Page 1
Form No. 3351-707
Z450 Z Master
With 52in TURBO FORCE
Side Discharge Mower
Model No. 74414—Serial No. 250000001 and Up
Operator ’s Manual
Register your product at www.Toro.com
Original Instructions (EN)
Page 2
Warning
CALIFORNIA
Proposition 65 Warning
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
Important This engine is not equipped with a spark
arrester muffler. It is a violation of California Public
Resource Code Section 4442 to use or operate this engine
on any forest-covered, brush-covered, or grass-covered
land. Other states or federal areas may have similar laws.
This spark ignition system complies with Canadian
ICES-002.
Ce système d’allumage par étincelle de véhicule est
conforme à la norme NMB-002 du Canada.
The enclosed Engine Owner’s Manual is supplied for
information regarding The U.S. Environmental
Protection Agency (EPA) and the California Emission
Control Regulation of emission systems, maintenance
and warranty.
Keep this engine Owner’s Manual with your unit.
Should this engine Owner’s Manual become damaged
or illegible, replace immediately. Replacements may be
ordered through the engine manufacturer.
Contents
Page
Introduction 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe Operating Practices 3. . . . . . . . . . . . . . . . . . . .
Slope Chart 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals 9. . . . . . . . . . . . . . . .
Gasoline and Oil 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Gasoline 14. . . . . . . . . . . . . . . . . . . .
Using a Fuel Stabilizer/Conditioner 14. . . . . . . . . . .
Filling the Fuel Tank 14. . . . . . . . . . . . . . . . . . . . . .
Checking the Engine Oil Level 15. . . . . . . . . . . . . .
Operation 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using the Rollover Protection System (ROPS) 15. .
Think Safety First 16. . . . . . . . . . . . . . . . . . . . . . . . .
Controls 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating the Parking Brake 18. . . . . . . . . . . . . . . .
Starting and Stopping the Engine 18. . . . . . . . . . . . .
Operating the Power Takeoff (PTO) 19. . . . . . . . . . .
The Safety Interlock System 19. . . . . . . . . . . . . . . .
Driving Forward or Backward 20. . . . . . . . . . . . . . .
Page
Stopping the Machine 20. . . . . . . . . . . . . . . . . . . . . .
Adjusting the Height-of-Cut 21. . . . . . . . . . . . . . . . .
Adjusting the Anti-scalp Rollers 21. . . . . . . . . . . . .
Positioning the Seat 22. . . . . . . . . . . . . . . . . . . . . . .
Pushing the Machine by Hand 22. . . . . . . . . . . . . . .
Operating with the Side Discharge 23. . . . . . . . . . . .
Transporting the Machine 23. . . . . . . . . . . . . . . . . . .
Loading the Machines 23. . . . . . . . . . . . . . . . . . . . .
Tips for Mowing Grass 24. . . . . . . . . . . . . . . . . . . . .
Maintenance 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Maintenance Schedule 25. . . . . . . . .
Servicing the Cutting Blades 26. . . . . . . . . . . . . . . .
Cleaning the Cooling System 28. . . . . . . . . . . . . . . .
Servicing the Air Cleaner 29. . . . . . . . . . . . . . . . . . .
Servicing the Engine Oil 30. . . . . . . . . . . . . . . . . . .
Servicing the Spark Plug(s) 31. . . . . . . . . . . . . . . . .
Replacing the Fuel Filter 32. . . . . . . . . . . . . . . . . . .
Draining the Fuel Tank 32. . . . . . . . . . . . . . . . . . . . .
Greasing and Lubrication 33. . . . . . . . . . . . . . . . . . .
Checking the Tire Pressure 34. . . . . . . . . . . . . . . . . .
Servicing the Hydraulic System 34. . . . . . . . . . . . . .
Waste Disposal 36. . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Handle Neutral Position 36. . . . . . . . .
Setting the Hydraulic Pump Neutral Position 37. . . .
Adjusting the Tracking 38. . . . . . . . . . . . . . . . . . . . .
Adjusting the Caster Pivot Bearing 39. . . . . . . . . . .
Checking the Wheel Hub Slotted Nut 39. . . . . . . . .
Leveling the Mower at Three Positions 40. . . . . . . .
Adjusting the Push Arms 42. . . . . . . . . . . . . . . . . . .
Cleaning Under the Mower 42. . . . . . . . . . . . . . . . .
Inspecting the Belts 42. . . . . . . . . . . . . . . . . . . . . . .
Replacing the Mower Belt 42. . . . . . . . . . . . . . . . . .
Replacing the Pump Drive Belt 43. . . . . . . . . . . . . .
Adjusting the Parking Brake 44. . . . . . . . . . . . . . . .
Servicing the Fuses 44. . . . . . . . . . . . . . . . . . . . . . . .
Servicing the Battery 44. . . . . . . . . . . . . . . . . . . . . .
Replacing the Grass Deflector 47. . . . . . . . . . . . . . .
Waste Disposal 47. . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Diagram 48. . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Storage 49. . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Toro Total Coverage Guarantee 52. . . . . . . . . . . . .
2004 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
Contact us at www.Toro.com
All Rights Reserved
2
Printed in the USA
Page 3
Introduction
Read this manual carefully to learn how to operate and
maintain your product properly. The information in this
manual can help you and others avoid injury and product
damage. Although Toro designs and produces safe
products, you are responsible for operating the product
properly and safely.
You may contact Toro directly at www.Toro.com for
product and accessory information, help finding a dealer, or
to register your product.
Whenever you need service, genuine Toro parts, or
additional information, contact an Authorized Service
Dealer or Toro Customer Service and have the model and
serial numbers of your product ready. Figure 1 illustrates
the location of the model and serial numbers on the
product.
This manual uses 2 other words to highlight information.
Important calls attention to special mechanical
information and Note: emphasizes general information
worthy of special attention.
Safety
Improper use or maintenance by the operator or owner
can result in injury. To reduce the potential for injury,
comply with these safety instructions and always pay
attention to the safety alert symbol, which means
CAUTION, WARNING, or DANGER—“personal
safety instruction.” Failure to comply with the
instruction may result in personal injury or death.
This product is capable of amputating hands and feet and
throwing objects. Always follow all safety instructions to
avoid serious injury or death.
1
m–3648
Figure 1
1. Location of the model and serial numbers
Write the product model and serial numbers in the space
below:
Model No.
Serial No.
This manual identifies potential hazards and has special
safety messages that help you and others avoid personal
injury and even death. Danger, Warning, and Caution are
signal words used to identify the level of hazard. However,
regardless of the hazard, be extremely careful.
Danger signals an extreme hazard that will cause serious
injury or death if you do not follow the recommended
precautions.
Warning signals a hazard that may cause serious injury or
death if you do not follow the recommended precautions.
Caution signals a hazard that may cause minor or moderate
injury if you do not follow the recommended precautions.
This product is designed for cutting and recycling grass or,
when equipped with a grass bagger, for catching cut grass.
Any use for purposes other than these could prove
dangerous to user and bystanders.
Safe Operating Practices
The following instructions are from ANSI standard
B71.4—2004.
Training
• Read the Operator’s Manual and other training material.
If the operator(s) or mechanic(s) can not read English it
is the owner’s responsibility to explain this material to
them.
• Become familiar with the safe operation of the
equipment, operator controls, and safety signs.
• All operators and mechanics should be trained. The
owner is responsible for training the users.
• Never let children or untrained people operate or
service the equipment. Local regulations may restrict
the age of the operator.
• The owner/user can prevent and is responsible for
accidents or injuries occurring to himself or herself,
other people or property.
Preparation
• Evaluate the terrain to determine what accessories and
attachments are needed to properly and safely perform
the job. Only use accessories and attachments approved
by the manufacturer.
• Wear appropriate clothing including hard hat, safety
glasses and hearing protection. Long hair, loose
clothing or jewelry may get tangled in moving parts.
3
Page 4
• Inspect the area where the equipment is to be used and
remove all objects such as rocks, toys and wire which
can be thrown by the machine.
• Use extra care when handling gasoline and other fuels.
They are flammable and vapors are explosive.
• Use only an approved container
• Never remove gas cap or add fuel with engine
running. Allow engine to cool before refueling.
Do not smoke.
• Never refuel or drain the machine indoors.
• Check that operator’s presence controls, safety switches
and shields are attached and functioning properly. Do
not operate unless they are functioning properly.
Operation
• Do not operate the mower under the influence of
alcohol or drugs.
• Use extreme care when loading or unloading the
machine into a trailer or truck.
• Use care when approaching blind corners, shrubs, trees,
or other objects that may obscure vision.
Slope Operation
• Do not mow slopes greater than 15 degrees.
• Do not mow near drop–offs, ditches, steep banks or
water. Wheels dropping over edges can cause rollovers,
which may result in serious injury, death or drowning.
• Do not mow slopes when grass is wet. Slippery
conditions reduce traction and could cause sliding and
loss of control.
• Never run an engine in an enclosed area.
• Only operate in good light, keeping away from holes
and hidden hazards.
• Be sure all drives are in neutral and parking brake is
engaged before starting engine. Start the engine only
from the operator’s position.
• Never raise deck with the blades running.
• Never operate without the PTO shield, or other guards
securely in place. Be sure all interlocks are functioning
properly.
• Never operate with the discharge deflector raised,
removed or altered, unless using a grass catcher.
• Do not change the engine governor setting or overspeed
the engine.
• Stop on level ground, lower implements, disengage
drives, engage parking brake, shut off engine before
leaving the operator’s position for any reason including
emptying the catchers or unclogging the chute.
• Stop equipment and inspect blades after striking objects
or if an abnormal vibration occurs. Make necessary
repairs before resuming operations.
• Do not make sudden turns or rapid speed changes.
• Use a walk behind mower and/or a hand trimmer near
drop–offs, ditches, steep banks or water.
• Reduce speed and use extreme caution on slopes.
• Remove or mark obstacles such as rocks, tree limbs,
etc. from the mowing area. Tall grass can hide
obstacles.
• Watch for ditches, holes, rocks, dips, and rises that
change the operating angle, as rough terrain could
overturn the machine.
• Avoid sudden starts when mowing uphill because the
mower may tip backwards.
• Be aware that loss of traction may occur going
downhill. Weight transfer to the front wheels may cause
drive wheels to slip and cause loss of braking and
steering.
• Always avoid sudden starting or stopping on a slope. If
tires lose traction, disengage the blades and proceed
slowly off the slope.
• Follow the manufacturer’s recommendations for wheel
weights or counterweights to improve stability.
• Keep hands and feet away from the cutting units.
• Never carry passengers and keep pets and bystanders
away.
• Be alert, slow down and use caution when making
turns. Look behind and to the side before changing
directions.
• Slow down and use caution when crossing roads and
sidewalks. Stop blades if not mowing.
• Be aware of the mower discharge direction and do not
point it at anyone.
• Use extreme care with grass catchers or other
attachments. These can change the stability of the
machine and cause loss of control.
4
Page 5
Using the Rollover Protection System
(ROPS)
• Keep the roll bar in the raised and locked position and
use the seat belt when operating the machine.
• Be certain that the seat belt can be released quickly in
the event of an emergency.
• Be aware there is no rollover protection when the roll
bar is down.
• Check the area to be mowed and never fold the ROPS
in areas where there are slopes, drop offs or water.
• Lower the roll bar only when absolutely necessary. Do
not wear the seat belt with the roll bar folded down.
• Check carefully for overhead clearances (i.e. branches,
doorways, electrical wires) before driving under any
objects and do not contact them.
Maintenance and storage
• Disengage drives, lower implement, set parking brake,
stop engine and remove key or disconnect spark plug
wire. Wait for all movement to stop before adjusting,
cleaning or repairing.
• Keep all parts in good working condition and all
hardware tightened. Replace all worn or damaged
decals.
• Use only Toro-approved attachments. Warranty may be
voided if used with unapproved attachments.
• Clean grass and debris from cutting units, drives,
mufflers, and engine to help prevent fires. Clean up oil
or fuel spillage.
• Let engine cool before storing and do not store near
flame.
