Toro 74444, 74445 Operator's Manual

FormNo.3364-226RevA

g012081

Z400ZMaster

witha48inor52inTURBOFORCE
DischargeMower

ModelNo.74444—SerialNo.310000001andUp

ModelNo.74445—SerialNo.310000001andUp

®

Side

ToregisteryourproductordownloadanOperator'sManualorPartsCatalogatnocharge,gotowww.T oro.com.OriginalInstructions(EN)

Thisrotary-blade,ridinglawnmowerisintendedto
beusedbyresidentialhomeownersorprofessional,
hiredoperators.Itisdesignedprimarilyforcutting
grassonwell-maintainedlawnsonresidential
orcommercialproperties.Itisnotdesignedfor
cuttingbrushorforagriculturaluses.

Warning

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

Important:Thisengineisnotequippedwitha
sparkarrestermufer.ItisaviolationofCalifornia
PublicResourceCodeSection4442touseoroperate
theengineonanyforest-covered,brush-covered,or
grass-coveredland.Otherstatesorfederalareas
mayhavesimilarlaws.

ThissparkignitionsystemcomplieswithCanadian
ICES-002.

Theenclosed

Engine Owner’ s Man ual

forinformationregardingtheUSEnvironmental
ProtectionAgency(EPA)andtheCalifornia
EmissionControlRegulationofemissionsystems,
maintenance,andwarranty.Replacementsmaybe
orderedthroughtheenginemanufacturer.

issupplied

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

Thismanualidentiespotentialhazardsandhas
safetymessagesidentiedbythesafetyalertsymbol
(Figure2),whichsignalsahazardthatmaycauseserious
injuryordeathifyoudonotfollowtherecommended
precautions.

Figure2

1.Safetyalertsymbol

Introduction

Readthisinformationcarefullytolearnhowtooperate
andmaintainyourproductproperlyandtoavoidinjury
andproductdamage.Youareresponsibleforoperating
theproductproperlyandsafely.

YoumaycontactTorodirectlyatwww .T oro.comfor
productandaccessoryinformation,helpndinga
dealer,ortoregisteryourproduct.

Wheneveryouneedservice,genuineToroparts,or
additionalinformation,contactanAuthorizedService
DealerorToroCustomerServiceandhavethemodel
andserialnumbersofyourproductready .Figure1
identiesthelocationofthemodelandserialnumbers
ontheproduct.Writethenumbersinthespace
provided.

©2009—TheT oro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420

Thismanualuses2otherwordstohighlightinformation.
Importantcallsattentiontospecialmechanical
informationandNoteemphasizesgeneralinformation
worthyofspecialattention.

Contents

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

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

SafeOperatingPractices.......................................4

SlopeIndicator.....................................................6

SafetyandInstructionalDecals.............................7

ProductOverview......................................................11

Controls.............................................................11

Operation...................................................................13

AddingFuel.......................................................13

CheckingtheEngineOilLevel............................14

Contactusatwww.T oro.com.

2

PrintedintheUSA.

AllRightsReserved

UsingtheRolloverProtectionSystem

(ROPS)..........................................................14

ThinkSafetyFirst...............................................15

OperatingtheParkingBrake...............................16

StartingandStoppingtheEngine........................16

OperatingthePowerTakeOff(PTO).................17

TheSafetyInterlockSystem................................18

DrivingForwardorBackward.............................18

StoppingtheMachine.........................................19

AdjustingtheHeight-of-Cut...............................20

AdjustingtheAnti-ScalpRollers.........................20

AdjustingtheFlowBafe...................................21

PositioningtheFlowBafe.................................21

UsingtheLiftAssistLever..................................22

PositioningtheSeat............................................22

UnlatchingtheSeat.............................................22

PushingtheMachinebyHand.............................22

UsingtheSideDischarge....................................23

BreakingInaNewMachine................................23

TransportingMachines.......................................23

LoadingMachines..............................................24

OperatingTips...................................................24

Maintenance...............................................................26

RecommendedMaintenanceSchedule(s)................26

Lubrication.............................................................27

GreasingandLubrication...................................27

GreasingtheMowerDeckandBelt

Idlers..............................................................28

EngineMaintenance...............................................29

ServicingtheAirCleaner....................................29

ServicingtheEngineOil.....................................29

ServicingtheSparkPlugs....................................31

FuelSystemMaintenance.......................................32

ReplacingtheFuelFilter.....................................32

ServicingtheFuelTank......................................32

ElectricalSystemMaintenance................................33

ServicingtheBattery...........................................33

ServicingtheFuses.............................................34

DriveSystemMaintenance.....................................35

AdjustingtheTracking........................................35

CheckingtheTirePressure.................................35

CheckingtheWheelHubSlottedNut..................36

AdjustingtheCasterPivotBearing......................36

CoolingSystemMaintenance..................................37

CleaningtheAirIntakeScreen............................37

CleaningtheCoolingSystem...............................37

BrakeMaintenance.................................................38

AdjustingtheParkingBrake................................38

BeltMaintenance....................................................39

InspectingtheBelts............................................39

ReplacingtheMowerBelt...................................39

ReplacingthePumpDriveBelt...........................40

AdjustingthePushArms....................................40

ControlsSystemMaintenance.................................41

AdjustingtheControlHandleNeutral

Position..........................................................41

HydraulicSystemMaintenance...............................42

ServicingtheHydraulicSystem...........................42

SettingtheHydraulicPumpNeutral

Position..........................................................44

MowerDeckMaintenance......................................46

LevelingtheMoweratThreePositions................46

ServicingtheCuttingBlades...............................48

ReplacingtheGrassDeector.............................50

Cleaning.................................................................51

CleaningUndertheMower.................................51

WasteDisposal...................................................51

Storage.......................................................................51

Troubleshooting.........................................................53

Schematics.................................................................55

3

Safety

•Useextracarewhenhandlinggasolineandother
fuels.Theyareammableandvaporsareexplosive.

Improperuseormaintenancebytheoperatororowner
canresultininjury.Toreducethepotentialforinjury,
complywiththesesafetyinstructionsandalwayspay
attentiontothesafetyalertsymbol,whichmeans
CAUTION,WARNING,orDANGER-“personal
safetyinstruction."Failuretocomplywiththe
instructionmayresultinpersonalinjuryordeath.

Thisproductiscapableofamputatinghandsand
feetandthrowingobjects.Alwaysfollowallsafety
instructionstoavoidseriousinjuryordeath.

Thisproductisdesignedforcuttingandrecyclinggrass
or,whenequippedwithagrassbagger,forcatching
cutgrass.Anyuseforpurposesotherthanthesecould
provedangeroustouserandbystanders.

SafeOperatingPractices

ThefollowinginstructionsarefromANSIstandard
B71.4-2004.

Training

•ReadtheOperator’sManualandothertraining
material.Iftheoperator(s)ormechanic(s)cannot
readEnglishitistheowner’sresponsibilitytoexplain
thismaterialtothem.

•Becomefamiliarwiththesafeoperationofthe
equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.The
ownerisresponsiblefortrainingtheusers.

•Neverletchildrenoruntrainedpeopleoperateor
servicetheequipment.Localregulationsmayrestrict
theageoftheoperator.

•Theowner/usercanpreventandisresponsiblefor
accidentsorinjuriesoccurringtohimselforherself,
otherpeopleorproperty.

–Useonlyanapprovedcontainer

–Neverrefuelordrainthemachineindoors.

–Neverremovegascaporaddfuelwithengine

running.Allowenginetocoolbeforerefueling.
Donotsmoke.

•Checkthatoperator’spresencecontrols,safety
switchesandshieldsareattachedandfunctioning
properly.Donotoperateunlesstheyarefunctioning
properly.

Operation

•Lightningcancausesevereinjuryordeath.If
lightningisseenorthunderisheardinthearea,do
notoperatethemachine;seekshelter.

•Neverrunanengineinanenclosedarea.

•Onlyoperateingoodlight,keepingawayfromholes
andhiddenhazards.

•Besurealldrivesareinneutralandparkingbrakeis
engagedbeforestartingengine.Starttheengineonly
fromtheoperator’sposition.Useseatbelts.

•Neverraisemowerwiththebladesrunning.

•NeveroperatewithoutthePTOshield,orother
guardssecurelyinplace.Besureallinterlocksare
attached,adjustedproperly,andfunctioningproperly .

•Neveroperatewiththedischargedeectorraised,
removedoraltered,unlessusingagrasscatcher.

•Donotchangetheenginegovernorsettingor
overspeedtheengine.

•Stoponlevelground,lowerimplements,disengage
drives,engageparkingbrake,shutoffenginebefore
leavingtheoperator’spositionforanyreason
includingemptyingthecatchersoruncloggingthe
chute.

Preparation

•Evaluatetheterraintodeterminewhataccessories
andattachmentsareneededtoproperlyand
safelyperformthejob.Onlyuseaccessoriesand
attachmentsapprovedbythemanufacturer.

•Wearappropriateclothingincludinghardhat,safety
glassesandhearingprotection.Longhair,loose
clothingorjewelrymaygettangledinmovingparts.

•Inspecttheareawheretheequipmentistobeused
andremoveallobjectssuchasrocks,toysandwire
whichcanbethrownbythemachine.

•Stopequipmentandinspectbladesafterstriking
objectsorifanabnormalvibrationoccurs.Make
necessaryrepairsbeforeresumingoperations.

•Keephandsandfeetawayfromthecuttingunits.

