjust the adjustment bolt to g et a measurement of 3-1/8 to 3-1/4 inc hes ( Figure 64 ).

Note: It is recommended that both sides of the mo w er are adjusted the same distance .

9. Tighten the jam n ut under the rear suppor t ar m and tighten the bolt securing the c hain to the rear suppor t ar m.

10. Adjust the opposite side if needed.

Adjusting the Front-to-Rear Mower Pitch

1. P osition the right blade front-to-rear ( Figure 65 ).

2. Measure the right blade at the A location, from a lev el surface to the cutting edg e of the blade tip ( Figure 65 ).

3. R ecord this measurement.

4. Measure the right blade at the B location, from a lev el surface to the cutting edg e of the blade tip ( Figure 65 ).

5. R ecord this measurement.

6. T he mo w er blade should be a 1/4 to 3/8 inc h (6 to 10 mm) lo w er at position A than at position B ( Figure 65 ). If it is not cor rect, proceed to the follo wing ste ps .

Note: Both of the front swi v els need to be adjusted the same amount to maintain equal c hain tension.

7. Loosen the front swi v el jam n uts , at the front of the right and left swi v els , appro ximately a 1/2 inc h (13 mm) ( Figure 64 ).

8. Adjust the lift n uts on both the left and the right side of the mac hine to ac hiev e 1/4 to 3/8 inc h (6 to 10 mm) lo w er in front at A than in the rear at B ( Figure 64 ).

9. Tighten both swi v el jam n uts ag ainst the front swi v el to loc k the height.

10. Chec k to mak e sure there is equal tension on the c hains and adjust ag ain if needed.

Page 50

Adjusting the Compression Spring

1. Raise the mo w er lift lev er to the transpor t position.

2. Chec k the distance betw een the tw o larg e w ashers , it needs to be 11-1/8 inc hes (28.2 cm) for 52 inc h mo w er dec ks , 10-1/2 inc hes (26.7 cm) for 60 inc h mo w er dec ks or 11–1/2 inc hes (29.2 cm) for 72 inc h mo w er dec ks ( Figure 66 ).

Chec k the cutter blades daily for shar pness , and for any w ear or damag e . File do wn any nic ks and shar pen the blades as necessar y . If a blade is damag ed or w or n, re place it immediately with a g en uine T oro re placement blade . F or con v enient shar pening and re placement, y ou ma y w ant to k ee p extra blades on hand.

A w or n or dama ged blade can br eak, and a piece of the blade could be thr o wn into the operator’ s or bystander’ s ar ea, r esulting in serious per sonal injur y or death.

• Inspect the blade periodicall y f or w ear or dama ge.

• R eplace a w or n or dama ged blade.

Inspect and c hec k the blades ev er y 8 hours .

Before Inspecting or Servicing the Blades

Figure 66

1. 11–1/8 inch (28.2 cm) between the large washers for 52 inch mower decks

2. Front nut

3. Spring jam nut

4. Front swivel

5. Swivel jam nut

6. Lift nut

7. Front support arm

8. Large washer

9. 10-1/2 inch (26.7 cm) between the large washers for 60 inch mower decks

10. 11-1/2 inch (29.2 cm) between the large washers for 72 inch mower decks

3. Adjust this distance , b y loosening the spring jam n ut and tur ning the n ut in front of eac h spring ( Figure 66 ). T ur ning the n ut cloc kwise will shor ten the spring; counter -cloc kwise will lengthen the spring .

4. Loc k the n ut into position b y tightening the spring jam n ut ( Figure 66 ).

1. P ark the mac hine on a lev el surface , diseng ag e the blade control (PTO), and set the parking brak e .

2. T ur n the ignition k ey to Off and remo v e the k ey .

3. Disconnect the spark plug wire(s) from the spark plug(s).

Inspecting the Blades

1. Inspect the cutting edg es ( Figure 67 ).

If the edg es are not shar p or ha v e nic ks , remo v e and shar pen the blades . R efer to Shar pening the Blades .