• Shut off fuel while storing or transporting. Do not store
fuel near flames or drain indoors.
• Park machine on level ground. Never allow untrained
personnel to service machine.
• Use jack stands to support components when required.
• Carefully release pressure from components with stored
energy.
• Disconnect battery or remove spark plug wire before
making any repairs. Disconnect the negative terminal
first and the positive last. Reconnect positive first and
negative last.
• Use care when checking blades. Wrap the blade(s) or
wear gloves, and use caution when servicing them.
Only replace blades. Never straighten or weld them.
• Keep hands and feet away from moving parts. If
possible, do not make adjustments with the engine
running.
• Charge batteries in an open well ventilated area, away
from spark and flames. Unplug charger before
connecting or disconnecting from battery. Wear
protective clothing and use insulated tools.
5
Page 6
6
Page 7
Slope Chart
Example: Compare
slope with folded
edge.
Fold along appropriate line
Align this edge with a vertical surface
(Tree, Building, Fence post, pole, etc.)
7
Page 8
8
Page 9
Safety and Instruction Decals
Safety decals and instructions are easily visible to the operator and are located near any area
of potential danger. Replace any decal that is damaged or lost.
1-523552
1-633818
58-6520
1. Grease
65–2690
43-8480
54-9220
66-1340
68-8340
9
Page 10
98-4387
1. Warning—wear hearing protection.
98-5954
103-1997
107-1613
103–2644
104-8569
105-7798
107-1622
10
Page 11
107-2100
107-1687
11
107-2102
Page 12
107-2112
107-2148
1. Warning—read the
2. Read the
Operator’s Manual.
Operator’s Manual
107-9309
for information on charging the battery; contains lead; do not discard.
12
Page 13
108-1050
Battery Symbols
Some or all of these symbols are on your battery.
1. Explosion hazard
2. No fire, open flames, or
smoking.
3. Caustic liquid/chemical
burn hazard
4. Wear eye protection
5. Read the
Manual.
6. Keep bystanders a safe
distance from the battery.
Operator’s
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.
108-1051
13
Page 14
Gasoline and Oil
Recommended Gasoline
Use unleaded regular gasoline suitable for automotive use
(85 pump octane minimum). You may use leaded regular
gasoline if unleaded regular is not available.
Important Never use methanol, gasoline containing
methanol, or gasohol containing more than 10% ethanol
because the fuel system could be damaged. Do not mix oil
with gasoline.
Danger
In certain conditions, gasoline is extremely
flammable and highly explosive. A fire or
explosion from gasoline can burn you and others
and can damage property.
• Fill the fuel tank outdoors, in an open area,
when the engine is cold. Wipe up any gasoline
that spills.
• Never fill the fuel tank inside an enclosed trailer.
• Do not fill the fuel tank completely full. Add
gasoline to the fuel tank until the level is 1/4 to
1/2 inch (6 to 13 mm) below the bottom of the
filler neck. This empty space in the tank allows
gasoline to expand.
• Never smoke when handling gasoline, and stay
away from an open flame or where gasoline
fumes may be ignited by a spark.
• Store gasoline in an approved container and
keep it out of the reach of children. Never buy
more than a 30-day supply of gasoline.
• Always place gasoline containers on the ground,
away from your vehicle before filling.
• Do not fill gasoline containers inside a vehicle or
on a truck or trailer bed because interior
carpets or plastic truck bed liners may insulate
the container and slow the loss of any static
charge.
• When practical, remove gasoline-powered
equipment from the truck or trailer and refuel
the equipment with its wheels on the ground.
• If this is not possible, then refuel such
equipment on a truck or trailer from a portable
container rather than from a gasoline dispenser
nozzle.
• If you must use a gasoline dispenser nozzle, keep
the nozzle in contact with the rim of the fuel
tank or container opening at all times until
fueling is complete.
• Do not operate the machine without the entire
exhaust system in place and in proper working
condition.
Warning
Gasoline is harmful or fatal if swallowed.
Long-term exposure to vapors can cause serious
injury and illness.
• Avoid prolonged breathing of vapors.
• Keep your face away from the nozzle and fuel
tank or conditioner opening.
• Keep gasoline away from eyes and skin.
Using a Fuel
Stabilizer/Conditioner
Use a fuel stabilizer/conditioner in the machine to provide
the following benefits:
• Keeps stored gasoline fresh for 90 days or less; for
longer storage, drain the fuel tank.
• Cleans the engine while it runs
• Eliminates gum-like varnish buildup in the fuel system,
which causes hard starting
Important Do not use fuel additives containing
methanol or ethanol.
Add the correct amount of stabilizer/conditioner to the
gasoline.
Note: A fuel stabilizer/conditioner is most effective when it
is mixed with fresh gasoline. To minimize the chance of
varnish deposits in the fuel system, use fuel stabilizer at all
times.
Filling the Fuel Tank
1. Shut the engine off and set the parking brake.
2. Clean around each fuel tank cap and remove the cap.
Add unleaded regular gasoline to both fuel tanks until
the level is 1/4 to 1/2 inch (6 to 13 mm) below the
bottom of the filler neck. This space in the tank allows
gasoline to expand. Do not fill the fuel tanks completely
full.
3. Install fuel tank caps securely. Wipe up any gasoline
that spills.
14
Page 15
Checking the Engine Oil Level
Before you start the engine and use the machine, check the
oil level in the engine crankcase; refer to Checking the
Engine Oil Level on page 30.
1. To lower the roll bar, loosen the front handles (Fig. 2).
Operation
Note: Determine the left and right sides of the machine
from the normal operating position.
Using the Rollover Protection
System (ROPS)
Warning
To avoid injury or death from a rollover, keep the
roll bar in the raised locked position and use the
seat belt.
Ensure that the rear part of the seat is secured
with the seat latch.
Warning
There is no rollover protection when the roll bar is
in the down position.
1
m-7406
Figure 2
1. Front handle
2. Remove the hairpin cotter pins and remove the 2 pins
(Fig. 3).
1
2
3
4
• Lower the roll bar only when absolutely
necessary.
• Do not wear the seat belt when the roll bar is in
the down position.
• Drive slowly and carefully.
• Raise the roll bar as soon as clearance permits.
• Check carefully for overhead clearances (e.g.,
branches, doorways, and electrical wires) before
driving under any objects and do not contact
them.
Important Lower the roll bar only when absolutely
necessary.
1. Roll bar
2. Raised position
m-7431
Figure 3
3. Pin
4. Hairpin cotter pin
15
Page 16
3. Lower the the roll bar to the down position.
Note: There are 2 down positions. See Figure 4 for the
positions.
Danger
Operating the machine on wet grass or steep slopes
can cause sliding and loss of control.
2
1
Wheels dropping over the edges can cause
rollovers, which may result in serious injury,
death, or drowning.
There is no rollover protection when the roll bar is
down.
m-7432a
Figure 4
1. Full down position 2. Down position with
bagger installed
4. Install the 2 pins and secure them with the hairpin cotter
pins (Fig. 3).
Important Always use the seat belt with the roll bar in
the raised position.
Important Ensure that the rear part of the seat is
secured with the seat latch.
5. To raise the roll bar, remove the hairpin cotter pins and
remove the 2 pins (Fig. 3).
6. Raise the roll bar to the upright position and install the
2 pins and secure them with the hairpin cotter pins
(Fig. 3).
7. Tighten the front handles against the center roll bar ends
(Fig. 2).
Always keep the roll bar in the raised and locked
position, and use the seat belt.
Read and follow the rollover protection
instructions and warnings.
To avoid loss of control and the possibility of
rollover:
• Do not operate the machine near dropoffs or
near water.
• Do not operate the machine on slopes greater
than 15 degrees.
• Reduce the speed and use extreme caution on
slopes.
• Avoid sudden turns or rapid speed changes.
• Avoid operating the machine on wet grass.
2
1
Think Safety First
Read all safety instructions and symbols in the safety
section. Knowing this information could help you or
bystanders avoid injury.
3
Figure 5
1. Safe Zone—use the
Z Master here on slopes
less than 15 degrees or
flat areas.
2. Use the walk behind
mower or hand trimmer
near dropoffs and water.
3. Water
Toro recommends that you use protective equipment for
your eyes, ears, feet, and head.
16
m–6478
Page 17
Caution
This machine produces sound levels in excess of
85 dBA at the operators ear and can cause hearing
loss through extended periods of exposure.
Wear hearing protection when operating this
machine.
Using the Hour Meter
The hour meter (Fig. 8) records the number of hours the
engine has operated. It operates when the engine is running.
Use these times for scheduling regular maintenance.
1
m–4202
Figure 8
1. Hour meter
Figure 6
1. Warning—wear hearing protection.
Controls
Become familiar with all the controls (Fig. 7) before you
start the engine and operate the machine.
2
7
1. Ignition switch
2. Motion control lever
3. Parking brake lever
4. Throttle
5. Choke
8
Figure 7
5
1
4
3
6
6. Power takeoff (PTO)
7. Height-of-cut lever
8. Fuel cap
9. Hourmeter
9
m–7701
Using the Fuel Shutoff Valve
The machine has 2 fuel tanks, one on the left side and the
other on the right side. Each tank connects to a check valve
and then to a tee. From there a common fuel line leads to
the engine (Fig. 9).
1
m–7702
Figure 9
1. Fuel shutoff valve
Close the fuel shutoff valve before transporting or storing
the machine.
17
Page 18
Operating the Parking Brake
Always set the parking brake when you stop the machine or
leave it unattended.
Important Do not park the machine on slopes unless
the wheels are chocked or blocked.
3. Move the PTO (power takeoff) to Off (Fig. 11).
2
1
2
Setting the Parking Brake
1. Move the motion control levers (Fig. 10) to the neutral
lock position.
1
2
m–4121
Figure 10
1. Parking brake—On 2. Parking brake—Off
2. Pull back and up on the parking brake lever to set the
parking brake (Fig. 10).
Note: The parking brake lever should stay firmly in the
Engaged position.
m–2719
Figure 11
1. PTO—On
2. PTO—Off
m–4201
Figure 12
1. Choke—On
2. Choke—Off
4. Move the choke control to On before starting a cold
engine (Fig. 12).
Note: A warm or hot engine may require choking. After
the engine starts, move the choke control to the Off
position.
5. Move the throttle control to Fast before starting a cold
engine (Fig. 13).
1
1
2
3
2
1
Releasing the Parking Brake
Push forward and down on the parking brake lever to
release the parking brake (Fig. 10).
Starting and Stopping the
Engine
Starting the Engine
1. Sit on the seat and move the motion controls to the
neutral locked position.
2. Set the parking brake; refer to Setting the Parking Brake
on page 18.
m-4268
Figure 13
1. Fast
2. Slow
m–2720a
Figure 14
1. Off
2. Run
3. Start
6. Turn the ignition key to Start to energize the starter.
When the engine starts, release the key (Fig. 14).
Important Do not engage the starter for more than
10 seconds at a time. If the engine fails to start, allow a
30 second cool down period between attempts. Failure to
follow these instructions can burn out the starter motor.
7. After the engine starts, move the choke to Off (Fig. 12).
If the engine stalls or hesitates, move the choke back to
On for a few seconds. Then move the throttle lever to
the desired setting. Repeat this step as necessary.
18
Page 19
Stopping the Engine
1. Push the PTO to Off (Fig. 13).
3. Pull out the power takeoff (PTO) switch to engage the
PTO (Fig. 15).
2. Move the throttle lever midway between Slow and Fast
(Fig. 13).
3. Let the engine idle for 60 seconds (Fig. 14).
4. Turn the ignition key to Off (Fig. 14).
5. Disconnect the wire from the spark plug(s) to prevent
the possibility of someone accidentally starting the
machine before it is transported or stored.
6. Close the fuel shutoff valve before transporting or
storing the machine.
Important Make sure that the fuel shutoff valve is
closed before transporting or storing the machine to prevent
fuel leakage. Set the parking brake before transporting the
machine. Make sure to remove the key, for the fuel pump
may run and cause the battery to lose its charge.
Caution
Children or bystanders may be injured if they
move or attempt to operate the machine while it is
unattended.