•Nevercarrypassengersandkeeppetsandbystanders
away.

•Bealert,slowdownandusecautionwhenmaking
turns.Lookbehindandtothesidebeforechanging
directions.

•Slowdownandusecautionwhencrossingroadsand
sidewalks.Stopbladesifnotmowing.

4

•Beawareofthemowerdischargedirectionanddo
notpointitatanyone.

•Donotoperatethemowerundertheinuenceof
alcoholordrugs.

•Useextremecarewhenloadingorunloadingthe
machineintoatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs,
trees,orotherobjectsthatmayobscurevision.

SlopeOperation

•Donotmowslopesgreaterthan15degrees.

•Donotmowneardrop-offs,ditches,steepbanks
orwater.Wheelsdroppingoveredgescancause
rollovers,whichmayresultinseriousinjury,death
ordrowning.

•Donotmowslopeswhengrassiswet.Slippery
conditionsreducetractionandcouldcausesliding
andlossofcontrol.

•Donotmakesuddenturnsorrapidspeedchanges.

•Useawalkbehindmowerand/orahandtrimmer
neardrop-offs,ditches,steepbanksorwater.

•Reducespeedanduseextremecautiononslopes.

•Removeormarkobstaclessuchasrocks,treelimbs,
etc.fromthemowingarea.Tallgrasscanhide
obstacles.

•Watchforditches,holes,rocks,dips,andrisesthat
changetheoperatingangle,asroughterraincould
overturnthemachine.

•Avoidsuddenstartswhenmowinguphillbecause
themowermaytipbackwards.

•Beawarethatlossoftractionmayoccurgoing
downhill.Weighttransfertothefrontwheelsmay
causedrivewheelstoslipandcauselossofbraking
andsteering.

•Alwaysavoidsuddenstartingorstoppingona
slope.Iftireslosetraction,disengagethebladesand
proceedslowlyofftheslope.

•Followthemanufacturer’srecommendationsfor
wheelweightsorcounterweightstoimprovestability.

•Useextremecarewithgrasscatchersorother
attachments.Thesecanchangethestabilityofthe
machineandcauselossofcontrol.

UsingtheRolloverProtectionSystem
(ROPS)

•Keeptherollbarintheraisedandlockedposition
andusetheseatbeltwhenoperatingthemachine.

•Becertainthattheseatbeltcanbereleasedquickly
intheeventofanemergency.

•Beawarethereisnorolloverprotectionwhenthe
rollbarisdown.

•Checktheareatobemowedandneverfoldthe
ROPSinareaswherethereareslopes,dropoffsor
water.

•Lowertherollbaronlywhenabsolutelynecessary.
Donotweartheseatbeltwiththerollbarfolded
down.

•Checkcarefullyforoverheadclearances(i.e.
branches,doorways,electricalwires)beforedriving
underanyobjectsanddonotcontactthem.

Maintenanceandstorage

•Disengagedrives,lowerimplement,setparking
brake,stopengineandremovekeyordisconnect
sparkplugwire.Waitforallmovementtostop
beforeadjusting,cleaningorrepairing.

•Cleangrassanddebrisfromcuttingunits,drives,
mufers,andenginetohelppreventres.Cleanup
oilorfuelspillage.

•Letenginecoolbeforestoringanddonotstorenear
ame.

•Shutofffuelwhilestoringortransporting.Donot
storefuelnearamesordrainindoors.

•Parkmachineonlevelground.Neverallowuntrained
personneltoservicemachine.

•Usejackstandstosupportcomponentswhen
required.

•Carefullyreleasepressurefromcomponentswith
storedenergy.

•Disconnectbatteryorremovesparkplugwirebefore
makinganyrepairs.Disconnectthenegativeterminal
rstandthepositivelast.Reconnectpositiverst
andnegativelast.

•Usecarewhencheckingblades.Wraptheblade(s)or
weargloves,andusecautionwhenservicingthem.
Onlyreplaceblades.Neverstraightenorweldthem.

•Keephandsandfeetawayfrommovingparts.If
possible,donotmakeadjustmentswiththeengine
running.

•Chargebatteriesinanopenwellventilatedarea,
awayfromsparkandames.Unplugchargerbefore
connectingordisconnectingfrombattery.W ear
protectiveclothinganduseinsulatedtools.

•Keepallpartsingoodworkingconditionandall
hardwaretightened.Replaceallwornordamaged
decals.

•UseonlyToroapprovedattachments.W arrantymay
bevoidedifusedwithunapprovedattachments.

5

SlopeIndicator

G011841

Figure3

Thispagemaybecopiedforpersonaluse.

1.Themaximumslopeyoucansafelyoperatethemachineonis15degrees.Usetheslopecharttodeterminethedegreeofslope
ofhillsbeforeoperating.Donotoperatethismachineonaslopegreaterthan15degrees.Foldalongtheappropriateline
tomatchtherecommendedslope.

2.Alignthisedgewithaverticalsurface,atree,building,fencepole,etc.

3.Exampleofhowtocompareslopewithfoldededge.

6

SafetyandInstructional
Decals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaof
potentialdanger.Replaceanydecalthatisdamagedorlost.

66-1340

1-403005

1-633818

54-9220

1.Warning—wearhearingprotection.

65-2690

68-8340

98-4387

58-6520

1.Grease

7

98-5954

103-2644

105-7798

107-2102

BatterySymbols

Someorallofthesesymbolsareonyourbattery

1.Explosionhazard

2.Nore,opename,or
smoking.

3.Causticliquid/chemical
burnhazard

4.Weareyeprotection9.Flusheyesimmediately

5.ReadtheOperator’s

Manual.

6.Keepbystandersasafe

7.Weareyeprotection;

8.Batteryacidcancause

10.Containslead;donot

distancefromthebattery.

explosivegasescan
causeblindnessandother
injuries

blindnessorsevereburns.

withwaterandgetmedical
helpfast.

discard.

107-2112

8

110-2068

1.ReadtheOperator’sManual.

108-1050

112-8651

1.Interval

2.PowerT ake-off(PTO)

3.Parkingbrake

4.Neutral

5.Operatorpresenceswitch

6.Battery

108-1051

109-7949

115-4212

1.Hydraulicoillevel3.Warning—donottouch

2.ReadtheOperator’s
Manual.

thehotsurface.

110-2067

117–2718

9

Manufacturer’sMark

1.Indicatesthebladeisidentiedasapartfromtheoriginal
machinemanufacturer.

117-3821

107-8445

107-9309

1.Warning—readtheOperator’sManualforinformationonchargingthebattery;containslead;donotdiscard.

2.ReadtheOperator’sManual.

108-5995

1.Fast

2.Slow

3.Neutral4.Reverse

10

117-0904

g012082

1 2 3

4 5 6

7
8
9

10

11

g012084

1 2

3 4 5

7 6

1.Fast

2.Continuousvariablesetting3.Slow

ProductOverview

Figure5

1.Motioncontrollever5.Hourmeter

2.Fuelcap(bothsides)6.PTOSwitch

3.Throttlecontrol7.Ignitionswitch

4.Choke

Figure4

1.Sidedischarge7.Fuelcap(bothsides)

2.Liftassistlever8.Controls

3.Height-of-cutlever

4.Motioncontrollever10.Mowerdeck

5.Seatbelt

6.Rollbar

Controls

9.Parkingbrakelever

11.Frontcasterwheel

Becomefamiliarwithallthecontrolsbeforeyoustartthe
engineandoperatethemachine(Figure4andFigure5).

HourMeter

Thehourmeterrecordsthenumberofhourstheengine
hasoperated.Itoperateswhentheengineisrunning.
Usethesetimesforschedulingregularmaintenance
(Figure6).

SafetyInterlockIndicators

Therearesymbolsonthehourmeterandtheyindicate
withablacktrianglethattheinterlockcomponentisin
thecorrectposition(Figure6).

BatteryIndicatorLight

WhentheignitionkeyisinitiallyturnedtotheRun
positionforafewseconds,thebatteryvoltagewillbe

11

displayedintheareawherethehoursarenormally
displayed.

Thebatterylightturnsonwhentheignitionisturned
onandwhenthechargeisbelowthecorrectoperating
level(Figure6).

Figure6

1.Safetyinterlocksymbols

2.Hourmeter

3.Batterylight

ThrottleControl

Attachments/Accessories

AselectionofToroapprovedattachmentsand
accessoriesareavailableforusewiththemachineto
enhanceandexpanditscapabilities.Contactyour
AuthorizedServiceDealerorDistributororgoto
www.Toro.comforalistofallapprovedattachments
andaccessories.

ThethrottlecontrolisvariablebetweenFastandSlow.

Choke

Usethechoketostartacoldengine.

MotionControlLevers

Themotioncontrolleversareusedtodrivethemachine
forward,reverse,andturneitherdirection.

NeutralLockPosition

Theneutrallockpositionisusedwiththesafetyinterlock
systemandtodetermineneutralposition.

FuelShut-offValve

Closethefuelshut-offvalve(neartheengine)when
transportingorstoringthemower.

BladeControlSwitch(PTO)

Thebladecontrolswitch(PTO)isusedtoengagethe
electricclutchtodrivethemowerbladeswiththemotion
controlleversinthecenter,un-lockedposition.Pullthe
switchuptoengagethebladesandrelease.Todisengage
theblades,pushthebladecontrolswitch(PTO)down.

IgnitionSwitch

Thisswitchisusedtostartthemowerengineandhas
threepositions:Start,RunandOff.