Servicing the Cutting Blades

Maintain shar p blades throughout the cutting season because shar p blades cut cleanly without tearing or shredding the g rass blades . T earing and shredding tur ns g rass bro wn at the edg es , whic h slo ws g ro wth and increases the c hance of disease .

Page 51

Figure 67

1. Cutting Edge 3. Wear/slot Forming

2. Curved Area

2. R otate the opposite ends of the blades forw ard.

3. Measure from a lev el surface to the cutting edg e of the blades at the same position as in ste p 1 abo v e .

T he difference betw een the dimensions obtained in ste ps 1 and 2 m ust not ex ceed 1/8 inc h (3 mm). If this dimension ex ceeds 1/8 inc h (3 mm), the blade is bent and m ust be re placed; refer to R emo ving the Blades and Installing the Blades .

A blade that is bent or dama ged could br eak apar t and could seriousl y injur e or kill y ou or bystander s.

2. Inspect the blades , especially the cur v ed area ( Figure 67 ).

If y ou notice any damag e , w ear , or a slot for ming in this area ( Figure 67 ), immediately install a new blade .

Checking for Bent Blades

1. R otate the blades until the ends face forw ard and bac kw ard ( Figure 68 ). Measure from a lev el surface to the cutting edg e , position A , of the blades ( Figure 68 ). Note this dimension.

• Al w ays r eplace bent or dama ged blade with a new blade.

• Nev er ﬁle or cr eate shar p notches in the edges or surf aces of blade.

Removing the Blades

Blades m ust be re placed if a solid object is hit, if the blade is out of balance or is bent. T o ensure optim um perfor mance and contin ued safety confor mance of the mac hine , use g en uine T oro re placement blades . R e placement blades made b y other man ufacturers ma y result in non-confor mance with safety standards .

Contact with a shar p blade can cause serious injur y .

W ear g lo v es or wrap shar p edges of the blade with a ra g .

1. Measure here from blade to hard surface

1. Hold the blade end using a rag or thic kly-padded glo v e .

2. R emo v e the blade bolt, spring disk and blade from the spindle shaft ( Figure 71 ).

Figure 68

2. Position A

Page 52

Sharpening the Blades

W hen shar pening blade, pieces of blade could be thr o wn and cause serious injur y .

W ear pr oper ey e pr otection when shar pening blade.

1. Use a ﬁle to shar pen the cutting edg e at both ends of the blade ( Figure 69 ). Maintain the original angle . T he blade retains its balance if the same amount of material is remo v ed from both cutting edg es .

Figure 71

1. Sail Area of Blade 4. Blade Bolt

2. Blade 5. Cone Towards Bolt Head

3. Spring Disk

3. T or que the blade bolt to 85-110 ft-lb (115-150 N ⋅ m).

Replacing the Grass

Figure 69

1. Sharpen at original angle

2. Chec k the balance of the blade b y putting it on a blade balancer ( Figure 70 ). If the blade sta ys 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 ( Figure 71 ). R e peat this procedure until the blade is balanced.

Figure 70

1. Blade 2. Balancer

Installing the Blades

1. Install the blade onto the spindle shaft ( Figure 71 ).

Important: T he cur v ed par t of the blade must be pointing up w ard to w ard the inside of the mo w er to ensur e pr oper cutting .

2. Install the spring disk and blade bolt. T he spring disk cone m ust be installed to w ard the bolt head ( Figure 71 ).

Deector

An unco v er ed discharge opening could allo w the la wn mo w er to thr o w objects in the operator’ s or bystander’ s dir ection and r esult in serious injur y . Also, contact with the blade could occur .

• Nev er operate the la wn mo w er unless y ou install a co v er plate, a mulch plate, or a g rass chute and catcher .

• Mak e sur e the g rass deﬂector is in the do wn position.