Always remove the ignition key and set the
parking brake when leaving the machine
unattended, even for a few minutes.
2
1
m–4201
Figure 15
1. PTO—Off 2. PTO—On
Disengaging the PTO
To disengage, push the PTO switch to Off (Fig. 15).
The Safety Interlock System
Caution
If safety interlock switches are disconnected or
damaged, the machine could operate unexpectedly,
causing personal injury.
Operating the Power Takeoff
(PTO)
The power takeoff (PTO) switch engages and disengages
power to the electric clutch.
Engaging the PTO
1. While seated, release the pressure on the traction
control levers and shift the machine into neutral.
2. Shift the throttle to Fast.
• Do not tamper with the interlock switches.
• Check the operation of the interlock switches
daily and replace any damaged switches before
operating the machine.
Understanding the Safety Interlock
System
The safety interlock system is designed to prevent the
engine from starting unless:
• You are sitting on the seat.
• The parking brake is engaged.
• The power takeoff (PTO) is disengaged.
• The motion control levers are in the neutral lock
position.
The safety interlock system is also designed to stop the
engine when you move the traction controls with the
parking brake is engaged or when you rise from the seat
while the PTO is engaged.
19
Page 20
Testing the Safety Interlock System
Test the safety interlock system before you use the machine
each time. If the safety system does not operate as
described below, have an Authorized Service Dealer repair
it immediately.
1. While sitting on the seat, engage the parking brake,
engage the PTO, and try to start the engine; the engine
should not crank.
2. While sitting on the seat, engage the parking brake,
disengage the PTO, and move either of the motion
control levers (forward or reverse). Then try starting the
engine; the engine should not crank. Repeat for the
other motion control lever.
3. While sitting on the seat, engage the parking brake,
disengage the PTO, lock the motion control levers in
neutral, and start the engine. While the engine is
running, release the parking brake, engage the PTO, and
rise slightly from the seat; the engine should stop.
4. While sitting on the seat, engage the parking brake,
disengage the PTO, lock the motion control levers in
neutral, and start the engine. While the engine is
running, center the motion controls and move (forward
or reverse); the engine should stop.
3. To go forward, slowly push the motion control levers
forward (Fig. 16).
3
4
Figure 16
1. Motion control
lever—neutral lock
position
Note: The engine will stop if you move the traction control
levers while the parking brake is engaged.
2
1
m–2715
2. Center unlock position
3. Forward
4. Backward
Driving Backward
1. Move the levers to the center, unlocked position.
5. While sitting on the seat, disengage the parking brake,
disengage the PTO, and move the motion control levers
to the neutral lock position. Try starting the engine; the
engine should not crank.
Driving Forward or Backward
The throttle control regulates the engine speed as measured
in RPM (revolutions per minute). Always operate the
throttle control in the Fast position for best performance.
Caution
The machine can spin very rapidly. The operator
may lose control of the machine and cause
personal injury or damage to the machine.
• Use caution when turning the machine.
• Slow the machine down before making sharp
turns.
Driving Forward
1. Release the parking brake; refer to Releasing the
Parking Brake on page 18.
2. Move the levers to the center, unlocked position.
2. To go backward, slowly pull the motion control levers
rearward (Fig. 16).
Driving Tips
• To go straight, apply equal pressure to both motion
control levers (Fig. 16).
• To turn, release the pressure on the motion control lever
toward the direction you want to turn (Fig. 16).
Note: The farther you move the traction control levers
in either direction, the faster the machine will move in
that direction.
• To stop, push the motion control levers to neutral.
Stopping the Machine
1. Move the traction control levers to neutral and separate
them to lock them.
2. Disengage the power takeoff (PTO).
3. Turn the ignition key to Off to stop the engine.
4. Set the parking brake when you leave the machine;
refer to Setting the Parking Brake on page 18.
5. Remove the key from the ignition switch.
20
Page 21
Caution
Children or bystanders may be injured if they
move or attempt to operate the machine while it is
unattended.
Adjusting the Anti-scalp
Rollers
Whenever you change the height-of-cut, adjust the height
of the anti-scalp rollers.
Always remove the ignition key and set the
parking brake when leaving the machine
unattended, even for a few minutes.
Adjusting the Height-of-Cut
The height-of-cut adjusts from 1-1/2 to 4-1/2 inches (38 to
114 mm) in 1/4 inch (6 mm) increments by relocating the
clevis pin in different hole locations.
1. Raise the height-of-cut lever to the transport position
(also the 4-1/2 inch [114 mm] cutting height position)
(Fig. 17).
1
2
Adjusting the Outer Roller
1. Disengage the PTO, move the motion control levers to
the neutral locked position, and set the parking brake.
2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
3. After adjusting the height-of-cut, remove the flange nut,
bushing, spacer, and bolt (Fig. 18).
5
2
m–4122
Figure 17
1. Height-of-cut lever 2. Clevis pin
2. Remove the clevis pin from the height-of-cut bracket
(Fig. 17).
3. Select the hole in the height-of-cut bracket
corresponding to the height-of-cut desired, and insert
the clevis pin (Fig. 17).
4. Lower the height-of-cut lever onto the clevis pin
(Fig. 17).
1
3
Figure 18
1. Outer roller
2. Spacer
3. Bushing
4. Select a hole so that the outer roller is positioned to the
nearest corresponding height-of-cut desired (Fig. 18).
5. Install the outer roller, bushing, spacer, bolt, and nut
(Fig. 18).
6. Torque the bolt to 40 to 45 ft-lb (54 to 61 N⋅m).
4. Bolt
5. Nut
4
m–7714
21
Page 22
Adjusting the Center Rollers
1. Disengage the PTO, move the motion control levers to
the neutral locked position, and set the parking brake.
2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
3. After adjusting the height-of-cut, remove the flange nut,
bushing, and bolt (Fig. 19).
Positioning the Seat
The seat can move forward and backward. Position the seat
where you have the best control of the machine and are
most comfortable.
1. To adjust, move the lever sideways to unlock the seat
(Fig. 20).
4
2
3
1
m–7712
Figure 19
1. Center rollers
2. Bushing
3. Bolt
4. Nut
4. Select a hole so that the center rollers are positioned to
the nearest corresponding height-of-cut desired
(Fig. 19).
Note: Do not adjust the rollers to support the mower
housing.
5. Install the center rollers, bushing, spacer, bolt, and nut
(Fig. 19).
1
m–3655
Figure 20
1. Adjustment lever
2. Slide the seat to the desired position and release the
lever to lock the seat in position.
Pushing the Machine by Hand
Important Always push the machine by hand. Never
tow the machine, because hydraulic damage may occur.
To Push the Machine
1. Disengage the power takeoff (PTO) and turn the
ignition key to Off.
2. Rotate the bypass valves counterclockwise 1 turn to
push. This allows the hydraulic fluid to bypass the
pump, enabling the wheels to turn (Fig. 21).
6. Torque the bolt to 40 to 45 ft-lb (54 to 61 N⋅m).
1
m–6279
Figure 21
1. Bypass valve
Important Do not rotate the bypass valves more than
1 turn. This prevents the valves from coming out of the
body and causing fluid to run out.
22
Page 23
Changing to Machine Operation
Turn the bypass valves in to operate (Fig. 21).
Warning
Note: Do not overtighten the bypass valves.
Note: The machine will not drive unless the bypass valves
are turned in.
Operating with the Side
Discharge
The mower has a hinged grass deflector that disperses the
clippings to the side and down toward the turf.
Danger
Without the grass deflector, discharge cover, or
complete grass catcher assembly mounted in place,
you and others are exposed to blade contact and
thrown debris. Contact with the rotating mower
blade(s) and thrown debris will cause injury or
death.
• Never remove the grass deflector from the
mower because the grass deflector routes
material down toward the turf. If the grass
deflector is ever damaged, replace it
immediately.
• Never put your hands or feet under the mower.
• Never try to clear the discharge area or the
mower blades unless you move the power
takeoff (PTO) to Off and rotate the ignition key
to Off. Also remove the key and disconnect the
wire from the spark plug(s).
• Ensure that the grass deflector is in the down
position.
Driving on a street or roadway without turn
signals, lights, reflective markings, or a slow
moving vehicle emblem is dangerous and can lead
to accidents that cause personal injury.
Do not drive the machine on a public street or
roadway.
Loading the Machines
Use extreme caution when loading machines on trailers or
trucks. One full-width ramp that is wide enough to extend
beyond the rear tires is recommended instead of individual
ramps for each side of the machine (Fig. 22). The lower
rear section of the machine frame extends back between the
rear wheels and serves as a stop for tipping backward.
Having a full-width ramp provides a surface for the frame
members to contact if the machine starts to tip backward. If
it is not possible to use one full width ramp, use enough
individual ramps to simulate a full width continuous ramp.
1
4
2
3
1
Transporting the Machine
Use a heavy-duty trailer or truck to transport the machine.
Ensure that the trailer or truck has all necessary lighting
and marking as required by law. Please carefully read all
the safety instructions. Knowing this information could
help you, your family, pets, or bystanders avoid injury.
To transport the machine:
• Lock the brake and block the wheels.
• Securely fasten the machine to the trailer or truck with
straps, chains, cable, or ropes.
• Secure a trailer to the towing vehicle with safety chains.
m–6841
Figure 22
1. Trailer
2. Full width ramp
3. Not greater than
15 degrees
The ramp should be long enough so that the angles do not
exceed 15 degrees (Fig. 22). A steeper angle may cause
mower housing components to get caught as the machine
moves from the ramp to the trailer or truck. Steeper angles
may also cause the machine to tip backward. If loading on
or near a slope, position the trailer or truck so that it is on
the downside of the slope and the ramp extends up the
slope. This will minimize the ramp angle. The trailer or
truck should be as level as possible.
23
4. Full width ramp—side
view
Page 24
Important Do not attempt to turn the machine while on
the ramp; you may lose control and drive off the side.
Avoid sudden acceleration when driving up a ramp and
sudden deceleration when backing down a ramp. Both
maneuvers can cause the machine to tip backward.
Warning
Loading a machine onto a trailer or truck
increases the possibility of backward tip over and
could cause serious injury or death.
• Use extreme caution when operating a machine
on a ramp.
• Use only a single, full-width ramp; do not use
individual ramps for each side of the machine.
• If you must use individual ramps, use enough
ramps to create an unbroken ramp surface
wider than the machine.
• Do not exceed a 15-degree angle between the
ramp and the ground or between the ramp and
the trailer or truck.
• Avoid sudden acceleration while driving the
machine up a ramp to avoid tipping backward.
• Avoid sudden deceleration while backing
machine down a ramp to avoid tipping
backward.
Mowing Direction
Alternate the mowing direction to keep the grass standing
straight. This also helps disperse clippings, which enhances
decomposition and fertilization.
Mow at Correct Intervals
Normally, mow every 4 days. But remember, grass grows at
different rates at different times. So to maintain the same
cutting height, which is a good practice, mow more often in
early spring. As the grass growth rate slows in mid summer,
mow less frequently. If you cannot mow for an extended
period, first mow at a high cutting height; then mow again
2 days later at a lower height setting.
Cutting Speed
To improve the quality of cut, use a slower ground speed.
Avoid Cutting Too Low
If the cutting width of the mower is wider than the mower
you previously used, raise the cutting height to ensure that
uneven turf is not cut too short.
Long Grass
Tips for Mowing Grass
Fast Throttle Setting
For best mowing and maximum air circulation, operate the
engine at Fast. Air is required to thoroughly cut grass
clippings, so do not set the height-of-cut so low as to totally
surround the mower by uncut grass. Always try to have one
side of the mower free from uncut grass, which allows air
to be drawn into the mower.
Cutting a Lawn for the First Time
Cut grass slightly longer than normal to ensure that the
cutting height of the mower does not scalp any uneven
ground. However, the cutting height used in the past is
generally the best one to use. When cutting grass longer
than 6 inches (15 cm) tall, you may want to cut the lawn
twice to ensure an acceptable quality of cut.