12

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

AddingFuel

UseUnleadedRegularGasolinesuitablefor
automotiveuse(85pumpoctaneminimum).Leaded
regulargasolinemaybeusedifunleadedregularisnot
available.

Important:Neverusemethanol,gasoline
containingmethanol,orgasoholcontainingmore
than10%ethanolbecausethefuelsystemcouldbe
damaged.Donotmixoilwithgasoline.

Incertainconditions,gasolineisextremely
ammableandhighlyexplosive.Areor
explosionfromgasolinecanburnyouand
othersandcandamageproperty.

•Fillthefueltankoutdoors,inanopenarea,
whentheengineiscold.Wipeupany
gasolinethatspills.

•Neverllthefueltankinsideanenclosed
trailer.

Incertainconditionsduringfueling,static
electricitycanbereleasedcausingaspark
whichcanignitethegasolinevapors.Are
orexplosionfromgasolinecanburnyouand
othersandcandamageproperty.

•Alwaysplacegasolinecontainersonthe
groundawayfromyourvehiclebeforelling.

•Donotllgasolinecontainersinsidea
vehicleoronatruckortrailerbedbecause
interiorcarpetsorplastictruckbedliners
mayinsulatethecontainerandslowtheloss
ofanystaticcharge.

•Whenpractical,removegas-powered
equipmentfromthetruckortrailerand
refueltheequipmentwithitswheelsonthe
ground.

•Ifthisisnotpossible,thenrefuelsuch
equipmentonatruckortrailerfroma
portablecontainer,ratherthanfroma
gasolinedispensernozzle.

•Ifagasolinedispensernozzlemustbeused,
keepthenozzleincontactwiththerimof
thefueltankorcontaineropeningatall
timesuntilfuelingiscomplete.

•Donotllthefueltankcompletelyfull.Add
gasolinetothefueltankuntilthelevelis1/4
to1/2inch(6to13mm)belowthebottomof
thellerneck.Thisemptyspaceinthetank
allowsgasolinetoexpand.

•Neversmokewhenhandlinggasoline,and
stayawayfromanopenameorwhere
gasolinefumesmaybeignitedbyaspark.

•Storegasolineinanapprovedcontainerand
keepitoutofthereachofchildren.Never
buymorethana30-daysupplyofgasoline.

•Donotoperatewithoutentireexhaust
systeminplaceandinproperworking
condition.

Gasolineisharmfulorfatalifswallowed.
Long-termexposuretovaporscancauseserious
injuryandillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgastankor
conditioneropening.

•Keepgasawayfromeyesandskin.

UsingStabilizer/Conditioner

Useafuelstabilizer/conditionerinthemachineto
providethefollowingbenets:

•Keepsgasolinefreshduringstorageof90daysor
less.Forlongerstorageitisrecommendedthatthe
fueltankbedrained.

•Cleanstheenginewhileitruns

•Eliminatesgum-likevarnishbuildupinthefuel
system,whichcauseshardstarting

13

Important:Donotusefueladditivescontaining
methanolorethanol.

Addthecorrectamountofgasstabilizer/conditioner
tothegas.

Note:Afuelstabilizer/conditionerismosteffective
whenmixedwithfreshgasoline.Tominimizethe
chanceofvarnishdepositsinthefuelsystem,usefuel
stabilizeratalltimes.

FillingtheFuelTank

1.Shuttheengineoffandsettheparkingbrake.

2.Cleanaroundeachfueltankcapandremovethecap.

3.Addunleadedregulargasolinetobothfueltanks,
untilthelevelis1/4to1/2inch(6mmto13mm)
belowthebottomofthellerneck.

Thisspaceinthetankallowsgasolinetoexpand.
Donotllthefueltankscompletelyfull.

4.Installfueltankcapssecurely.

5.Wipeupanygasolinethatmayhavespilled.

CheckingtheEngineOilLevel

Beforeyoustarttheengineandusethemachine,check
theoillevelintheenginecrankcase;refertoChecking
OilLevelin,page

Thereisnorolloverprotectionwhentherollbar
isinthedownposition.

•Lowertherollbaronlywhenabsolutely
necessary.

•Donotweartheseatbeltwhentherollbaris
inthedownposition.

•Driveslowlyandcarefully.

•Raisetherollbarassoonasclearance
permits.

•Checkcarefullyforoverheadclearances(i.e.
branches,doorways,electricalwires)before
drivingunderanyobjectsanddonotcontact
them.

Important:Lowertherollbaronlywhen
absolutelynecessary.

1.Removethehairpincotterpinsandremovethetwo
pins(Figure8).

2.Lowertherollbartothedownposition.Thereare
twodownpositions.SeeFigure7forthepositions.

3.Installthetwopinsandsecurethemwiththe
hairpincotterpins(Figure8).

UsingtheRolloverProtection
System(ROPS)

Toavoidinjuryordeathfromrollover:keepthe
rollbarintheraisedlockedpositionanduse
theseatbelt.

Ensurethattherearpartoftheseatissecured
withtheseatlatch.

Figure7

1.Fulldownposition2.Downpositionwithbagger
installed

Important:Ensurethattherearpartofthe
seatissecuredwiththeseatlatch.

4.Toraisetherollbar,removethehairpincotterpins
andremovethetwopins(Figure8).

5.Raisetherollbartotheuprightpositionandinstall
thetwopinsandsecurethemwiththehairpincotter
pins(Figure8).

14

Important:Alwaysusetheseatbeltwiththe

G004955

1

2

3

4

rollbarintheraisedposition.

Figure8

1.Rollbar3.Pin

2.Raisedposition4.Hairpincotterpin

Operatingonwetgrassorsteepslopescan
causeslidingandlossofcontrol.

Wheelsdroppingoveredgescancauserollovers,
whichmayresultinseriousinjury,deathor
drowning.

Thereisnorolloverprotectionwhentheroll
barisdown.

Alwayskeeptherollbarintheraisedandlocked
positionandusetheseatbelt.

Readandfollowtherolloverprotection
instructionsandwarnings.

Toavoidlossofcontrolandpossibilityof
rollover:

•Donotoperateneardrop-offsornearwater.

•Donotoperateonslopesgreaterthan
15degrees.

•Reducespeedanduseextremecautionon
slopes.

•Avoidsuddenturnsorrapidspeedchanges.

ThinkSafetyFirst

Pleasereadallsafetyinstructionsandsymbolsinthe
safetysection.Knowingthisinformationcouldhelp
youorbystandersavoidinjury.

1.SafeZone-usethe
ZMasterhereonslopes
lessthan15degreesor
atareas.

2.Usewalkbehindmower
and/orhandtrimmernear
drop-offsandwater.

Figure9

3.Water

15

Thismachineproducessoundlevelsinexcess
of85dBAattheoperatorsearandcancause
hearinglossthroughextendedperiodsof
exposure.

Wearhearingprotectionwhenoperatingthis
machine.

Useprotectiveequipmentforyoureyes,ears,feet,and
head.

Figure11

1.Parkingbrake-ON2.Parkingbrake-OFF

Figure10

1.Warning—wearhearingprotection

OperatingtheParkingBrake

Alwayssettheparkingbrakewhenyoustopthe
machineorleaveitunattended.

SettingtheParkingBrake

1.Movethemotioncontrollevers(Figure18)outto
theneutrallockposition.

2.Pullupandbackontheparkingbrakelevertoset
theparkingbrake(Figure11).Theparkingbrake
levershouldstayrmlyintheengagedposition.

Parkingbrakemaynotholdmachineparked
onaslopeandcouldcausepersonalinjuryor
propertydamage.

StartingandStoppingthe
Engine

StartingtheEngine

1.Sitontheseatandmovethemotioncontrolsto
neutrallockedposition.

2.Settheparkingbrake;refertoSettingtheParking
Brake.

3.MovethePTO(powertakeoff)switchtotheOff
position(Figure12).

Donotparkonslopesunlesswheelsare
chockedorblocked

ReleasingtheParkingBrake

Pushforwardanddownontheparkingbrakeleverto
releasetheparkingbrake(Figure11).

Figure12

1.PTO—on2.PTO—off

4.Movethechokecontroltotheonpositionbefore
startingacoldengine(Figure13).

Note:Awarmorhotenginemaynotrequire
choking.Afterenginestarts,movechokecontrol
totheoffposition.

16

thethrottlelevertodesiredsetting.Repeatthisas
required.

StoppingtheEngine

1.PushthePTOtotheoffposition(Figure12).

2.Movethethrottlelevermidwaybetweentheslow
andfastpositions(Figure14).

3.Lettheengineidlefor60seconds.

4.Turntheignitionkeytotheoffpositionandremove
thekey(Figure15).

Figure13

1.Choke—on2.Choke—off

5.MovethethrottlecontroltotheFastposition
beforestartingacoldengine(Figure14).

Figure14

1.Throttle—fast

2.Throttle—slow

6.TurntheignitionkeytoStart.Whentheengines
starts,releasethekey(Figure15).

Important:Donotengagestarterformore
than10secondsatatime.Ifenginefailsto
startallow30secondcool-downperiodbetween
attempts.Failuretofollowtheseinstructions
canburnoutstartermotor.

5.Closethefuelshutoffvalvebeforetransporting
orstoringthemachine.