1. R emo v e the loc kn ut, bolt, spring and spacer holding the deﬂector to the pi v ot brac k ets ( Figure 72 ).

2. R emo v e the damag ed or w or n g rass deﬂector .

3. Place the spacer and spring onto the g rass deﬂector . Place the L end of the spring behind the dec k edg e .

Note: Mak e sure the L end of the spring is installed behind the dec k edg e before installing the bolt as sho wn in Figure 72

4. Install the bolt and n ut.

5. Place the J hook end of the spring around the g rass deﬂector ( Figure 72 ).

Page 53

Important: T he g rass deﬂector must be a ble to lo w er do wn into position. Lift the deﬂector up to test that it lo w er s into the full do wn position.

Figure 72

1. Bolt 5. Spring installed

2. Spacer

3. Locknut 7. L end of spring, place

4. Spring

6. Grass Deector

behind deck edge before installing bolt

8. J hook end of spring

Cleaning

Cleaning Under the Mower

R emo v e the g rass buildup under the mo w er daily .

1. Diseng ag e the PTO , mo v e the motion control lev ers to the neutral loc k ed position and set the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. Raise the mo w er to the transpor t position.

Waste Disposal

Engine oil, batteries , h y draulic oil, and engine coolant are pollutants to the en vironment. Dispose of these according to y our state and local regulations .

Page 54

Storage

1. Diseng ag e the po w er tak e off (PTO), set the parking brak e and tur n the ignition k ey to off . R emo v e spark plug wire . R emo v e the k ey .

2. R emo v e g rass clippings , dir t, and g rime from the exter nal par ts of the entire mac hine , especially the engine and h y draulic system. Clean dir t and c haff from the outside of the engine’ s cylinder head ﬁns and blo w er housing .

Important: Y ou can w ash the machine with mild detergent and w ater . Do not pr essur e w ash the machine. A v oid ex cessi v e use of w ater , especiall y near the contr ol panel, engine, h y draulic pumps and motor s.

3. Ser vice the air cleaner; refer to Ser vicing the Air Cleaner in Engine Maintenance , pag e 30 .

4. Grease and oil the mac hine; refer to Greasing and Lubrication in Lubrication , pag e 28 .

stabilizer man ufacture . Do not use an alcohol based stabilizer (ethanol or methanol).

Note: A fuel stabilizer/conditioner is most effecti v e when mix ed with fresh g asoline and used at all times .

B . R un engine to distribute conditioned fuel

through the fuel system (5 min utes).

C . Stop engine , allo w to cool and drain the

fuel tank; refer to Ser vicing the Fuel T ank in Fuel System Maintenance , pag e 33 .

D . R estar t engine and r un it until it stops .

E. Chok e the engine . Star t and r un engine

until it will not star t.

F . Dispose of fuel properly . R ecycle as per

local codes .

Important: Do not stor e sta biliz er/conditioned gasoline o v er 90 days.

5. Chang e the crankcase oil; refer to Ser vicing the Engine Oil in Engine Maintenance , pag e 30 .

6. Chang e the h y draulic ﬁlter; refer to Ser vicing the Hy draulic System in Hy draulic System Maintenance , pag e 43 .

7. Chec k the tire pressure; refer to Chec king the Tire Pressure in Dri v e System Maintenance , pag e 37 .

8. Charg e the batter y; refer to Ser vicing the Batter y in Electrical System Maintenance , pag e 34 .

9. Scrape any hea vy buildup of g rass and dir t from the underside of the mo w er , then w ash the mo w er with a g arden hose .

Note: R un the mac hine with the PTO eng ag ed and the engine at high idle for 2 to 5 min utes after w ashing .

10. Chec k the condition of the blades . R efer to Ser vicing the Cutting Blades .

12. R emo v e the spark plug(s) and c hec k its condition; refer to Ser vicing the Spark Plug in Engine Maintenance , pag e 30 . With the spark plug(s) remo v ed from the engine , pour tw o tablespoons of engine oil into the spark plug hole . No w use the star ter 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. Chec k and tighten all bolts , n uts , and screws . R e pair or re place any par t that is damag ed or defecti v e .