Cut 1/3 of the Grass Blade
It is best to cut only about 1/3 of the grass blade. Cutting
more than that is not recommended unless grass is sparse,
or it is late fall when grass grows more slowly.
If you allow the grass to grow slightly longer than normal,
or if it contains a high degree of moisture, raise the cutting
height higher than usual and cut the grass at this setting.
Then cut the grass again using the lower, normal setting.
When Stopping
If you must stop the machine’s forward motion while
mowing, a clump of grass clippings may drop onto your
lawn. To avoid this, move onto a previously cut area with
the blades engaged.
Keep the Underside of the Mower Clean
Clean clippings and dirt from the underside of the mower
after each use. If grass and dirt build up inside the mower,
the cutting quality will eventually become unsatisfactory.
Blade Maintenance
Maintain a sharp blade throughout the cutting season,
because a sharp blade cuts cleanly without tearing or
shredding the grass blades. Tearing and shredding turns
grass brown at the edges, which slows its growth and
increases the chance of disease. Check the cutter blades
daily for sharpness, and for any wear or damage. File down
any nicks and sharpen the blades as necessary. If a blade is
damaged or worn, replace it immediately with a genuine
Toro replacement blade.
24
Page 25
Maintenance
Note: Determine the left and right sides of the machine from the normal operating position.
Recommended Maintenance Schedule
Maintenance Service
Interval
After First 8 Hours
Each Use
Every 5 Hours • Check the cutting blades.
Every 25 Hours • Check the battery electrolyte.
Every 50 Hours
Maintenance Procedure
• Check the hydraulic fluid level.
• Change the hydraulic filter.
• Check the engine oil level.
• Check the safety system.
• Clean the engine air intake1.
• Clean the mower housing.
• Check the hydraulic fluid level.
• Grease the brake lever.
• Oil the linkage bushings1.
• Grease the mower support and push arms.
• Grease the blade spindle bearings.
• Grease both idler pulley pivots.
• Grease the front wheels.
• Check the tire pressure.
• Check the belts for wear and cracks.
• Change the engine oil1.
Every 100 Hours
Every 200 Hours
Every 250 Hours • Service the main air cleaner element1.
Every 500 Hours or at
Storage
Before Storage
1
More often in dusty, dirty conditions
Important Refer to your engine operator’s manual for additional maintenance procedures.
• Check the spark plug(s).
• Check the hydraulic lines.
• Change the hydraulic filter.
• Change the oil filter1.
• Replace the fuel filter.
• Grease the brake lever pivot.
• Adjust and grease the caster pivot.
• Adjust the wheel hub slotted nut.
• Replace the inner air cleaner element1.
• Perform all the maintenance procedures listed above before storage.
• Drain the gasoline.
• Charge the battery and disconnect the cables.
• Paint any chipped surfaces.
25
Page 26
Caution
If you leave the key in the ignition switch, someone could accidently start the engine and
seriously injure you or other bystanders.
Remove the key from the ignition and disconnect the wire from the spark plug(s) before you do
any maintenance. Set the wire aside so that it does not accidentally contact the spark plug.
Servicing the Cutting Blades
Maintain sharp blades throughout the cutting season,
because sharp blades cut cleanly without tearing or
shredding the grass blades. Tearing and shredding turns the
grass brown at the edges, which slows growth and increases
the chance of disease.
Check the cutter blades daily for sharpness, and for any
wear or damage. File down any nicks and sharpen the
blades as necessary. If a blade is damaged or worn, replace
it immediately with a genuine Toro replacement blade. For
convenient sharpening and replacement, keep extra blades
on hand.
Danger
A worn or damaged blade can break, and a piece
of the blade could be thrown into the operator’s or
bystander’s area, resulting in serious personal
injury or death.
• Inspect the blade periodically for wear or
damage.
• Replace a worn or damaged blade.
Inspecting the Blades
1. Inspect the cutting edges (Fig. 23).
2
Figure 23
1. Cutting edge
2. Curved area
Note: If the edges are not sharp or have nicks, remove
and sharpen the blades; refer to Sharpening the Blades
on page 28.
3. Wear/slot forming
1
3
m–151
Before Inspecting or Servicing the Blades
1. Park the machine on a level surface, disengage the
blade control (PTO), and set the parking brake.
2. Turn the ignition key to Off and remove the key.
3. Disconnect the spark plug wire(s) from the spark
plug(s).
2. Inspect the blades, especially the curved area (Fig. 23).
Note: If you notice any damage, wear, or a slot forming
in this area (item 3 in Fig. 23), immediately install a
new blade.
26
Page 27
Checking for Bent Blades
Removing the Blades
1. Rotate the blades until the ends face forward and
backward (Fig. 24). Measure from a level surface to the
cutting edge of the blades (Fig. 25). Note this
dimension.
Front
Figure 24
MEASURE FROM
CUTTING EDGE TO A
LEVEL SURFACE
Figure 25
m–1078
m–2539
Replace any blade if it hits a solid object, is out of balance,
or is bent. To ensure optimum performance and continued
safety conformance of the machine, use genuine Toro
replacement blades. Using replacement blades made by
other manufacturers may cause the machine to be out of
conformance with safety standards.
Hold the blade end using a rag or thickly padded glove.
Remove the blade bolt, spring disk, and blade from the
spindle shaft (Fig. 26).
Warning
Contact with a sharp blade can cause serious
injury.
Wear gloves or wrap the sharp edges of the blade
with a rag.
3
5
4
1
4
2
3
2. Rotate the opposite ends of the blades forward.
3. Measure from a level surface to the cutting edge of the
blades at the same position as in step 1 above.
Note: The difference between the dimensions obtained
in steps 1 and 3 must not exceed 1/8 inch (3 mm). If this
dimension exceeds 1/8 inch (3 mm), the blade is bent
and must be replaced; refer to Removing the Blades and
Installing the Blades on page 28.
Warning
A blade that is bent or damaged could break apart
and could seriously injure or kill you or
bystanders.
• Always replace a bent or damaged blade with a
new blade.
• Never file or create sharp notches in the edges
or surfaces of a blade.
1. Sail area of blade
2. Blade
3. Spring disk
m-4226
Figure 26
4. Blade bolt
5. Cone toward bolt head
27
Page 28
Sharpening the Blades
Cleaning the Cooling System
Warning
When you sharpen the blade, pieces of the blade
could be thrown and cause serious injury.
Wear proper eye protection when you sharpen the
blade.
1. Use a file to sharpen the cutting edge at both ends of the
blade at the original angle (Fig. 27).
1
m–1854
Figure 27
1. Sharpen at original angle
Note: The blade retains its balance if the same amount
of material is removed from both cutting edges.
2. Check the balance of the blade by putting it on a blade
balancer (Fig. 28). If the blade stays in a horizontal
position, the blade is balanced and can be used. If the
blade is not balanced, file some metal off the end of the
sail area only (Fig. 26). Repeat this procedure until the
blade is balanced.
Cleaning the Engine Screen
Before each use, check and clean the engine screen.
Remove any buildup of grass, dirt, or other debris from the
engine air intake (Fig. 29).
1
m–3801
Figure 29
1. Engine screen
Cleaning the Engine Fins
Clean engine cylinder and cylinder head cooling fins after
every 100 operating hours . Also clean around the
carburetor, the governor levers and the linkage. This will
ensure that the hydraulic pumps, motors and engine are
adequately cooled to reduce the possibility of overheating
and mechanical damage.
1. Remove the panels from the engine shroud (Fig. 30).
1
3
2
1
m–1855
Figure 28
1. Blade 2. Balancer
Installing the Blades
1. Install the blade onto the spindle shaft (Fig. 26).
Important The curved part of the blade must be
pointing upward toward the inside of the mower to ensure
proper cutting.
2. Install the flat washer, lock washer, and blade bolt
(Fig. 26).
Note: Torque the blade bolt to 85–110 ft-lb
(115–150 N⋅m).
2
Figure 30
1. Panel
2. Engine shroud
3. Screws
2. Clean the engine cooling fins.
3. Install the panels onto the engine shroud (Fig. 30).
m–5616
m–3801
28
Page 29
Servicing the Air Cleaner
Primary Filter: Check and/or replace it after every
200 operating hours or more often in dusty conditions.
Safety Filter: Replace it after every 600 operating hours.
Note: Check the filters more frequently if the operating
conditions are extremely dusty or sandy.
Servicing the Primary Filter
• Check and/or replace the primary filter after
200 operating hours.
• If the primary filter is dirty, bent, or damaged,
replace it.
• Do not clean the primary filter.
Removing the Filters
1. Disengage the PTO, move the motion control levers to
the neutral locked position, and set the parking brake.
2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
3. Release the latches on the air cleaner and pull the air
cleaner cover off the air cleaner body (Fig. 31).
5
1. Latch
2. Air cleaner cover
3. Air filter body
3
4
2
1
Figure 31
4. Primary filter
5. Safety filter
1
m-7703
Servicing the Safety Filter
Replace the safety filter after 600 operating hours.
Important Never attempt to clean the safety filter. If
the safety filter is dirty, then the primary filter is damaged.
Replace both filters.
Installing the Filters
Important To prevent engine damage, always operate
the engine with both air filters and cover installed.
1. If installing new filters, check each filter for shipping
damage. Do not use a damaged filter.
2. If the safety filter is being replaced, carefully slide it
into the filter body (Fig. 31).
3. Carefully slide the primary filter over the safety filter
(Fig. 31).
Note: Ensure that the primary filter is fully seated by
pushing on its outer rim while installing it.
Important Do not press on the soft inside area of
the filter.
4. Install the air cleaner cover with the side indicated as
UP facing upward and secure the latches (Fig. 31).
4. Clean the inside of the air cleaner cover with
compressed air.
5. Gently slide the primary filter out of the air cleaner
body (Fig. 31).
Note: Avoid knocking the filter into the side of the
body.
6. Remove the safety filter only if you intend to replace
it.
Important Never attempt to clean the safety filter. If
the safety filter is dirty, then the primary filter is damaged.
Replace both filters.
7. Inspect the primary filter for damage by looking into
the filter while shining a bright light on the outside of
the filter. Holes in the filter will appear as bright spots.
If the filter is damaged, discard it.
29
Page 30
Servicing the Engine Oil
Service Interval/Specification
Change the oil after every 100 operating hours.
Note: Change the oil more frequently when the operating
conditions are extremely dusty or sandy.
Oil Type: Detergent oil (API service SG or SH)
Crankcase Capacity: w/filter, 67 oz. (2 l)
Viscosity: See the table below.
5. Unscrew the oil dipstick and wipe the metal end clean
(Fig. 32).
6. Slide the oil dipstick fully into the filler tube. Do not
thread it onto the tube (Fig. 32).
7. Pull the dipstick out and look at the metal end. If the oil
level is low, slowly pour only enough oil into the filler
tube to raise the level to the Full mark.
Important Do not overfill the crankcase with oil and
run the engine, and do not run the engine with the oil level
below the Low mark. Engine damage may result.
USE THESE SAE VISCOSITY OILS
10W–30, 10W–40
5W–20, 5W–30
–20 0 20
40 60
32
80 100
°F
–30 –20 –10
01020
30 40
°C
Checking the Oil Level
1. Park the machine on a level surface.
2. Disengage the PTO, move the motion control levers to
the neutral locked position, and set the parking brake.
3. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
Changing the Engine Oil
1. Start the engine and let it run 5 minutes.
Note: This warms the oil so that it drains better.
2. Park the machine so that the drain side is slightly lower
than the opposite side to ensure that the oil drains
completely.
3. Disengage the power take off (PTO), set the parking
brake, stop the engine, and remove the key.
4. Place a pan below the oil drain. Remove the oil drain
cap (Fig. 33).
1
4. Clean around the oil dipstick (Fig. 32) so that dirt
cannot fall into the filler hole and damage the engine.
1
3
2
m–5626
Figure 32
1. Oil dipstick
2. Filler tube
3. Metal end
m–3219
m–5626
Figure 33
1. Oil drain cap
5. When the oil has drained completely, install the drain
cap.
Note: Dispose the used oil at a certified recycling center.