Important:Makesurethatthefuelshutoff
valveisclosedbeforetransportingorstoring
themachine,asfuelleakagemayoccur.Setthe
parkingbrakebeforetransporting.Makesure
toremovethekeyasthefuelpumpmayrun
andcausethebatterytolosecharge.

Childrenorbystandersmaybeinjuredifthey
moveorattempttooperatethetractorwhileit
isunattended.

Alwaysremovetheignitionkeyandsetthe
parkingbrakewhenleavingthemachine
unattended,evenifjustforafewminutes.

OperatingthePowerTakeOff
(PTO)

Thepowertakeoff(PTO)switchstartsandstopsthe
mowerbladesandanypoweredattachments.

Figure15

1.Off3.Start

2.Run

7.Aftertheenginestarts,movethechoketooff
(Figure13).Iftheenginestallsorhesitates,move
thechokebacktoonforafewseconds,thenmove

EngagingthePTO

1.Iftheengineiscold,allowtheenginetowarmup5
to10minutesbeforeengagingthePTO.

2.Whileseatedintheseat,releasethepressureonthe
tractioncontrolleversandplaceinneutral.

3.Placethethrottleinthefastposition.

Note:EngagingthePTOwiththethrottleatthe
halforlesspositionwillcauseexcessiveweartothe
drivebelts.

4.Pulloutonthepowertakeoff(PTO)switchto
engageit(Figure16).

17

Figure16

1.PTO-On2.PTO-Off

Figure17

1.Triangleslightupwhentheinterlockcomponentsareinthe
correctposition

TestingtheSafetyInterlockSystem

DisengagingthePTO

Todisengage,pushthePTOswitchtotheoffposition
(Figure16).

TheSafetyInterlockSystem

Ifsafetyinterlockswitchesaredisconnected
ordamagedthemachinecouldoperate
unexpectedlycausingpersonalinjury.

•Donottamperwiththeinterlockswitches.

•Checktheoperationoftheinterlock
switchesdailyandreplaceanydamaged
switchesbeforeoperatingthemachine.

UnderstandingtheSafetyInterlock
System

Thesafetyinterlocksystemisdesignedtopreventthe
enginefromstartingunless:

•Theparkingbrakeisengaged.

•Thepowertakeoff(PTO)isdisengaged.

•Themotioncontrolleversareintheneutrallocked
position

Thesafetyinterlocksystemalsoisdesignedtostopthe
enginewhenthetractioncontrolsaremovedfromthe
lockedpositionwiththeparkingbrakeengagedorif
yourisefromtheseatwhenthePTOisengaged.

Thehourmeterhassymbolstonotifytheuserwhenthe
interlockcomponentisinthecorrectposition.When
thecomponentisinthecorrectposition,atrianglewill
lightupinthecorrespondingsquare.

ServiceInterval:Beforeeachuseordaily

Testthesafetyinterlocksystembeforeyouusethe
machineeachtime.Ifthesafetysystemdoesnot
operateasdescribedbelow,haveanAuthorizedService
Dealerrepairthesafetysystemimmediately .

1.Sittingontheseat,engagetheparkingbrakeand
movethePTOtoon.Trystartingtheengine;the
engineshouldnotcrank.

2.Sittingontheseat,engagetheparkingbrakeand
movethePTOtooff.Moveeithermotioncontrol
lever(outofneutrallockedposition).Trystarting
theengine;theengineshouldnotcrank.Repeatfor
othercontrollever.

3.Sittingontheseat,engagetheparkingbrake,
movethePTOswitchtooffandmovethemotion
controlleverstoneutrallockposition.Nowstart
theengine.Whiletheengineisrunning,release
theparkingbrake,engagethePTOandriseslightly
fromtheseat;theengineshouldstop.

4.Sittingontheseat,engagetheparkingbrake,move
thePTOswitchtooffandmovethemotioncontrol
leverstoneutrallockposition.Nowstarttheengine.
Whiletheengineisrunning,centereithermotion
controlandmove(forwardorreverse);theengine
shouldstop.Repeatforothermotioncontrol.

5.Sittingontheseat,disengagetheparkingbrake,
movethePTOswitchtooffandmovethemotion
controlleverstoneutrallockposition.Trystarting
theengine;theengineshouldnotcrank.

DrivingForwardorBackward

Thethrottlecontrolregulatestheenginespeedas
measuredinRPM(revolutionsperminute).Place
thethrottlecontrolinthefastpositionforbest

18

performance.Alwaysoperateinthefullthrottle
positionwhenmowing.

Machinecanspinveryrapidly.Operatormay
losecontrolofmachineandcausepersonal
injuryordamagetomachine.

•Usecautionwhenmakingturns.

•Slowthemachinedownbeforemaking
sharpturns.

DrivingForward

1.Releasetheparkingbrake;refertoReleasingthe
ParkingBrakein,page.

2.Movetheleverstothecenter,un-lockedposition.

3.Togoforward,slowlypushthemotioncontrol
leversforward(Figure18).

Note:Theenginewillkillifthetractioncontrol
leversaremovedwiththeparkingbrakeengaged.

Togostraight,applyequalpressuretobothmotion
controllevers(Figure18).

Toturn,movethemotioncontrollevertoward
neutralinthedirectionyouwanttoturn(Figure18).

Thefartheryoumovethetractioncontrolleversin
eitherdirection,thefasterthemachinewillmovein
thatdirection.

Tostop,pullthemotioncontrolleverstotheneutral
position.

Figure18

1.Motioncontrol
lever-neutrallockposition

2.Centerun-lockposition

3.Forward

4.Backward

DrivingBackward

1.Movetheleverstothecenter,un-lockedposition.

2.Togobackward,slowlypullthemotioncontrol
leversrearward(Figure18).

Togostraight,applyequalpressuretobothmotion
controllevers(Figure18).

Toturn,releasepressureonthemotioncontrollever
towardthedirectionyouwanttoturn(Figure18).

Tostop,pushthemotioncontrolleverstothe
neutralposition.

StoppingtheMachine

Tostopthemachine,movethetractioncontrollevers
toneutralandmovetolockedposition,disengagethe
powertakeoff(PTO),andturntheignitionkeytooff.

Settheparkingbrakewhenyouleavethemachine;refer
toSettingtheParkingBrakein,page.Rememberto
removethekeyfromtheignitionswitch.

19

Childrenorbystandersmaybeinjuredifthey
moveorattempttooperatethetractorwhileit
isunattended.

Alwaysremovetheignitionkeyandsetthe
parkingbrakewhenleavingthemachine
unattended,evenifjustforafewminutes.

AdjustingtheHeight-of-Cut

Theheight-of-cutisadjustedfrom1-1/2to4-1/2inch
(38to114mm)in1/4inch(6mm)incrementsby
relocatingtheclevispinintodifferentholelocations.

1.Raisetheheight-of-cutlevertothetransport
position(alsothe4-1/2inch(114mm)cutting
heightposition)(Figure19).

2.Toadjust,removetheclevispinfromthe
height-of-cutbracket(Figure19).

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Afteradjustingtheheight-of-cut,adjusttherollers
byremovingtheangenut,bushing,spacer,and
bolt(Figure20,Figure21andFigure52).

Note:Thetwomiddlerollerswillnothaveaspacer
(Figure21).

4.Selectaholesotheanti-scalprollerispositionedto
thenearestcorrespondingheight-of-cutdesired.

5.Installtheangenutbushing,spacer,andbolt.
Torqueto40-45ft-lb(54-61N-m)(Figure20,
Figure21andFigure52).

6.Repeatthisadjustmentontheotheranti-scalp
rollers.

3.Selectaholeintheheight-of-cutbracket
correspondingtotheheight-of-cutdesiredand,
inserttheclevispin(Figure19).

4.Movethelevertotheselectedheight.

Figure19

1.Heightofcutlever2.ClevisPin

Figure20

1.Anti-scalproller4.FlangeNut

2.Spacer

3.Bushing

5.Bolt

AdjustingtheAnti-Scalp
Rollers

Wheneveryouchangetheheight-of-cut,adjustthe
heightoftheanti-scalprollers.

1.DisengagethePTO,movethemotioncontrol
leverstotheneutrallockedpositionandsetthe
parkingbrake.

20

Figure21

g0121 19

1 2

G012120

G012121

1.Anti-scalproller3.FlangeNut

2.Bushing4.Bolt

AdjustingtheFlowBafe

Themowerdischargeowcanbeadjustedfordifferent
typesofmowingconditions.Positionthenutandbafe
togivethebestqualityofcut.

PositioningtheFlowBafe

Thefollowingguresareonlyrecommendationsfor
use.Adjustmentswillvarybygrasstype,moisture
content,andheightofgrass.

Note:Iftheenginepowerdrawsdownandthemower
groundspeedisthesame,openupthebafe.

PositionA

Thisisthefullrearposition.Thesuggesteduseforthis
positionisafollows.

•Useforshort,lightgrassmowingconditions.

•Useindryconditions.

•Forsmallergrassclippings.

•Propelsgrassclippingsfartherawayfromthe
mower.

1.DisengagethePTO,movethemotioncontrol
leverstotheneutrallockedpositionandsetthe
parkingbrake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Toadjustthebafe,loosenthenut(Figure22).

4.Adjustthebafeandnutintheslottothedesired
dischargeowandtightenthenut.

Figure23

PositionB

Usethispositionwhenbagging.

Figure22

2.Nut

Figure24

21

1.Slot

PositionC

G012122

G008962

Thisisthefullopenposition.Thesuggestedusefor
thispositionisasfollows.