14. P aint all scratc hed or bare metal surfaces . P aint is a v ailable from y our A uthorized Ser vice Dealer .

15. Store the mac hine in a clean, dr y g arag e or storag e area. R emo v e the k ey from the ignition switc h and k ee p it out of reac h of c hildren or other unauthorized users . Co v er the mac hine to protect it and k ee p it clean.

11. Pre pare the mac hine for storag e when non-use occurs o v er 30 da ys . Pre pare mac hine for storag e as follo ws .

A. Add a petroleum based

stabilizer/conditioner to fuel in the tank. F ollo w mixing instr uctions from

Page 55

Troubleshooting

Problem

Starter does not crank

Engine will not start, starts hard, or fails to keep running.

Engine loses power.

Possible Cause Corrective Action

1. Blade control (PTO) is engaged.

2. Parking brake is not on. 2. Set the parking brake.

3. Operator is not seated. 3. Sit on the seat.

4. Battery is dead. 4. Charge the battery.

5. Electrical connections are corroded or loose.

6. Fuse is blown. 6. Replace fuse.

7. Relay or switch is defective.

1. Fuel tank is empty. 1. Fill fuel tank with fuel.

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

3. Dirt in the fuel lter. 3. Replace the fuel lter.

4. Dirt, water, or stale fuel is in the fuel system.

1. Engine load is excessive. 1. Reduce the ground

1. Move blade contro (PTO) to disengaged.

5. Check the electrical connections for good contact.

7. Contact an Authorized Service Dealer.

cleaner element.

4. Contact an Authorized Service Dealer.

speed.

2. Air cleaner is dirty. 2. Clean the air cleaner element.

3. Oil level in the crankcase

is low.

4. Cooling ns and air

passages above the engine are plugged.

5. Vent hole in the fuel cap

is plugged.

6. Dirt in the fuel lter. 6. Replace the fuel lter.

7. Dirt, water, or stale fuel

is in the fuel system.

Engine overheats.

1. Engine load is excessive. 1. Reduce the ground

2. Oil level in the crankcase

is low.

3. Cooling ns and air

passages above the engine are plugged.

3. Add oil to the crankcase.

4. Remove the obstruction from the cooling ns and air passages.

5. Clean or replace the fuel cap.

7. Contact an Authorized Service Dealer.

speed.

2. Add oil to the crankcase.

3. Remove the obstruction from the cooling ns and air passages.

Page 56

Problem

Possible Cause Corrective Action

Machine does not drive.

Abnormal vibration.

1. By pass valve is not

1. Tighten the by pass

closed tight.

2. Drive or pump belt is

2. Change the belt.

worn, loose or broken.

3. Drive or pump belt is off

3. Change the belt.

a pulley.

4. Broken or missing idler

4. Replace the spring.

spring.

5. Hydraulic uid level is

5. Add hydraulic uid to

low or too hot.

1. Cutting blade(s) is/are

1. Install new cutting

bent or unbalanced.

2. Blade mounting bolt is

2. Tighten the blade

loose.

3. Engine mounting bolts

3. Tighten the engine

are loose.

4. Loose engine pulley,

4. Tighten the appropriate idler pulley, or blade pulley.

5. Engine pulley is

5. Contact an Authorized damaged.

6. Blade spindle is bent. 6. Contact an Authorized

7. Motor mount is loose or

7. Contact an Authorized worn.

valve.

reservoir or let it cool down.

blade(s).

mounting bolt.

mounting bolts.

pulley.

Service Dealer.

Uneven cutting height.

1. Blade(s) not sharp. 1. Sharpen the 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 and front-to-rear.

4. Underside of the mower

is dirty.

5. Tire pressure is not

4. Clean the underside of the mower.

5. Adjust the tire pressure.

correct.