6. Slowly pour approximately 80% of the specified oil into
the filler cap (Fig. 32). Refer to Servicing the Engine
Oil on page 30.
7. Check the oil level; refer to Checking the Oil Level on
page 30.
8. Slowly add additional oil to bring it to the Full mark.
30
Page 31
Changing the Oil Filter
Removing the Spark Plug(s)
Replace the oil filter every 200 operating hours or every
other oil change.
Note: Change 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 Oil
on page 30.
2. Remove the old filter and wipe the filter adapter
(Fig. 34) gasket surface.
3
1
2
m–1256
Figure 34
1. Oil filter
2. Gasket
3. Adapter
3. Pour new oil in through the center hole. Stop pouring
the oil when it reaches the bottom of the threads.
1. Disengage the PTO and set the parking brake.
2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
3. Disconnect the wire(s) from the spark plug(s) (Fig. 35).
2
1
m–4089
Figure 35
1. Spark-plug wire 2. Spark plug
4. Clean around the spark plug(s) to prevent dirt from
falling into the engine and potentially causing damage.
5. Remove the spark plug(s) and the metal washer(s).
4. Allow the filter material to absorb the new oil for 1 to
2 minutes.
5. Apply a thin coat of new oil to the rubber gasket on the
replacement filter (Fig. 34).
6. Install the replacement oil filter to the filter adapter.
Turn the oil filter clockwise until the rubber gasket
contacts the filter adapter; then tighten the filter an
additional 1/2 turn (Fig. 34).
7. Fill the crankcase with the proper type of new oil; refer
to Servicing the Engine Oil on page 30.
Servicing the Spark Plug(s)
Service Interval/Specification
Check the spark plug(s) after every 200 operating hours.
Ensure that the air gap between the center and side
electrodes is correct before installing the spark plug(s). Use
a spark plug wrench for removing and installing the spark
plug(s) and a gapping tool/feeler gauge to check and adjust
the air gap. Install a new spark plug if necessary.
Type: Champion RC12YC or equivalent
Air Gap: 0.030 inch (0.76 mm)
Checking the Spark Plug(s)
1. Look at the center of the spark plug(s) (Fig. 36). If you
see light brown or gray on the insulator, the engine is
operating properly. A black coating on the insulator
usually means that the air cleaner is dirty.
2
1
Figure 36
1. Center electrode insulator
2. Side electrode
3. Air gap (not to scale)
Important Always replace the spark plug(s) when it
has a black coating, worn electrodes, an oily film, or
cracks.
3
0.030 inch
(0.76 mm)
31
Page 32
2. Check the gap between the center and side electrodes
(Fig. 36).
7. Install a new filter and move the hose clamps close to
the filter (Fig. 37).
Note: Bend the side electrode (Fig. 36) if the gap is not
correct.
Installing the Spark Plug(s)
1. Install the spark plug(s) and the metal washer(s).
Note: Ensure that the air gap is set correctly.
2. Tighten the spark plug(s) to 20 ft-lb (27 Nm).
3. Connect the wire(s) to the spark plug(s) (Fig. 35).
Replacing the Fuel Filter
Replace the fuel filter after every 200 operating hours or
yearly, whichever occurs first.
Never install a dirty filter if it is removed from the fuel line.
1. Disengage the PTO, move the motion control levers to
the neutral locked position, and set the parking brake.
2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
3. Allow the machine to cool down.
4. Close the fuel shutoff valve on the console.
5. Squeeze the ends of the hose clamps together and slide
them away from the filter (Fig. 37).
8. Open the fuel shutoff valve on the console.
Draining the Fuel Tank
Danger
In certain conditions, gasoline is extremely
flammable and highly explosive. A fire or
explosion from gasoline can burn you and others
and can damage property.
• Drain gasoline from the fuel tank when the
engine is cold. Do this outdoors in an open area.
Wipe up any gasoline that spills.
• Never smoke when draining gasoline, and stay
away from an open flame or where a spark may
ignite the gasoline fumes.
1. Park the machine on a level surface to ensure that the
fuel tanks drain completely.
2. Disengage the power takeoff (PTO), set the parking
brake, stop the engine, and remove the key.
3. Close the fuel shutoff valve (Fig. 37).
4. Loosen the hose clamp at the fuel filter and slide it up
the fuel line away from the fuel filter (Fig. 37).
5. Disconnect the fuel line from the fuel filter (Fig. 37).
6. Open the fuel shutoff valve for the left and right tanks.
Figure 37
1. Fuel filter 2. Hose clamp
6. Remove the filter from the fuel lines.
Note: Allow gasoline to drain into a fuel container can
or drain pan (Fig. 37).
1
2
m–4088
Note: Now 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
(Fig. 37).
32
Page 33
Greasing and Lubrication
Lubricate the machine at the intervals shown on the Check
Service Reference Aid decal (Fig. 38). Lubricate more
frequently when operating conditions are extremely dusty
or sandy.
Figure 38
Greasing the Front Caster Pivots
Lubricate the front caster pivots once a year.
1. Remove the dust cap and adjust the caster pivots.
Note: Keep dust cap off until greasing is done. Refer to
Adjusting the Caster Pivot Bearing on page 39.
2. Remove the hex plug and thread a grease zerk into the
hole.
3. Pump grease into the zerk until it oozes out around the
top bearing.
4. Remove the grease zerk in the hole and install the hex
plug and cap.
Greasing the Bearings
Lubricate the cutting machine regularly; refer to the
Recommended Maintenance Schedule on page 25. Grease
with No. 2 general-purpose lithium-base or
molybdenum-base grease.
1. Disengage the PTO, move the motion control levers to
the neutral locked position, and set the parking brake.
2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
Lubricate with No. 2 general-purpose lithium-base or
molybdenum-base grease.
How to Grease
1. Disengage the PTO, move the motion control levers to
the neutral locked position, and set the parking brake.
2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
3. Clean the grease fittings with a rag. Make sure to scrape
any paint off the front of the fitting(s).
4. Connect a grease gun to the fitting and pump grease
into the fittings until the grease begins to ooze out from
the bearings.
5. Wipe up any excess grease.
Where to Add Grease
Lubricate the grease fittings as shown on the Check
Service Reference Aid decal (Fig. 38).
3. Grease the fittings on the 3 spindle bearings (Fig. 39).
m–7706
Figure 39
4. Grease the idler pulley pivot (Fig. 39).
5. Grease the fittings on the push arms (Fig. 39).
33
Page 34
Where to Add Light Oil or Spray
Lubrication
Lubricate the machine in the following areas with spray
type lubricant or light oil. Lubricate every 160 hours.
• Seat switch actuator
• Brake handle pivot
• Brake rod bushings
• Motion control bronze bushings
Checking the Tire Pressure
Maintain the air pressure in the front and rear tires as
specified. Uneven tire pressure can cause an uneven cut.
Check the pressure at the valve stem after every
50 operating hours or monthly, whichever occurs first
(Fig. 40). Check the tires when they are cold to get the most
accurate pressure reading.
Pressure: 13 psi (90 kPa) drive wheels and caster wheels
Important Use the specified oil or equivalent. Other
fluids could cause system damage.
Hydraulic System Oil Capacity: 67 oz. (2.0 l)
Note: There are 2 ways of checking the hydraulic oil. One
is for warm oil and the other for cold oil. The baffle inside
the tank has 2 levels depending on whether the oil is warm
or cold.
1. Move the machine onto a level surface and set the
parking brake.
2. Clean area around filler neck of hydraulic tank
(Fig. 41).
1
2
4
3
1
m–1872
Figure 40
1. Valve stem
Servicing the Hydraulic System
Checking the Hydraulic Fluid
Check the hydraulic fluid level:
• Before the engine is first started
• After the first 8 operating hours
• After every 25 operating hours
Fluid Type: Mobil 1 15W-50 synthetic motor oil or
equivalent synthetic oil.
m–5615
Figure 41
1. Cap
2. Baffle
3. Remove the cap from the filler neck and look inside to
check if there is fluid in the reservoir (Fig. 41).
4. If there is no fluid, add fluid to the reservoir until it
reaches the Cold level of the baffle.
5. Run the machine at low idle for 15 minutes to allow any
air to purge out of the system and warm the fluid. Refer
to Starting and Stopping the Engine on page 18.
6. Check the fluid level while the fluid is warm. The fluid
should be between the Cold and Hot levels.
7. If required, add fluid to the hydraulic tank.
Note: The fluid level should be to the top of the Hot
level of the baffle when the fluid is hot (Fig. 41).
8. Install cap on filler neck.
3. Cold fluid level—full
4. Hot fluid level—full
34
Page 35
Warning
Hydraulic fluid escaping under pressure can
penetrate skin and cause injury.
• If hydraulic fluid is injected into the skin, it
must be surgically removed within a few hours
by a doctor familiar with this type of injury;
otherwise, gangrene may result.
• Keep your body and hands away from pin hole
leaks or nozzles that eject high-pressure
hydraulic fluid.
• Use cardboard or paper to find hydraulic leaks.
• Safely relieve all pressure in the hydraulic
system before performing any work on the
hydraulic system.
• Ensure that all hydraulic fluid hoses and lines
are in good condition and all hydraulic
connections and fittings are tight before
applying pressure to the hydraulic system.
Replacing the Hydraulic Filter
Change the hydraulic filter:
• After the first 8 operating hours
• After every 200 operating hours
Use a summer filter above 32°F (0°C)
Use a winter filter below 32°F (0°C)
1. Disengage the PTO, move the motion control levers to
the neutral locked position, and set the parking brake.
2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
Important Do not substitute an automotive oil filter for
a hydraulic filter; this can severely damage the hydraulic
system.
3. Place a drain pan under the filter, remove the old filter,
and wipe the filter adapter gasket surface clean
(Fig. 42).
4. Apply a thin coat hydro fluid to the rubber gasket on the
replacement filter (Fig. 43).
1
3
2
m–1256
Figure 43
1. Hydraulic filter
2. Gasket
3. Adapter
5. Install the replacement hydraulic filter onto the filter
adapter, but do not tighten.
6. Fill the hydraulic tank with hydraulic fluid until the
fluid overflows the filter
7. Turn the oil filter clockwise until the rubber gasket
contacts the filter adapter, then tighten the filter an
additional 1/2 turn (Fig. 43).
8. Clean up any spilled fluid.
9. Add fluid to the cold level of the baffle in the hydraulic
tank.
10.Start the engine and let it run for about 2 minutes to
purge air from the system. Stop the engine and check
for leaks.
Note: If one or both wheels will not drive, refer
Bleeding Hydraulic System on page 35.
11. Check the fluid level while the fluid is warm.
Note: The fluid should be between cold and hot.
12.If required, add fluid to the hydraulic tank. Do not
overfill.
Bleeding the Hydraulic System
1. Hydraulic filter
Figure 42
The traction system is self bleeding; however, it may be
necessary to bleed the system if the fluid is changed or after
work is performed on the system.
1
m-4763
1. Raise the rear of the machine so that the wheels are off
the ground and support it with jack stands.
2. Start the engine and run at low idle speed.
3. Engage the lever and traction on one side and spin the
wheel by hand.
35
Page 36
4. When the wheel begins to spin on its own, keep it
engaged until wheel drives smoothly. (minimum
2 minutes)
Adjusting the Handle Neutral
Position
5. Check hydraulic fluid level and add fluid as required to
maintain the proper level.
6. Repeat this procedure on the opposite wheel.
Warning
Hydraulic fluid escaping under pressure can
penetrate skin and cause injury.
• If hydraulic fluid is injected into the skin it must
be surgically removed within a few hours by a
doctor familiar with this type of injury;
otherwise, gangrene may result.
• Keep your body and hands away from pin hole
leaks or nozzles that eject high pressure
hydraulic fluid.
• Use cardboard or paper to find hydraulic leaks.
• Safely relieve all pressure in the hydraulic
system before performing any work on the
hydraulic system.
• Ensure that all hydraulic fluid hoses and lines
are in good condition and all hydraulic
connections and fittings are tight before
applying pressure to hydraulic system.