•Useintall,densegrassmowingconditions.

•Useinwetconditions.

•Lowerstheenginepowerconsumption.

•Allowsincreasedgroundspeedinheavyconditions.

•ThispositionissimilartothebenetsoftheT oro
SFSmower.

Toadjust,movetheleversidewaystounlockseat
(Figure27).

Slidetheseattothedesiredpositionandreleaselever
tolockinposition.

Figure27

UnlatchingtheSeat

Pushtheseatlatchrearwardtounlatchtheseat.
Thiswillallowaccesstothemachineundertheseat
(Figure28).

Figure25

UsingtheLiftAssistLever

Theliftassistleverisusedalongwiththeheight-of-cut
leverforraisingthemowerdeck.Thisallowsforeasier
raisingofthemowerdeck.

1.Placeyourfootontoliftassistlever.

2.Pressontheliftassistleverwhilepullinguponthe
height-of-cutlever(Figure26).

Figure26

Figure28

1.Seatlatch3.Seat

2.Fuelcap

PushingtheMachinebyHand

Important:Alwayspushthemachinebyhand.

Nevertowthemachinebecausehydraulicdamage
mayoccur.

PushingtheMachine

PositioningtheSeat

Theseatcanmoveforwardandbackward.Positionthe
seatwhereyouhavethebestcontrolofthemachine
andaremostcomfortable.

1.Disengagethepowertakeoff(PTO)andturnthe
ignitionkeytooff.Movetheleverstoneutrallocked
positionandapplyparkingbrake.Removethekey.

2.Rotatetheby-passvalvescounterclockwise1turn
topush.Thisallowshydraulicuidtoby-passthe
pumpenablingthewheelstoturn(Figure29).

22

Important:Donotrotateby-passvalvesmore
than1turn.Thispreventsvalvesfromcoming
outofthebodyandcausinguidtorunout.

3.Disengageparkingbrakebeforepushing.

ChangingtoMachineOperation

Rotatetheby-passvalvesclockwise1turntooperate
machine(Figure29).

Note:Donotovertightentheby-passvalves.

Themachinewillnotdriveunlessby-passvalvesare
turnedin.

Withoutthegrassdeector,dischargecover,
orcompletegrasscatcherassemblymounted
inplace,youandothersareexposedtoblade
contactandthrowndebris.Contactwith
rotatingmowerblade(s)andthrowndebriswill
causeinjuryordeath.

•Neverremovethegrassdeectorfrom
themowerbecausethegrassdeector
routesmaterialdowntowardtheturf.Ifthe
grassdeectoriseverdamaged,replaceit
immediately.

•Neverputyourhandsorfeetunderthe
mower.

•Nevertrytoclearthedischargeareaor
mowerbladesunlessyoumovethepower
takeoff(PTO)totheoffposition,rotatethe
ignitionkeytooffandremovethekey .

•Makesurethegrassdeectorisinthedown
position.

Figure29

1.Sideconsolecontrols

2.By-passvalve

3.Hydraulicpumps

UsingtheSideDischarge

Themowerhasahingedgrassdeectorthatdisperses
clippingstothesideanddowntowardtheturf.

BreakingInaNewMachine

Newenginestaketimetodevelopfullpower.Mower
decksanddrivesystemshavehigherfrictionwhennew,
placingadditionalloadontheengine.Allow40to50
hoursofbreak-intimefornewmachinestodevelopfull
powerandbestperformance.

TransportingMachines

Useaheavy-dutytrailerortrucktotransportthe
machine.Ensurethatthetrailerortruckhasall
necessarylightingandmarkingasrequiredbylaw .
Pleasecarefullyreadallthesafetyinstructions.
Knowingthisinformationcouldhelpyou,yourfamily,
petsorbystandersavoidinjury.

Totransportthemachine:

•Lockthebrakeandblockthewheels.

•Securelyfastenthemachinetothetrailerortruck
withstraps,chains,cable,orropes.

•Secureatrailertothetowingvehiclewithsafety
chains.

23

Drivingonthestreetorroadwaywithoutturn
signals,lights,reectivemarkings,oraslow
movingvehicleemblemisdangerousandcan
leadtoaccidentscausingpersonalinjury.

Donotdrivemachineonapublicstreetor
roadway.

LoadingMachines

Useextremecautionwhenloadingunitsontrailersor
trucks.Onefullwidthrampthatiswideenoughto
extendbeyondthereartiresisrecommendedinsteadof
individualrampsforeachsideoftheunit(Figure30).
Thelowerrearsectionofthetractorframeextends
backbetweentherearwheelsandservesasastopfor
tippingbackward.Havingafullwidthrampprovides
asurfacefortheframememberstocontactifthe
unitstartstotipbackward.Ifitisnotpossibletouse
onefullwidthramp,useenoughindividualrampsto
simulateafullwidthcontinuousramp.

Loadingaunitontoatrailerortruckincreases
thepossibilityofbackwardtip-overandcould
causeseriousinjuryordeath.

•Useextremecautionwhenoperatingaunit
onaramp.

•Useonlyasingle,fullwidthramp;DoNot
useindividualrampsforeachsideofthe
unit.

•Ifindividualrampsmustbeused,use
enoughrampstocreateanunbrokenramp
surfacewiderthantheunit.

•Donotexceeda15degreeanglebetween
rampandgroundorbetweenrampand
trailerortruck.

•Avoidsuddenaccelerationwhiledrivingunit
uparamptoavoidtippingbackward.

•Avoidsuddendecelerationwhilebacking
unitdownaramptoavoidtippingbackward.

Therampshouldbelongenoughsothattheangles
donotexceed15degrees(Figure30).Asteeperangle
maycausemowercomponentstogetcaughtastheunit
movesfromramptotrailerortruck.Steeperangles
mayalsocausetheunittotipbackward.Ifloadingon
ornearaslope,positionthetrailerortrucksoitison
thedownsideoftheslopeandtherampextendsupthe
slope.Thiswillminimizetherampangle.Thetraileror
truckshouldbeaslevelaspossible.

Important:DoNotattempttoturntheunitwhile
ontheramp;youmaylosecontrolanddriveoff
theside.

Avoidsuddenaccelerationwhendrivinguparampand
suddendecelerationwhenbackingdownaramp.Both
maneuverscancausetheunittotipbackward.

Figure30

1.Trailer3.Notgreaterthan
15degrees

2.Fullwidthramp4.Fullwidthramp—sideview

OperatingTips

FastThrottleSetting

Forbestmowingandmaximumaircirculation,operate
theengineatthefastthrottleposition.Airisrequired

24

tothoroughlycutgrassclippings,sodonotsetthe
height-of-cutsolowastototallysurroundthemower
byuncutgrass.Alwaystrytohaveonesideofthe
mowerfreefromuncutgrass,whichallowsairtobe
drawnintothemower.

CuttingaLawnfortheFirstTime

Cutgrassslightlylongerthannormaltoensurethe
cuttingheightofthemowerdoesnotscalpanyuneven
ground.However,thecuttingheightusedinthepastis
generallythebestonetouse.Whencuttinggrasslonger
thansixinchestall,youmaywanttocutthelawntwice
toensureanacceptablequalityofcut.

Cut1/3oftheGrassBlade

Itisbesttocutonlyabout1/3ofthegrassblade.
Cuttingmorethanthatisnotrecommendedunless
grassissparse,oritislatefallwhengrassgrowsmore
slowly.

MowingDirection

Alternatemowingdirectiontokeepthegrassstanding
straight.Thisalsohelpsdisperseclippingswhich
enhancesdecompositionandfertilization.

MowatCorrectIntervals

thissetting.Thencutthegrassagainusingthelower,
normalsetting.

WhenStopping

Ifthemachine’sforwardmotionmustbestoppedwhile
mowing,aclumpofgrassclippingsmaydropontoyour
lawn.T oavoidthis,moveontoapreviouslycutarea
withthebladesengaged.

KeeptheUndersideoftheMower
Clean

Cleanclippingsanddirtfromtheundersideofthe
moweraftereachuse.Ifgrassanddirtbuildupinside
themower,cuttingqualitywilleventuallybecome
unsatisfactory.

BladeMaintenance

Maintainasharpbladethroughoutthecuttingseason
becauseasharpbladecutscleanlywithouttearingor
shreddingthegrassblades.Tearingandshreddingturns
grassbrownattheedges,whichslowsgrowthand
increasesthechanceofdisease.Checkthecutterblades
dailyforsharpness,andforanywearordamage.File
downanynicksandsharpenthebladesasnecessary.If
abladeisdamagedorworn,replaceitimmediatelywith
agenuineTOROreplacementblade.

Normally,moweveryfourdays.Butremember,
grassgrowsatdifferentratesatdifferenttimes.So
tomaintainthesamecuttingheight,whichisagood
practice,mowmoreofteninearlyspring.Asthegrass
growthrateslowsinmidsummer,mowlessfrequently.
Ifyoucannotmowforanextendedperiod,rstmow
atahighcuttingheight;thenmowagaintwodayslater
atalowerheightsetting.

CuttingSpeed

Toimprovecutquality,useaslowergroundspeedin
certainconditions.

AvoidCuttingTooLow

Ifthecuttingwidthofthemoweriswiderthanthe
moweryoupreviouslyused,raisethecuttingheightto
ensurethatuneventurfisnotcuttooshort.