6. Blade spindle bent. 6. Contact an Authorized Service Dealer.

Page 57

Problem

Possible Cause Corrective Action

Blades do not rotate.

1. Drive belt is worn, loose

1. Check the belt tension.

or broken.

2. Drive belt is off pulley. 2. Install drive belt and check adjusting shafts and belt guides for correct position.

3. Deck belt is worn, loose

3. Install new deck belt.

or broken.

4. Deck belt is off pulley. 4. Install deck pulley and check the idler pulley, idler arm and spring for correct position and function.

5. Broken or missing idler

5. Replace the spring.

spring.

Page 58

Schematics

Wire Diagram (Rev. A)

Page 59

Evaporative Emission Control Warranty Statement

California Evaporative Emission Control Warranty Statement

Your Warranty Rights and Obligations

Introduction

The California Air Resources Board and The Toro® Company are pleased to explain the evaporative emission control system’s warranty on your 2006 model year equipment. In California, new equipment that use small off-road engines must be designed, built, and equipped to meet the State’s stringent anti-smog standards. The Toro® Company must warrant the evaporative emission control system on your equipment for two years provided there has been no abuse, neglect or improper maintenance of your equipment.

Your evaporative emission control system may include parts such as: fuel lines, fuel line ttings, and clamps.

Manufacturer’s Warranty Coverage:

This evaporative emission control system is warranted for two years. If any evaporative emission-related part on your equipment is defective, the part will be repaired or replaced by The Toro® Company.

Owner’s Warranty Responsibilities:

• As the equipment owner, you are responsible for performance of the required maintenance listed in your Operator’s Manual.

The Toro® Company recommends that you retain all receipts covering maintenance on your equipment, but The Toro® Company cannot deny warranty solely for the lack of receipts.

• As the equipment owner, you should however be aware that The Toro® Company may deny you warranty coverage if your emission

warranty parts have failed due to abuse, neglect, or improper maintenance or unapproved modications.

• You are responsible for presenting your equipment to an Authorized Service Dealer as soon as the problem exists. The warranty

repairs should be completed in a reasonable amount of time, not to exceed 30 days. If you have a question regarding your warranty coverage, you should contact The Toro® Company at 1-952–948–4027 or call us toll free at the number listed in your Toro Warranty statement.

Defects Warranty Requirements:

1. The warranty period begins on the date the engine or equipment is delivered to an ultimate purchaser.

2. General Evaporative Emissions Warranty Coverage. The emission warranty parts must be warranted to the ultimate purchaser and any subsequent owner that the evaporative emission control system when installed was:

A. Designed, built, and equipped so as to conform with all applicable regulations; and B. Free from defects in materials and workmanship that causes the failure of a warranted part for a period of two years.

3. The warranty on evaporative emissions-related parts will be interpreted as follows: A. Any warranted part that is not scheduled for replacement as required maintenance in the written instructions must be

warranted for the warranty period of two years. If any such part fails during the period of warranty coverage, it must be repaired or replaced by The Toro® Company. Any such part repaired or replaced under the warranty must be warranted for a time not less than the remaining warranty period.

B. Any warranted part that is scheduled only for regular inspection in the written instructions must be warranted for the warranty

period of two years. A statement in such written instructions to the effect of “repair or replace as necessary” will not reduce the period of warranty coverage. Any such part repaired or replaced under warranty must be warranted for a time not less than the remaining warranty period.

C. Any warranted part that is scheduled for replacement as required maintenance in the written instructions must be warranted

for the period of time prior to the rst scheduled replacement point for that part. If the part fails prior to the rst scheduled replacement, the part must be repaired or replaced by The Toro® Company. Any such part repaired or replaced under warranty must be warranted for a time not less than the remainder of the period prior to the rst scheduled replacement point for the part.

D. Repair or replacement of any warranted part under the warranty provisions of this article must be performed at no charge to

the owner at an Authorized Service Dealer.