If the motion control levers do not align or move easily into
the console notch, adjustment them. Adjust each lever,
spring, and rod separately.
Note: The motion control levers must be installed correctly.
See Installing the Motion Control Levers in the Setup
instructions.
1. Disengage the PTO, move the motion control levers to
the neutral locked position, and set the parking brake.
2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
3. Tilt the seat forward.
4. Begin with either the left or right motion control lever.
5. Move lever to the neutral position but not locked
(Fig. 44).
2
3
Checking the Hydraulic Lines
After every 100 operating hours, check the hydraulic lines
and hoses for leaks, loose fittings, kinked lines, loose
mounting supports, wear, weather, and chemical
deterioration. Make necessary repairs before operating.
Note: Keep areas around the hydraulic system clean from
grass and debris buildup.
Waste Disposal
Engine oil, hydraulic oil, and engine coolant are pollutants
to the environment. Dispose of these according to your
state and local regulations.
1. Neutral locked position
2. Control lever
1
m–6282
Figure 44
3. Neutral potion
36
Page 37
6. Pull the lever back until the clevis pin (on the arm
below the pivot shaft) contacts the end of the slot (just
beginning to put pressure on the spring) (Fig. 45).
Setting the Hydraulic Pump
Neutral Position
Note: Adjust the handle neutral first. That has to be correct
before you can perform the following adjustment.
2
6
9
1
m–4118
1. Clevis pin in slot
2. Nut
3. Nut—Left hand thread
4. Adjustment bolt
5. Pump rod
8
1
Figure 45
6. Double nuts
7. Jam nut
8. Yoke
9. Ball joint
4 3
8
Danger
9
Mechanical or hydraulic jacks may fail to support
the machine and cause a serious injury.
• Use jack stands when supporting the machine.
• Do not use hydraulic jacks.
Warning
2
7
The engine must be running so that you can adjust
the motion control. Contact with moving parts or
hot surfaces may cause personal injury.
Keep your hands, feet, face, clothing and other
body parts away from rotating parts, muffler, and
other hot surfaces.
You must make this adjustment with the drive wheels
turning.
1. Raise the frame and block up the machine so that the
drive wheels can rotate freely.
2. Disconnect the electrical connector from the seat safety
switch. Temporarily install a jumper wire across
terminals in the wiring harness connector.
7. Check where the control lever is relative to the notch in
the console (Fig. 44). It should be centered, allowing
the lever to pivot outward to the neutral lock position.
8. If adjustment is needed, loosen the nut and jam nut
against the yoke (Fig. 45).
9. Apply slight rearward pressure on the motion control
lever, and turn the head of the adjustment bolt in the
appropriate direction until the control lever is centered
in the neutral lock position (Fig. 44).
Note: Keeping rearward pressure on the lever will keep
the pin at the end of the slot and allow the adjustment
bolt to move the lever to the appropriate position.
10.Tighten the nut and jam nut (Fig. 45).
11. Repeat on the opposite side of machine.
3. Slide the seat forward, disconnect the prop rod and tilt
the seat fully forward.
37
Page 38
Setting the Left-hand Hydraulic Pump
Neutral Position
1. Start the engine, open the throttle halfway and release
the parking brake. Refer to Starting and Stopping the
Engine on page 18.
Note: The motion control lever must be in neutral while
you are making any adjustments.
2. Adjust the pump rod length by rotating the knob in the
appropriate direction until the wheel is still or slightly
creeping in reverse (Fig. 46).
1
3
2
m–6283
Figure 46
1. Tracking knob
2. Pump rod
3. Move the motion control lever forward and reverse,
then back to neutral. The wheel must stop turning or
slightly creep in reverse.
4. Open throttle to fast.
Note: Ensure that the wheel remains stopped or slightly
creeps in reverse, and adjust it if necessary.
3. Adjustment bolt
3. Adjust the pump rod length by rotating the double nuts
on the rod in the appropriate direction until the wheel is
still or slightly creeps in reverse (Fig. 45).
4. Move the motion control lever forward and reverse,
then back to neutral. The wheel must stop turning or
slightly creep in reverse.
5. Open the throttle to Fast. Ensure that the wheel remains
stopped or slightly creeps in reverse, adjust if necessary.
6. Tighten the nuts at the ball joints (Fig. 45).
Warning
The electrical system will not perform the proper
safety shutoff with the jumper wire installed.
• Remove the jumper wire from the wire harness
connector and plug the connector into the seat
switch after completing the adjustment.
• Never operate the machine with the jumper wire
installed and the seat switch bypassed.
7. After both pump neutrals are set, shut off the machine.
8. Remove the jumper wire from the wire harness
connector and plug the connector into the seat switch.
9. Install the prop rod and lower the seat into position.
10.Remove the jack stands.
Adjusting the Tracking
The left-hand pump has a knob for adjusting the tracking.
Important Adjust the handle neutral and the hydraulic
pump neutral before adjusting the tracking. Refer to
Adjusting the Handle Neutral on page 36 and Adjusting the
Hydraulic Pump Neutral on page 37.
1. Push both control levers forward the same distance.
2. Check if the machine pulls to one side. If it does, stop
the machine and set the parking brake.
3. Tip the seat up to access the tracking knob.
Setting the Right-hand Hydraulic Pump
Neutral Position
1. Loosen the locknuts at the ball joints on the pump
control rod (Fig. 45).
2. Start the engine, open the throttle halfway, and release
the parking brake. Refer to Starting and Stopping the
Engine on page 18.
Note: The motion control lever must be in neutral while
you are making any adjustments.
Note: The front nut on the pump rod has left-hand threads.
Note: Determine the left and right sides of the machine
from the normal operating position.
38
Page 39
4. To make the machine move to the right, turn the knob
toward the right side of the machine; refer to Figure 47.
2
3
4. Tighten the locknut until the spring washers are flat,
then back off 1/4 turn to properly set the pre-load on the
bearings (Fig. 48).
Important Ensure that the spring washers are installed
correctly as shown in Figure 48.
Checking the Wheel Hub
4
Slotted Nut
Check after every 500 operating hours.
1
m–6280
Figure 47
1. Pump rod
2. Turn this way to track left
3. Tracking knob
4. Turn this way to track
right
5. To make the machine move to the left, turn the knob
toward the left side of the machine; refer to Figure 47.
6. Repeat the adjustment until the tracking is correct.
Adjusting the Caster Pivot
Bearing
Check after every 500 operating hours or at storage,
whichever occurs first.
1. Disengage the PTO, move the motion control levers to
the neutral locked position, and set the parking brake.
2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
3. Remove the dust cap from the caster and tighten the
locknut (Fig. 48).
3
2
1
The slotted nut needs to be torqued to 125 ft-lb (170 N⋅m).
1. Disengage the PTO, move the motion control levers to
the neutral locked position, and set the parking brake.
2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
3. Remove the cotter pin.
4. Torque the slotted nut to 125 ft-lb (170 N⋅m) (Fig. 49).
1
4
3
5
2
m–4638
Figure 49
1. Slotted nut
2. Two threads or less
showing
3. Hole in threaded shaft
4. Washer (if needed)
5. Slot
5. Check the distance from the bottom of the slot in the
nut to the inside edge of the hole.
Note: No more than 2 threads should be showing
(Fig. 49).
6. If more than 2 threads are showing, remove the nut and
install a washer between the hub and nut (Fig. 49).
7. Torque the slotted nut to 125 ft-lb (170 N⋅m) (Fig. 49).
8. Tighten the nut until the next set of slots line up with
the hole in the shaft (Fig. 49).
1. Spring washers
2. Locknut
Figure 48
3. Dust cap
m–4640
9. Install the cotter pin.
39
Page 40
Leveling the Mower at Three
Positions
Important There are only 3 measuring positions
needed to level the mower.
Setting Up the Machine
1. Position mower on a flat surface.
MEASURE FROM
CUTTING EDGE TO
A LEVEL SURFACE
Figure 51
m–2539
2. Disengage the PTO, move the motion control levers to
the neutral locked position, and set the parking brake.
3. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
4. Check tire pressure of all 4 tires. If needed, adjust them
to 13 psi (90 kPa)
5. Position the mower to the 3-inch (76 mm) height-of-cut
position.
6. Inspect the 4 chains; the chains need to have tension.
Note: Adjust the rear chains to the top of the slot, where
they are attached to the mower.
• If one rear chain is loose, lower (loosen) the front
support arm on the same side. Refer to Adjusting the
Front-to-Rear Mower Pitch on page 41.
• If one front chain is loose, raise (tighten) the front
support arm for that chain. Refer to Adjusting the
Front-to-Rear Mower Pitch on page 41.
Leveling the Mower Side-to-Side
1. Position the right blade front to rear (Fig. 50).
Front
C
Figure 50
2. Measure the right blade at the B location (Fig. 50), from
a level surface to the cutting edge of the blade tip
(Fig. 51).
B
m–1078
3. Record this measurement; this measurement must be
3-1/8 to 3-1/4 inches (79 to 83 mm).
4. Position the left blade front to rear (Fig. 50).
5. Measure the left blade at the C location (Fig. 50), from
a level surface to the cutting edge of the blade tip
(Fig. 51).
6. Record this measurement. This measurement must be
3-1/8 to 3-1/4 inches (79 to 83 mm).
7. If the measurements at positions B or C are incorrect,
loosen the bolt that attaches the rear chain to the rear
support arm (Fig. 52).
2
1
3
1
Front
7
2
4
5
Figure 52
1. Rear chain
2. Rear support arm
3. Bolt
4. Jam Nut
5. Adjustment bolt
6. Front swivel
7. Front support arm
8. Loosen the jam nut under the rear support arm and
adjust the adjustment bolt to get a measurement of
3-1/8 to 3-1/4 inches (79 to 83 mm).
Note: It is recommended that both sides of the mower are
adjusted the same distance.
9. Tighten the jam nut under the rear support arm and
tighten the bolt that secures the chain to the rear support
arm.
6
10.Adjust the opposite side if needed.
40
Page 41
Adjusting the Front-to-Rear Mower Pitch
1. Position the right blade front to rear (Fig. 53).
Front
A
B
m–1078
7. Loosen the front swivel jam nuts, at the front of the
right and left swivels, approximately 1/2 inch (13 mm)
(Fig. 55).
8
1
8
4
Figure 53
2. Measure the right blade at the A location (Fig. 53) from
a level surface to the cutting edge of the blade tip
(Fig. 54).
MEASURE FROM
CUTTING EDGE TO
A LEVEL SURFACE
m–2539
Figure 54
3. Record this measurement.
4. Measure the right blade at the B location (Fig. 53) from
a level surface to the cutting edge of the blade tip
(Fig. 54).
5. Record this measurement.
6. The mower blade should be 1/4 to 3/8 inch
(6 to 10 mm) lower at position A than at position B
(Fig. 53). If it is not correct, go to the following steps.
6
5
7
2
3
m–7704
Front
Figure 55
1. 10-1/2 inch (267 mm)
between the large
washers
2. Front nut
3. Spring jam nut
4. Front swivel
5. Swivel jam nut
6. Lift nut
7. Front support arm
8. Large washer
8. Adjust the lift nuts on both the left and the right side of
the machine to achieve 1/4 to 3/8 inch (6 to 10 mm)
lower in front at A than in the rear at B (Fig. 55).
9. Tighten both swivel jam nuts against the front swivel to
lock the height.
10.Check to ensure that there is equal tension on the chains
and adjust again if needed.
Adjusting the Compression Spring
1. Raise the mower lift lever to the transport position
(Fig. 55).
Note: You must adjust both of the front swivels the same
amount to maintain equal chain tension.
2. Check the distance between the 2 large washers; it must
be 10-1/2 inches (26.7 cm) (Fig. 55).
3. Adjust this distance by loosening the spring jam nut and
turning the nut in front of each spring (Fig. 55).
Note: Turning the nut clockwise shortens the spring;
turning the nut counterclockwise lengthens the spring.
4. Lock the nut into position by tightening the spring jam
nut (Fig. 55).
41
Page 42
Adjusting the Push Arms
Inspecting the Belts
If needed, adjust the push arms to increase or decrease the
mower belt tension.