LongGrass

Ifthegrassiseverallowedtogrowslightlylongerthan
normal,orifitcontainsahighdegreeofmoisture,raise
thecuttingheighthigherthanusualandcutthegrassat

25

Maintenance

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst8hours

Aftertherst25hours

Aftertherst100hours

Beforeeachuseordaily

Every50hours

Every100hours

Every150hours

MaintenanceProcedure

•Changetheengineoil.

•Checkthehydraulicuid.

•Changethehydrauliclter .

•Checkthewheelhubslottednut.

•Checkthewheellugnuts.

•Checkthesafetyinterlocksystem.

•Checktheengineoillevel.

•Cleantheengineairintakescreenfromgrassanddebris.

•Checkthemowerblades.

•Cleanthemowerdeck.

•Greasethemowerdeckidlerarmandspindles.

•Greasethepumpbeltidlerarm.

•Checkthetirepressure.

•Checkthehydraulicuid.

•Changetheengineoil.

•Checkthesparkplugs.

•Checkandcleanenginecoolingnsandshrouds.

•Inspectthebeltsforcracksandwear.

•Checkthehydraulichoses.

•Lubricatethemachinewithlightoil(RefertoLubrication).

•Replacetheairlter(moreoftenindirtyordustyconditions).

Every200hours

Every250hours

Every500hours

Yearly

Important:Refertoyour

•Replacetheoillter.

•Replacethefuellter.

•ChangethehydraulicltersandhydraulicoilwhenusingMobil®1oil.

•Checkthewheelhubslottednut.

•Checkthewheellugnuts.

•Adjustthecasterpivotbearing.

•ChangethehydraulicltersandhydraulicoilwhenusingT oro®HYPR-OIL™500
hydraulicoil.

•Greasethefrontcasterpivots(moreoftenindirtyordustyconditions).

•Lubricatethecasterwheelhubs

Engine Operator’ s Man ual

foradditionalmaintenanceprocedures.

Ifyouleavethekeyintheignitionswitch,someonecouldaccidentlystarttheengineandseriously
injureyouorotherbystanders.

Removethekeyfromtheignitionanddisconnectthewirefromthesparkplug(s)beforeyoudoany
maintenance.Setthewireasidesothatitdoesnotaccidentallycontactthesparkplug.

26

Lubrication

GreasingandLubrication

LubricatethemachinewhenshownontheCheck
ServiceReferenceAiddecal(Figure32).Greasemore
frequentlywhenoperatingconditionsareextremely
dustyorsandy.

GreaseType:General-purposegrease.

HowtoGrease

1.DisengagethePTO,movethemotioncontrollevers
totheneutrallockedpositionandsettheparking
brake.

2.Stoptheengine,removethekey ,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Cleanthegreasettingswitharag.Makesureto
scrapeanypaintoffthefrontofthetting(s).

4.Connectagreaseguntothetting.Pumpgrease
intothettingsuntilgreasebeginstooozeoutof
thebearings.

5.Wipeupanyexcessgrease.

GreasingtheFrontCasterPivots

ServiceInterval:Yearly

1.Removethedustcapandadjustthecasterpivots.
Keepthedustcapoffuntilgreasingisdone.Referto
AdjustingtheCasterPivotBearinginMaintenance.

2.Removethehexplug.Threadagreasezerkintothe
hole.

3.Pumpgreaseintothezerkuntilitoozesoutaround
thetopbearing.

4.Removethegreasezerkinthehole.Installthehex
plugandcap.

LubricateCasterWheelHubs

Figure31

1.Sealguard2.Spacernutwithwrench
ats

2.Removethecasterwheelfromthecasterforks.

3.Removethesealguardsfromthewheelhub.

4.Removeoneofthespacernutsfromtheaxle
assemblyinthecasterwheel.Notethatthread
lockingadhesivehasbeenappliedtolockthespacer
nutstotheaxle.Removetheaxle(withtheother
spacernutstillassembledtoit)fromthewheel
assembly.

5.Pryoutseals,andinspectbearingsforwearor
damageandreplaceifnecessary.

6.Packthebearingswithageneral-purposegrease.

7.Insertonebearing,onenewsealintothewheel.

Note:Thesealsmustbereplaced.

8.Iftheaxleassemblyhashadbothspacernuts
removed(orbrokenloose),applyathreadlocking
adhesivetoonespacernutandthreadontotheaxle
withthewrenchatsfacingoutward.DoNotthread
spacernutallofthewayontotheendoftheaxle.
Leaveapproximately1/8inch(3mm)fromthe
outersurfaceofthespacernuttotheendoftheaxle
insidethenut.

9.Inserttheassemblednutandaxleintothewheelon
thesideofthewheelwiththenewsealandbearing.

10.Withtheopenendofthewheelfacingup,ll
theareainsidethewheelaroundtheaxlefullof
general-purposegrease.

ServiceInterval:Yearly

1.Stoptheengine,waitforallmovingpartstostop,
andremovethekey.Engagetheparkingbrake.

11.Insertthesecondbearingandnewsealintothe
wheel.

12.Applyathreadlockingadhesivetothe2ndspacer
nutandthreadontotheaxlewiththewrenchats
facingoutward.

27

13.Torquethenutto75-80in-lb(8-9N-m),loosen,
thenre-torqueto20-25in-lb(2-3N-m).Makesure
axledoesnotextendbeyondeithernut.

GreasingtheMowerDeckand
BeltIdlers

14.Reinstallthesealguardsoverthewheelhuband
insertwheelintocasterfork.Reinstallcasterbolt
andtightennutfully .

Important:T opreventsealandbearingdamage,
checkthebearingadjustmentoften.Spinthecaster
tire.Thetireshouldnotspinfreely(morethan1or
2revolutions)orhaveanysideplay.Ifthewheel
spinsfreely,adjusttorqueonspacernutuntilthere
isaslightamountofdrag.Reapplythreadlocking
adhesive.

WheretoAddGrease

LubricatethegreasettingsasshownontheCheck
ServiceReferenceAiddecal(Figure32).

ServiceInterval:Every50hours—Greasethemower

deckidlerarmandspindles.

Every50hours—Greasethepump
beltidlerarm.

GreasewithNo.2generalpurposelithiumbaseor
molybdenumbasegrease.

Important:Makesurecuttingunitspindlesare
fullofgreaseweekly.

1.DisengagethePTO,movethemotioncontrollevers
totheneutrallockedpositionandsettheparking
brake.

2.Stoptheengine,removethekey ,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Removethebeltcovers.

4.Greasethethreespindlebearingsuntilgreasecomes
outthelowerseals(Figure33).

5.Greasetheidlerarmonthemowerdeck(Figure33).

Figure32

WheretoAddLightOilorSpray
Lubrication

ServiceInterval:Every150hours

•Seatswitchactuator.

•Brakehandlepivot.

•Brakerodbushings.

6.Greasethepumpbeltidlerarmundertheengine
deck.

Figure33

•Motioncontrolbronzebushings.

28

EngineMaintenance

1.Ifinstallinganewlter,checkitforshippingdamage.
Donotuseadamagedlter.

ServicingtheAirCleaner

Note:Servicetheltermorefrequentlyifoperating

conditionsareextremelydustyorsandy.

RemovingtheFilters

1.DisengagethePTO,movethemotioncontrollevers
totheneutrallockedpositionandsettheparking
brake.

2.Stoptheengine,removethekey ,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Releasethelatchesontheaircleanerandpulltheair
cleanercoveroffoftheaircleanerbody(Figure34).

2.Carefullyslidetheairlterintothebody(Figure34).

Note:Ensurethatitisfullyseatedbypushingon
theouterrimofthelterwhileinstallingit.

Important:Donotpressonthesoftinsidearea
ofthelter.

3.Installtheaircleanercoverwiththesideindicatedas
UPfacingupandsecurethelatches(Figure34).

ServicingtheEngineOil

ServiceInterval/Specication

Note:Changetheoilmorefrequentlywhenthe

operatingconditionsareextremelydustyorsandy.

OilType:Detergentoil(APIserviceSF,SG,SH,orSJ)

CrankcaseCapacity:58ounces(1.7liter)withthelter

removed;51ounces(1.5liter)withoutthelterremoved

Viscosity:Refertothetablebelow

Figure34

1.Latches

2.Aircleanercover

4.Cleantheinsideoftheaircleanercoverwith
compressedair.

5.Gentlyslidetheairlteroutoftheaircleanerbody
(Figure34).Avoidknockingthelterintotheside
ofthebody.

6.Inspecttheairlterfordamagebylookingintothe
lterwhileshiningabrightlightontheoutsideof
thelter.Holesinthelterwillappearasbright
spots.Ifthelterisdamageddiscardit.

3.Airlterbody

4.Primarylter

ServicingtheAirFilter

ServiceInterval:Every200hours

Donotcleanthelter,replaceit.

InstallingtheAirFilter

Important:Topreventenginedamage,always

operatetheenginewiththeairlterandcover
installed.

Figure35

CheckingtheEngineOilLevel

ServiceInterval:Beforeeachuseordaily

1.Parkthemachineonalevelsurface.

2.DisengagethePTO,turntheignitionkeytooff,and
removethekey.

3.Waitforallmovingpartstostopbeforeleavingthe
operatingpositionandthenchockorblocktires.

4.Cleanaroundtheoildipstick(Figure36)sothatdirt
cannotfallintothellerholeanddamagetheengine.

29

Figure36

1.Oildipstick

2.Fillertube

5.Unscrewtheoildipstickandwipetheendclean
(Figure36).