E. Notwithstanding the provisions of subsection (D) above, warranty services or repairs must be provided at an Authorized

Service Dealer.

F. The owner must not be charged for diagnostic labor that leads to the determination that a warranted part is in fact defective,

provided that such diagnostic work is performed at an Authorized Service Dealer.

G. Throughout the evaporative emission control system’s two year warranty period, The Toro® Company must maintain a supply

of warranted parts sufcient to meet the expected demand for such parts.

H. Manufacturer approved replacement parts must be used in the performance of any warranty maintenance or repairs and must

be provided without charge to the owner. Such use will not reduce the warranty obligations of The Toro® Company.

I. The use of any add-on or modied parts will be grounds for disallowing a warranty claim made in accordance with this

article. The Toro® Company will not be liable under this Article to warrant failures of warranted parts caused by the use of an add-on or modied part.

J. The Toro® Company shall provide any documents that describe the warranty procedures or policies within ve working

days of request by the Air Resources Board.

The following lists includes the parts covered under this warranty:

• Fuel Lines

• Fuel Line Fittings

• Clamps

Emission Warranty Parts List:

374-0092 Rev A

Page 60

LCE

The Toro Total Coverage Guarantee

A Limited Warranty

Conditions and Products Covered

The Toro® Company and its afliate, 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 All Spindles

Engines/Hydraulic Systems* on the following:

Outfront and Mid-Mount Z’s ProLine Mid-Size Mowers Groundsmaster[Symbol_registersans] Riding Mowers Backpack Blowers

Deck Shells (32 ″ -72 ″ ) on the following:

ProLine Mid-Size Mowers

Mid-Mount Z’s Electric Clutch on 500 Series Mid-Mount Z’s

This warranty includes the cost of parts and labor, but you must pay transportation costs.

This warranty applies to:

Warranty Period

2 years

t h i r d y e a r , p a r t s o n l y )

1 year

( p a r t s a n d l a b o r ;

2 years

• Outfront and Mid-Mount Z’s

• ProLine Mid-Size Mowers

• Groundsmaster Riding Mowers

• Turf Maintenance Equipment

• Debris Management Equipment

S o m e e n g i n e s u s e d o n T o r o L C E P r o d u c t s a r e w a r r a n t e d b y t h e e n g i n e m a n u f a c t u r e r .

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. You may also call our Toro Customer Care Department toll free at 888–577–7466 (U.S. Customers) or 877–484–9255 (Canada customers).

2. Bring the product and your proof of purchase (sales receipt) to the Service Dealer.

If for any reason you are dissatised with the Service Dealer’s analysis or with the assistance provided, contact us at:

Owner Responsibilities

You must maintain your Toro Product by following the maintenance procedures described in the operator’s manual. Such routine maintenance, whether performed by a dealer or by you, is at your expense.

Items and Conditions Not Covered

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 lters,

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.

General Conditions

Repair by an Authorized Toro Service Dealer is your sole remedy under this warranty.

Neither The Toro® Company nor Toro Warranty Company is liable for indirect, incidental or consequential damages in connection with the use of the Toro Products covered by this warranty, including any cost or expense of providing substitute equipment or service during reasonable periods of malfunction or non-use pending completion of repairs under this warranty.

Some states do not allow exclusions of incidental or consequential damages, or limitations on how long an implied warranty lasts, so the above exclusions and limitations may not apply to you.

All implied warranties of merchantability (that the product is t for ordinary use) and tness for use (that the product is t for a particular purpose) are limited to the duration of the express warranty.

This warranty gives you specic legal rights, and you may also have other rights which vary from state to state.

LCB Customer Service Department

Toro Warranty Company

8111 Lyndale Avenue South

Bloomington, MN 55420-1196

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 dissatised with your Distributor’s service or have difculty obtaining guarantee information, contact the Toro importer. If all other remedies fail, you may contact us at Toro Warranty Company.

374-0037 Rev D