1. Loosen the jam nut and rotate the ball joint
counterclockwise, one turn at a time.(Fig. 56).
1
3
4
2
m–7705
Figure 56
1. Push arm
2. 13-1/2 inch (343 mm)
nominal at 15° twist
3. Jam nut
4. Ball joint
2. Adjust each side the same amount. Each push arm
should have a nominal length of 13-1/2 inch (34 cm) at
a 15-degree twist (Fig. 56).
Note: Increase the tension by lengthening the push arms;
decrease the tension by shortening the push arms.
Inspect all belts every 50 hours.
Check belts for cracks, frayed edges, burn marks, or any
other damage. Replace damaged belts.
Replacing the Mower Belt
The signs of a worn mower belt are squealing while the belt
is rotating, blades slipping while you are cutting grass,
frayed belt edges, burn marks, and cracks. Replace the
mower belt if you detect any of these signs.
1. Disengage the PTO, move the motion control levers to
the neutral locked position, and set the parking brake.
2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
3. Remove the belt covers over the outside spindles.
4. Loosen the fixed idler arm and adjust it to relieve the
belt tension on the fixed idler pulley (Fig. 57).
5
3
6
Cleaning Under the Mower
Remove grass buildup under the mower housing daily.
1. Position the mower on a flat surface.
2. Disengage the PTO, move the motion control levers to
the neutral locked position, and set the parking brake.
3. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
4. Raise the mower housing to the transport position.
5. Lift the front of the machine and support the machine
using jack stands.
Danger
Mechanical or hydraulic jacks may fail to support
machine and cause a serious injury.
• Use the jack stand when supporting the
machine.
• Do not use hydraulic jacks.
2
1
m–7711
4
Figure 57
1. Fixed idler arm
2. Square hole
3. Fixed Idler pulley
4. Mower belt
5. Belt guide
6. Spring-loaded idler pulley
5. Remove the old belt.
6. Install the new belt through the belt guide and on the
pulleys (Fig. 57).
42
Page 43
7. Insert a ratchet with a short extension or a breaker bar
into the square hole in the fixed idler arm (Fig. 58).
1
Replacing the Pump Drive Belt
Check the pump drive belt for wear after every
50 operating hours.
1. Remove the mower belt first; refer to Replacing the
Mower Belt on page 42.
2. Remove the bolt from the clutch stop and unplug the
clutch electrical wire (Fig. 59).
2
m–7719
Figure 58
1. Ratchet with short
extension or breaker bar
2. Square hole
8. To increase the belt tension, rotate the ratchet or breaker
bar counterclockwise to move the fixed idler arm until
you feel increased resistance and the spring-loaded idler
pulley stops moving.
Note: Do not increase the belt tension beyond the point
where the fixed idler arm stops.
9. While holding the belt in tension, tighten the 2 bolts
that secure the fixed idler arm.
10.Remove the ratchet or breaker bar from the square hole
in the fixed idler arm.
11. Install the belt covers the outside spindles.
3
4
5
2
1
6
m–7718
Figure 59
1. Belt
2. Clutch electrical wire
3. Clutch stop
4. Bolt
5. Clutch
6. Idler
3. Pull the spring loaded idler to the side.
4. Remove the traction belt from the engine and the
hydraulic pump pulleys (Fig. 59).
5. Install the new belt around the engine and the hydraulic
pump pulleys (Fig. 59).
6. Pull the spring-loaded idler to the side and align the
belt.
7. Release the pressure on the spring loaded idler
(Fig. 59).
8. Install the mower belt.
43
Page 44
Adjusting the Parking Brake
Servicing the Fuses
Check the parking brake for proper adjustment.
1. Disengage the brake lever (lever down).
2. Measure the length of the spring; the measurement
should be 2-3/4 inch (74 mm) between the washers
(Fig. 60).
4
7
5
6
11
2
3
m-4120
Figure 60
1. Brake lever
2. Spring, 2-3/4 inch
(74 mm)
3. Adjusting nuts
4. Collar on brake rod
5. 3/16 to 1/4 inch
(5 to 7 mm)
6. Jam nut and yoke
7. Trunnion
3. If an adjustment is necessary, do the following:
A. Loosen the jam nut below the spring and tighten the
nut directly below the yoke (Fig. 60).
Service Interval/Specification
The electrical system is protected by fuses. It requires no
maintenance; however, if a fuse blows, check the
component/circuit for a malfunction or short.
Fuse: Main F1—30 amp, blade-type
Charge Circuit F2—25 amp, blade-type
Optional Headlight Kit—10 amp, blade type
1. Raise the seat to gain access to the fuse holder (Fig. 61).
4
5
Figure 61
1. Main—30 amp
2. Charge circuit—25 amp
3. For optional Headlight
Kit—10 amp
1
2
3
m–7724
4. Ignition switch
5. Throttle lever
B. Turn the nut until you obtain the correct
measurement.
C. Tighten the 2 nuts together and repeat on the
opposite side of the machine.
4. Turn the nuts clockwise to shorten the spring length;
counterclockwise to lengthen the spring.
5. Engage the parking brake, with the lever up.
6. Measure the distance between the trunnion roller and
the collar on the brake rod. The measurement should be
3/16 to 1/4 inch (5 to 7 mm) (Fig. 60).
7. If an adjustment is necessary, do the following:
A. Loosen the jam nut directly below the yoke.
B. Turn the bottom adjusting nuts until the correct
measurement is obtained (Fig. 60).
C. Tighten the jam nut at the yoke.
2. To replace a fuse, pull out on the fuse to remove it
(Fig. 61).
Servicing the Battery
Warning
CALIFORNIA
Proposition 65 Warning
Battery posts, terminals, and related accessories
contain lead and lead compounds, chemicals
known to the State of California to cause cancer
and reproductive harm. Wash hands after
handling.
44
Page 45
Checking the Electrolyte Level
Installing the Battery
1. Shut off the engine and wait for all moving parts to
stop.
2. Open the hood.
3. Look at the side of the battery. The electrolyte must be
up to the upper line (Fig. 62).
1
2
3
m–5004
Figure 62
1. Filler caps
2. Upper line
3. Lower line
Note: Do not allow the electrolyte to get below the
lower line (Fig. 62).
4. If the electrolyte is low, add the required amount of
distilled water; refer to Adding Water to the Battery on
page 46.
1. Position the battery in the tray with the terminal posts
toward the engine (Fig. 63).
11
9 5
4
2
7
6
7
3
10
8
1
m–5598
Figure 63
1. Battery
2. Terminal boot
3. Positive battery cable
4. Negative battery cable
5. Ground wire
6. Bolt, 1/4 x 3/4 inch
7. Washer, 1/4 inch
8. Locknut, 1/4 inch
9. Battery clamp
10. J-bolts
11. Wing nut, 1/4 inch
2. First, install the positive (red) battery cable to the
positive (+) battery terminal.
3. Then install the negative battery cable and the ground
wire to the negative (–) battery terminal.
4. Secure the cables with 2 bolts (1/4 x 3/4 inch),
2 washers (1/4 inch), and 2 locknuts (1/4 inch)
(Fig. 63).
5. Slide the red terminal boot onto the positive (red)
battery post.
6. Secure the battery with J-bolts, clamp, 2 washers
(1/4 inch), and 2 wing nuts (1/4 inch) (Fig. 63).
45
Page 46
Removing the Battery
Warning
The battery terminals or metal tools could short
against metal machine components, causing
sparks. Sparks can cause the battery gasses to
explode, resulting in personal injury.
• When removing or installing the battery, do not
allow the battery terminals to touch any metal
parts of the machine.
• Do not allow metal tools to short between the
battery terminals and metal parts of the
machine.
Adding Water to the Battery
The best time to add distilled water to the battery is just
before you operate the machine. This lets the water mix
thoroughly with the electrolyte solution.
Note: Never fill the battery with distilled water while the
battery installed in the machine. The electrolyte could be
spilled on other parts and cause corrosion.
1. Remove the battery from the machine.
2. Clean the top of the battery with a paper towel.
3. Remove the vent caps from the battery (Fig. 62).
4. Slowly pour distilled water into each battery cell until
the level is up to the upper line (Fig. 62) on the battery
case.
Warning
Incorrectly routing the battery cable could damage
the machine and cables, causing sparks. Sparks
can cause the battery gasses to explode, resulting
in personal injury.
• Always disconnect the negative (black) battery
cable before disconnecting the positive (red)
cable.
• Always connect the positive (red) battery cable
before connecting the negative (black) cable.
1. Disengage the PTO, move the motion control levers to
the neutral locked position, and set the parking brake.
2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
3. Tilt the seat up.
4. Disconnect the negative battery cable and the ground
wire from the negative (–) battery terminal (Fig. 63).
5. Slide the red terminal boot off the positive (red) battery
terminal.
6. Remove the positive (red) battery cable (Fig. 63).
7. Remove both wing nuts (1/4 inch) that secure the
battery clamp (Fig. 63).
8. Remove the battery.
Important Do not overfill the battery because
electrolyte (sulfuric acid) can cause severe corrosion and
damage to the chassis.
5. Wait 5 to 10 minutes after filling the battery cells, then
add distilled water, if necessary, until the electrolyte
level is up to the upper line (Fig. 62) on the battery
case.
6. Install battery vent caps.
Charging the Battery
Warning
Charging the battery produces gasses that can
explode.
Never smoke near the battery, and keep sparks
and flames away from the battery.
Important Always keep the battery fully charged
(1.265 specific gravity). This is especially important to
prevent battery damage when the temperature is below
32°F (0°C).
1. Remove the battery from the chassis; refer to Removing
the Battery on page 46.
2. Ensure that the filler caps are installed in battery.
3. Charge battery for a minimum of 1 hour at 6 to
10 amps.
46
Page 47
4. When the battery is fully charged, unplug the charger
from the electrical outlet, then disconnect the charger
leads from the battery posts (Fig. 64).
1. Remove the locknut, bolt, spring, and spacer that hold
the deflector to the pivot brackets (Fig. 65).
8
4
2
3
1
m–4970
Figure 64
1. Positive Battery Post
2. Negative Battery Post
3. Red (+) Charger Lead
4. Black (–) Charger Lead
5. Install the battery in the machine and connect the
battery cables; refer to Installing the Battery on page 45.
Note: Do not run the machine with the battery
disconnected to prevent electrical damage.
Replacing the Grass Deflector
6
4
2
3
1
m–7708
5
m–5037
Figure 65
1. Bolt
2. Spacer
3. Locknut
4. Spring
5. Spring installed
6. Grass deflector
7. Place behind mower
housing edge before
installing bolt
8. Hook end of spring
2. Remove the damaged or worn grass deflector.
3. Place the spacer and spring onto the grass deflector.
7
Warning
An uncovered discharge opening could allow the
lawn mower to throw objects in the operator’s or
bystander’s direction and result in serious injury.
Also, contact with the blade could occur.
• Never operate the lawn mower unless you install
a cover plate, a mulch plate, or a grass chute
and catcher.
• Ensure that the grass deflector is in the down
position.
Note: Install the straight end of the spring behind the
mower housing edge.
4. Install the bolt and nut.
5. Place the hook end of the spring around the grass
deflector (Fig. 65).
Important The grass deflector must be able to lower
down into position. Lift the deflector up to ensure that it
lowers into the full down position.
Waste Disposal
Engine oil, hydraulic oil, engine coolant, and the battery are
pollutants to the environment. Dispose of these according
to your local regulations.