6.Slidetheoildipstickfullyintothellertube,butdo
notthreadontotube(Figure36).

7.Pullthedipstickoutandlookatthemetalend.Ifthe
oillevelislow,slowlypouronlyenoughoilintothe
llertubetoraisetheleveltotheFullmark.

Important:Donotoverllthecrankcasewith
oilandruntheengine;enginedamagecan
result.

Figure37

1.Oildrainvalve2.Oildrainhose

9.Slowlypourapproximately80%ofthespeciedoil
intothellertube(Figure36).

10.Checktheoillevel;refertoCheckingtheEngineOil
Level.

ChangingtheOil

ServiceInterval:Aftertherst8hours

Every100hours

1.Starttheengineandletitrunveminutes.This
warmstheoilsoitdrainsbetter.

2.Parkthemachinesothatthedrainsideisslightly
lowerthantheoppositesidetoassuretheoildrains
completely.

3.DisengagethePTOandsettheparkingbrake.

4.Stoptheengine,removethekey ,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

5.Slidethedrainhoseovertheoildrainvalve.

6.Placeapanbelowthedrainhose.Rotateoildrain
valvetoallowoiltodrain(Figure37).

7.Whenoilhasdrainedcompletely,closethedrain
valve.

11.SlowlyaddtheadditionaloiltobringittotheFull
mark.

ChangingtheOilFilter

ServiceInterval:Every200hours

Note:Changetheoilltermorefrequentlywhenthe
operatingconditionsareextremelydustyorsandy.

1.Draintheoilfromtheengine;refertoChangingthe
EngineOil.

2.Removetheoldlter(Figure38).

8.Removethedrainhose(Figure37).

Note:Disposeoftheusedoilatarecyclingcenter.

Figure38

1.Oillter

30

2.Adapter

3.Applyathincoatofnewoiltotherubbergasketon
thereplacementlter(Figure38).

4.Installthereplacementoilltertothelteradapter,
turntheoillterclockwiseuntiltherubbergasket
contactsthelteradapter,thentightenthelteran
additional3/4turn(Figure38).

5.Fillthecrankcasewiththepropertypeofnewoil;
refertoServicingtheEngineOil.

6.Runtheengineforabout3minutes,stoptheengine,
andcheckforoilleaksaroundtheoillter.

7.Checktheengineoillevelandaddoilifneeded.

ServicingtheSparkPlugs

ServiceInterval/Specication

Ensurethattheairgapbetweenthecenterandside
electrodesiscorrectbeforeinstallingthesparkplug.
Useasparkplugwrenchforremovingandinstallingthe
sparkplugsandagappingtool/feelergaugetocheckand
adjusttheairgap.Installnewsparkplugsifnecessary.

Type:Champion®RCJ8YorequivalentAirGap:

0.030inch(0.75mm)

CheckingtheSparkPlugs

ServiceInterval:Every100hours

1.Lookatthecenterofthesparkplugs(Figure40).
Ifyouseelightbrownorgrayontheinsulator,the
engineisoperatingproperly .Ablackcoatingonthe
insulatorusuallymeansthattheaircleanerisdirty.

2.Ifneeded,cleanthesparkplugwithawirebrushto
removecarbondeposits.

Figure40

1.Centerelectrodeinsulator3.Airgap(nottoscale)

2.Sideelectrode

RemovingtheSparkPlugs

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey ,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Disconnectthewiresfromthesparkplugs
(Figure39).

Figure39

1.Spark-plugwire/sparkplug

Important:Alwaysreplacethesparkplugs
whenithasablackcoating,wornelectrodes,
anoilylm,orcracks.

3.Checkthegapbetweenthecenterandsideelectrodes
(Figure40).Bendthesideelectrode(Figure40)if
thegapisnotcorrect.

InstallingtheSparkPlugs

1.Installthesparkplugsandthemetalwasher.Ensure
thattheairgapissetcorrectly.

2.Tightenthesparkplugsto16ft-lb(22N-m).

3.Connectthewirestothesparkplugs(Figure40).

4.Cleanaroundthesparkplugstopreventdirtfrom
fallingintotheengineandpotentiallycausing
damage.

5.Removethesparkplugsandthemetalwashers.

31

FuelSystem

ServicingtheFuelTank

Maintenance

ReplacingtheFuelFilter

ServiceInterval:Every200hours/Yearly(whichever

comesrst)—Replacethefuellter.

Neverinstalladirtylterifitisremovedfromthefuel
line.

1.DisengagethePTO,movethemotioncontrollevers
totheneutrallockedposition,andsettheparking
brake.

2.Stoptheengine,removethekey ,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Allowthemachinetocooldown.

4.Stoptheengine,removethekey ,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

5.Closethefuelshutoffvalve(Figure41).

Incertainconditions,gasolineisextremely
ammableandhighlyexplosive.Areor
explosionfromgasolinecanburnyouand
othersandcandamageproperty.

•Draingasolinefromthefueltankwhenthe
engineiscold.Dothisoutdoorsinanopen
area.Wipeupanygasolinethatspills.

•Neversmokewhendraininggasoline,and
stayawayfromanopenameorwherea
sparkmayignitethegasolinefumes.

1.Parkthemachineonalevelsurfacetoensurethat
thefueltanksdraincompletely.

2.Disengagethepowertakeoff(PTO),settheparking
brake,stoptheengine,andremovethekey.

3.Closethefuelshutoffvalve(Figure41).

4.Loosenthehoseclampatthefuellterandslideit
upthefuellineawayfromthefuellter(Figure41).

5.Disconnectthefuellinefromthefuellter
(Figure41).

Figure41

1.Hoseclamp3.Filter

2.Fuelline

6.Squeezetheendsofthehoseclampstogetherand
slidethemawayfromthelter(Figure41).

7.Removethelterfromthefuellines.

8.Installanewlterandmovethehoseclampsclose
tothelter(Figure41).

6.Openthefuelshutoffvalve.

Note:Allowgasolinetodrainintoafuelcontainer
canordrainpan(Figure41).

Note:Nowisthebesttimetoinstallanewfuel
lterbecausethefueltankisempty.

7.Installthefuellineontothefuellter.Slidethehose
clampclosetothefuelltertosecurethefuelline
(Figure41).

9.Openthefuelshutoffvalve.

32

ElectricalSystem
Maintenance

ServicingtheBattery

Warning

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandleadcompounds,

chemicalsknowntotheStateofCalifornia

tocausecancerandreproductiveharm.

Washhandsafterhandling .

Batteryelectrolytecontainssulfuricacidwhich
isadeadlypoisonandcausessevereburns.

Donotdrinkelectrolyteandavoidcontactwith
skin,eyesorclothing.Wearsafetyglassesto
shieldyoureyesandrubberglovestoprotect
yourhands.

RemovingtheBattery

Incorrectbatterycableroutingcoulddamage
themachineandcablescausingsparks.Sparks
cancausethebatterygassestoexplode,
resultinginpersonalinjury.

•AlwaysDisconnectthenegative(black)
batterycablebeforedisconnectingthe
positive(red)cable.

•AlwaysReconnectthepositive(red)battery
cablebeforereconnectingthenegative
(black)cable.

1.DisengagethePTO,movethemotioncontrollevers
totheneutrallockedposition,andsettheparking
brake.

2.Stoptheengine,removethekey ,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Unlatchtheseatandtilttheseatup.

4.Firstdisconnectthenegativebatterycableand
groundwirefromthenegative(-)batteryterminal
(Figure42).

5.Slidetheredterminalbootoffthepositive(red)
batteryterminal.Thenremovethepositive(red)
batterycable(Figure42).

Batteryterminalsormetaltoolscouldshort
againstmetalmachinecomponentscausing
sparks.Sparkscancausethebatterygassesto
explode,resultinginpersonalinjury.

•Whenremovingorinstallingthebattery ,do
notallowthebatteryterminalstotouchany
metalpartsofthemachine.

•Donotallowmetaltoolstoshortbetween
thebatteryterminalsandmetalpartsofthe
machine.

Figure42

1.Battery

2.Terminalboot

3.Positivebatterycable9.Batteryclamp

4.Negativebatterycable10.J-bolts

5.Groundwire11.Wingnut(1/4inch)

6.Bolt(1/4x3/4inch)

7.Washer(1/4inch)

8.Locknut(1/4inch)

33

6.Removebothwingnuts(1/4inch)securingthe
batteryclamp(Figure42).

7.Removethebattery.

InstallingtheBattery

1.Positionbatteryinthetraywiththeterminalposts
towardtheengine(Figure42).

2.First,installthepositive(red)batterycableto
positive(+)batteryterminal.

3.Theninstallthenegativebatterycableandground
wiretothenegative(-)batteryterminal.

4.Securethecableswith2bolts(1/4x3/4inch),
2washers(1/4inch),and2locknuts(1/4inch)
(Figure42).

5.Slidetheredterminalbootontothepositive(red)
batterypost.

6.SecurebatterywithJ-bolts,holddownclampand
2washers(1/4inch),and2wingnuts(1/4inch)
(Figure42).

ChargingtheBattery

Chargingthebatteryproducesgassesthatcan
explode.

Neversmokenearthebatteryandkeepsparks
andamesawayfrombattery.

Important:Alwayskeepthebatteryfullycharged
(1.265specicgravity).Thisisespeciallyimportant
topreventbatterydamagewhenthetemperatureis
below32°F(0°C).