47
Page 48
Wiring Diagram
HEADLIGHT
HARNESS
CONNECTOR
A
B
WHITE
VIOLET
TAN
RED
PINK
W
VIO
T
R
PK
WIRE COLOR CODES
BLACK
BK
SW1
(IGNITION)
GREY
BLUE
GREEN
BROWN
GY
GN
BU
BN
IA
YB
SX
YELLOW
Y
ORANGE
OR
F3
VIO
PK
PK R
BNOR
VIO
10A
BK
IGNITION
SPARK PLUG SPARK PLUG
F2
25A
F1
30A
MODULES
MAG
2
W
R
PK
AC
3
REG
VIO
HOUR
AC
METER
OR
FUEL
SOLINIOD
FUEL
4
PK
–+
GN
GND
–+
BATTERY
ST
B
BU
STARTER
3
1
4
GYW
Y
BU
4
GY
2
5
BK
K1
(KILL RELAY)
OIL
SWITCH
R
OIL
1
GN
1
BN
235
Y
I
B
S
X
A
Y
KEY SWITCH PN 88–9830
OFF NO CONNECTION
ON B I A AND X Y
START B I S
KOHLER TWIN AIR–COOLED
KEY SW
TERMINAL VIEW FROM
BACK OF SWITCH
SW2
(PTO)
BN
PK
SHOWN IN
OFF POSITION
GY
OR
Y
SW6
SW3
(BRAKE)
(SEAT SW)
SHOWN WITH
OPERATOR
IN SEAT
P1–A
DELAY MODULE
100–6186
VIO
DISENGAGED
SHOWN WITH
PARK BRAKE
BN
T
P2–C
P1–C
VIO
PTO
CLUTCH
BK
P1–B
SHOWN WITH
LEVER IN
NEUTRAL
POSITION
SW4
(NEUTRAL)
BK
W
K2
(START RELAY)
SHOWN WITH
LEVER IN
SW5
Y
NEUTRAL
POSITION
(NEUTRAL)
BK
GND
48
Page 49
Cleaning and Storage
1. Disengage the power takeoff (PTO), set the parking
brake and turn the ignition key to off. Remove spark
plug wire. Remove the key.
2. Remove grass clippings, dirt, and grime from the
external parts of the entire machine, especially the
engine and hydraulic system. Clean dirt and chaff from
the outside of the engine’s cylinder head fins and
blower housing.
Important You can wash the machine with mild
detergent and water. Do not pressure wash the machine.
Avoid excessive use of water, especially near the control
panel, engine, hydraulic pumps and motors.
3. Service the air cleaner; refer to Servicing the Air
Cleaner on page 29.
4. Grease and oil the machine; refer to Greasing and
Lubrication on page 33.
5. Change the crankcase oil and filter; refer to Servicing
the Engine Oil on page 30.
6. Change the hydraulic filter; refer to Servicing the
Hydraulic System on page 34.
7. Check the tire pressure; refer to Checking the Tire
Pressure on page 34.
8. Charge the battery; refer to Servicing the Battery
page 44.
9. Scrape any heavy buildup of grass and dirt from the
underside of the mower, then wash the mower with a
garden hose.
Note: Run the machine with the PTO engaged and the
engine at high idle for 2 to 5 minutes after washing.
10.Check the condition of the blades. Refer to Servicing
the Cutting Blades on page 26.
A. Add a petroleum based stabilizer/conditioner to fuel
in the tank. Follow mixing instructions from
stabilizer manufacture. Do not use an alcohol
based stabilizer (ethanol or methanol).
Note: A fuel stabilizer/conditioner is most effective when
mixed with fresh gasoline and used at all times.
B. Run engine to distribute conditioned fuel through
the fuel system (5 minutes).
C. Stop engine, allow to cool and drain the fuel tank;
refer to Servicing the Fuel Tank on page 32.
D. Restart engine and run it until it stops.
E. Choke the engine. Start and run engine until it will
not start.
F. Dispose of fuel properly. Recycle as per local codes.
Important Do not store stabilizer/conditioned gasoline
over 90 days.
12.Remove the spark plug(s) and check its condition; refer
to Servicing the Spark Plug(s) on page 31. With the
spark plug(s) removed from the engine, pour 2
tablespoons of engine oil into the spark plug hole. Now
use the starter to crank the engine and distribute the oil
inside the cylinder. Install the spark plug(s). Do not
install the wire on the spark plug(s).
13.Check and tighten all bolts, nuts, and screws. Repair or
replace any part that is damaged or defective.
14.Paint all scratched or bare metal surfaces. Paint is
available from your Authorized Service Dealer.
15.Store the machine in a clean, dry garage or storage area.
Remove the key from the ignition switch and keep it in
a memorable place out of reach of children or other
unauthorized users. Cover the machine to protect it and
keep it clean.
11. Prepare the machine for storage when nonuse occurs
over 30 days. Prepare machine for storage as follows.
49
Page 50
Troubleshooting
g
g
g
Problem Possible Causes Corrective Action
Starter does not crank.
Engine will not start, starts hard, or
fails to keep running.
1. Blade control (PTO) is
engaged.
2. Parking brake is not on. 2. Set parking brake.
3. Operator is not seated. 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. 7. Contact Authorized Service
1. Fuel tank is empty. 1. Fill fuel tank with gasoline.
2. Fuel valve turned off. 2. Open fuel valve.
3. Choke is not on. 3. Move choke lever to on.
4. Air cleaner is dirty. 4. Clean or replace air cleaner
5. Spark plug wires are loose or
disconnected.
6. Spark plugs are pitted, fouled,
or gap is incorrect.
1. Move blade control (PTO) to
Disengaged.
5. Check electrical connections
for good contact.
Dealer.
element.
5. Install wires on spark plug.
6. Install new, correctly gapped
spark plugs.
Engine loses power.
Engine overheats.
7. Dirt in fuel filter. 7. Replace fuel filter.
8. Dirt, water, or stale fuel is in
fuel system.
1. Engine load is excessive. 1. Reduce ground speed.
2. Air cleaner is dirty. 2. Clean air cleaner element.
3. Oil level in crankcase is low. 3. Add oil to crankcase.
4. Cooling fins and air passages
under engine blower housing
are plugged.
5. Spark plugs are pitted, fouled,
or gap is incorrect.
6. Dirt in fuel filter. 6. Replace fuel filter.
7. Dirt, water, or stale fuel is in
fuel system.
1. Engine load is excessive. 1. Reduce ground speed.
2. Oil level in crankcase is low. 2. Add oil to crankcase.
3. Cooling fins and air passages
under engine blower housing
are plugged.
8. Contact Authorized Service
Dealer.
4. Remove obstruction from
cooling fins and air passages.
5. Install new, correctly gapped
spark plugs.
7. Contact Authorized Service
Dealer.
3. Remove obstruction from
cooling fins and air passages.
50
Page 51
Problem Corrective ActionPossible Causes
gg
Machine does not drive.
Abnormal vibration.
1. Traction belt is worn, loose or
broken.
2. Traction belt is off pulley. 2. Contact Authorized Service
3. Hydro fluid level low. 3. Add hydro fluid to reservoir.
1. Engine mounting bolts are
loose.
2. Loose engine pulley, idler
pulley, or blade pulley.
3. Engine pulley is damaged. 3. Contact Authorized Service
4. Cutting blade(s) is/are bent or
unbalanced.
5. Blade mounting bolt is loose. 5. Tighten blade mounting bolt.
6. Engine mounting bolts are
loose.
7. Loose engine pulley, idler
pulley, or blade pulley.
8. Engine pulley is damaged. 8. Contact Authorized Service
1. Contact Authorized Service
Dealer.
Dealer.
1. Tighten engine mounting bolts.
2. Tighten the appropriate pulley.
Dealer.
4. Install new cutting blade(s).
6. Tighten engine mounting bolts.
7. Tighten the appropriate pulley.
Dealer.
Uneven cutting height.
Blades do not rotate.
9. Blade spindle bent. 9. Contact Authorized Service
Dealer.
1. Blade(s) not sharp. 1. Sharpen blade(s).
2. Cutting blade(s) is/are bent. 2. Install new cutting blade(s).
3. Mower is not level. 3. Level mower from side-to-side
and front-to-rear.
4. Gage wheel not set correctly. 4. Adjust gage wheel height.
5. Underside of mower is dirty. 5. Clean the underside of the
mower.
6. Tire pressure is incorrect. 6. Adjust tire pressure.
7. Blade spindle bent. 7. Contact Authorized Service
Dealer.
1. Mower belt is off the pulley. 1. Install the mower belt and
check the adjusting plate, idler
arm and spring, and belt guides
for correct position
2. Mower belt is worn, loose or
broken.
3. Electric clutch does not
engage.
2. Install a new mower belt.
3. Contact Authorized Service
Dealer.
4. Electric clutch is worn. 4. Contact Authorized Service
Dealer.
51
Page 52
LCE
The Toro Total Coverage Guarantee
A Limited Warranty
Conditions and Products Covered
The Toro Company and its affiliate, Toro Warranty Company,
pursuant to an agreement between them, jointly promise to repair
the listed Toro Products if defective in materials or workmanship.
The following time periods apply from the date of purchase:
Products
• All Products 1 year
• All Spindles 2 years parts and labor;
• Engines/Hydraulic Systems* on
the following:
Outfront and Mid-Mount Z’s
ProLine Mid-Size Mowers
Groundsmaster
Backpack Blowers
• Deck Shells (36″–72″) on the
following:
ProLine Mid-Size Mowers
Mid-Mount Z’s
• Electric Clutch on 200 Series
Mid-Mount Z’s
This warranty includes the cost of parts and labor, but you must
pay transportation costs.
This warranty applies to:
• Outfront and Mid-Mount Z’s
• ProLine Mid-Size Mowers
• Groundsmaster Riding Mowers
• Turf Maintenance Equipment
• Debris Management Equipment
* Some engines used on Toro LCE Products are warranted by the
engine manufacturer.
Riding Mowers
Warranty Period
third year, parts only
2 years
2 years
2 years
Instructions for Obtaining Warranty Service
If you think that your T oro Product contains a defect in materials or
workmanship, follow this procedure:
1. Contact any Toro Authorized or Master Service Dealer to
arrange service at their dealership. To locate a dealer
convenient to you, access our website at www.Toro.com. U.S.
Customers may also call 800-348-2424.
2. Bring the product and your proof of purchase (sales receipt) to
the Service Dealer.
If for any reason you are dissatisfied with the Service Dealer’s
analysis or with the assistance provided, contact us at:
LCB Customer Service Department
Toro Warranty Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
888-577-7466 (U.S. customers)
877-484-9255 (Canada customers)
You must maintain your Toro Product by following the maintenance
procedures described in the operator’s manual. Such routine
maintenance, whether performed by a dealer or by you, is at your
expense.
There is no other express warranty except for special emission
system coverage on some products. This express warranty does
not cover the following:
• Cost of regular maintenance service or parts, such as filters,
fuel, lubricants, tune-up parts, blade sharpening, brake and
clutch adjustments.
• Any product or part which has been altered or misused or
required replacement or repair due to normal wear, accidents,
or lack of proper maintenance.
• Repairs necessary due to improper fuel, contaminants in the
fuel system, or failure to properly prepare the fuel system prior
to any period of non-use over three months.
• Pickup and delivery charges.
All repairs covered by this warranty must be performed by an
Authorized T oro Service Dealer using Toro approved replacement
parts.
Repair by an Authorized Toro Service Dealer is your sole remedy
under this warranty.
Neither The Toro Company nor Toro Warranty Company is liable
for indirect, incidental or consequential damages in connection
with the use of the Toro Products covered by this warranty,
including any cost or expense of providing substitute equipment or
service during reasonable periods of malfunction or non-use
pending completion of repairs under this warranty.
Some states do not allow exclusions of incidental or consequential
damages, or limitations on how long an implied warranty lasts, so
the above exclusions and limitations may not apply to you.
All implied warranties of merchantability (that the product is fit for
ordinary use) and fitness for use (that the product is fit for a
particular purpose) are limited to the duration of the express
warranty.
This warranty gives you specific legal rights, and you may also
have other rights which vary from state to state.
Owner Responsibilities
Items and Conditions Not Covered
General Conditions
Countries Other than the United States or Canada
Customers who have purchased Toro products exported from the United States or Canada should contact their Toro Distributor (Dealer)
to obtain guarantee policies for your country, province, or state. If for any reason you are dissatisfied with your Distributor’s service or
have difficulty obtaining guarantee information, contact the Toro importer. If all other remedies fail, you may contact us at Toro Warranty
Company.
Part No. 374-0037 Rev. C
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