Figure43

1.PositiveBatteryPost

2.NegativeBatteryPost

3.Red(+)ChargerLead

4.Black(-)ChargerLead

3.Installthebatteryinthemachineandconnectthe
batterycables;refertoInstallingtheBattery.

Note:Donotrunthemachinewiththebattery
disconnected,electricaldamagemayoccur.

ServicingtheFuses

Theelectricalsystemisprotectedbyfuses.Itrequires
nomaintenance,however,ifafuseblowscheck
component/circuitformalfunctionorshort.

1.Raisetheseattogainaccesstothefuseholder
(Figure44).

2.Toreplacethefuses,pulloutonthefusetoremove
it.

3.Installanewfuse(Figure44).

1.Chargebatteryfor10to15minutesat25to30amps
or30minutesat4-6amps.

2.Whenthebatteryisfullycharged,unplugthecharger
fromtheelectricaloutlet,thendisconnectthe
chargerleadsfromthebatteryposts(Figure43).

34

Figure44

1.Accessory—15amp4.Battery—30amp

2.Clutch—10amp5.Arrowpointstothefrontof
themachine

3.Chargecircuit—25amp6.Controlconsole

DriveSystem
Maintenance

AdjustingtheTracking

Note:Determinetheleftandrightsidesofthemachine

fromthenormaloperatingposition.

Themachinehasaknobforadjustingthetracking
locatedundertheseat.

Important:Adjustthehandleneutralandhydraulic
pumpneutralbeforeadjustingthetracking.Refer
toAdjustingtheHandleNeutralandAdjustingthe
HydraulicPumpNeutralinMaintenance.

1.Pushbothcontrolleversforwardthesamedistance.

2.Checkifthemachinepullstooneside.Ifitdoes,
stopthemachineandsettheparkingbrake.

3.Unlatchtheseatandtilttheseatforwardtoaccess
thetrackingknob.

4.Tomakethemachinegoright,turntheknobtowards
theright-sideofthemachine.RefertoFigure45.

5.Tomakethemachinegoleft,turntheknobtowards
theleft-sideofthemachine.RefertoFigure45.

6.Repeatadjustmentuntilthetrackingiscorrect.

Figure45

1.Pumprod3.Trackingknob

2.Turnthiswaytotrackleft

4.Turnthiswaytotrackright

CheckingtheTirePressure

ServiceInterval:Every50hours/Monthly(whichever

comesrst)

Checkthepressureatthevalvestem(Figure46).

Maintaintheairpressureinthefrontandreartiresat
13psi(90kPa).Uneventirepressurecancauseuneven

35

cut.Checkthetireswhentheyarecoldtogetthemost
accuratepressurereading.

Figure46

Figure47

1.SlottedNut3.Holeinthreadedshaft

2.Twothreadsorless
showing

5.Checkthedistancefrombottomofslotinnutto
insideedgeofhole.Twothreadsorlessshouldbe
showing(Figure47).

4.Washer(ifneeded)

CheckingtheWheelHub
SlottedNut

ServiceInterval:Aftertherst100hours—Checkthe

wheelhubslottednut.

Every500hours—Checkthewheel
hubslottednut.

Aftertherst100hours—Checkthe
wheellugnuts.

Every500hours—Checkthewheel
lugnuts.

Theslottednutneedstobetorquedto125ft-lb
(170N-m).

1.DisengagethePTO,movethemotioncontrollevers
totheneutrallockedpositionandsettheparking
brake.

2.Stoptheengine,removethekey ,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

6.Ifmorethantwothreadsareshowingremovenut
andinstallwasherbetweenhubandnut.

7.Torquetheslottednutto125ft-lb.(170N-m)
(Figure47).

8.Tightenthenutuntilthenextsetofslotslineupwith
theholeintheshaft(Figure47).

9.Replacethecotterpin.

AdjustingtheCasterPivot
Bearing

ServiceInterval:Every500hours/Yearly(whichever

comesrst)

1.DisengagethePTO,movethemotioncontrollevers
totheneutrallockedpositionandsettheparking
brake.

2.Stoptheengine,removethekey ,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Removethecotterpin.

4.Torquetheslottednutto125ft-lb(170N-m)
(Figure47).

3.Removethedustcapfromcasterandtightenlock
nut(Figure48).

4.Tightenthelocknutuntilthespringwashersareat
andthenbackoffa1/4turntoproperlysetthe
pre-loadonthebearings(Figure48).

Important:Makesurespringwashersare
installedcorrectlyasshowninFigure48.

5.Installthedustcap(Figure48).

36

Figure48

1.SpringWashers3.DustCap

2.LockNut

CoolingSystem
Maintenance

CleaningtheAirIntakeScreen

ServiceInterval:Beforeeachuseordaily—Cleanthe

engineairintakescreenfromgrass
anddebris.

Beforeeachuseremoveanybuild-upofgrass,dirt
orotherdebrisfromthecylinderandcylinderhead
coolingns,airintakescreenonywheelend,and
carburetor-governorleversandlinkage.Thiswillhelp
insureadequatecoolingandcorrectenginespeedand
willreducethepossibilityofoverheatingandmechanical
damagetotheengine.

CleaningtheCoolingSystem

ServiceInterval:Every100hours/Yearly(whichever

comesrst)—Checkandcleanengine
coolingnsandshrouds.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey ,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Removetheairintakescreen,recoilstarterandfan
housing(Figure49).

4.Cleanthedebrisandgrassfromtheengineparts.

5.Installairintakescreen,recoilstarterandfanhousing
(Figure49).

37

Figure49

1.Guard

2.Airintakescreen5.Bolt

3.Bolt

BrakeMaintenance

AdjustingtheParkingBrake

Checktheparkingbrakeforproperadjustment.

1.Disengagethebrakelever(leverdown).

2.Measurethelengthofthespring;themeasurement
shouldbe2-3/4inch(74mm)betweenthewashers
(Figure50).

4.Fanhousing

Figure50

1.Brakelever

2.Spring,2-3/4inch(74mm)

3.Adjustingnuts7.Trunnion

4.Collaronbrakerod

5.3/16to1/4inch(5to
7mm)

6.Jamnutandyoke

3.Ifanadjustmentisnecessary,dothefollowing:

A.Loosenthejamnutbelowthespringandtighten

thenutdirectlybelowtheyoke(Figure50).

B.Turnthenutuntilyouobtainthecorrect

measurement.

C.Tightenthe2nutstogetherandrepeatonthe

oppositesideofthemachine.

4.Turnthenutsclockwisetoshortenthespringlength;
counterclockwisetolengthenthespring.

5.Engagetheparkingbrake,withtheleverup.

38

6.Measurethedistancebetweenthetrunnionroller
andthecollaronthebrakerod.Themeasurement
shouldbe3/16to1/4inch(5to7mm)(Figure50).

7.Ifanadjustmentisnecessary,dothefollowing:

BeltMaintenance

InspectingtheBelts

A.Loosenthejamnutdirectlybelowtheyoke.

B.Turnthebottomadjustingnutsuntilthecorrect

measurementisobtained(Figure50).

C.Tightenthejamnutattheyoke.

ServiceInterval:Every100hours

Checkbeltsforcracks,frayededges,burnmarksorany
otherdamage.Replacedamagedbelts.

ReplacingtheMowerBelt

Thesignsofawornmowerbeltaresquealingwhilethe
beltisrotating,bladesslippingwhileyouarecutting
grass,frayedbeltedges,burnmarks,andcracks.Replace
themowerbeltifyoudetectanyofthesesigns.

1.DisengagethePTO,movethemotioncontrollevers
totheneutrallockedposition,andsettheparking
brake.

2.Stoptheengine,removethekey ,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Removethebeltcoversovertheoutsidespindles.

4.Loosenthexedidlerarmandadjustittorelievethe
belttensiononthexedidlerpulley(Figure51).

Figure51

1.Fixedidlerarm4.Mowerbelt

2.Squarehole

3.FixedIdlerpulley

5.Removetheoldbelt.

6.Installthenewbeltthroughthebeltguideandon
thepulleys(Figure51).

7.Insertaratchetwithashortextensionorabreaker
barintothesquareholeinthexedidlerarm
(Figure52).

39

5.Beltguide

6.Spring-loadedidlerpulley

1.Ratchetwithshort

g012213

4

2

1

6

3 5

extensionorbreaker
bar

Figure52

2.Squarehole

8.Toincreasethebelttension,rotatetheratchetor
breakerbarcounterclockwisetomovethexed
idlerarmuntilyoufeelincreasedresistanceandthe
spring-loadedidlerpulleystopsmoving.

Note:Donotincreasethebelttensionbeyondthe
pointwherethexedidlerarmstops.

9.Whileholdingthebeltintension,tightenthe2bolts
thatsecurethexedidlerarm.

10.Removetheratchetorbreakerbarfromthesquare
holeinthexedidlerarm.

11.Installthebeltcoversovertheoutsidespindles.

ReplacingthePumpDriveBelt

1.Removethemowerbeltrst;refertoReplacingthe
MowerBelt.

2.Removetheboltfromtheclutchstopandunplug
theclutchelectricalwire(Figure53).

3.Pullthespringloadedidlertotheside.

Figure53

1.Belt4.Bolt

2.Clutchelectricalwire5.Clutch

3.Clutchstop

6.Idler

AdjustingthePushArms

Ifneeded,adjustthepusharmstoincreaseordecrease
themowerbelttension.

1.Loosenthejamnutandrotatetheballjoint
counterclockwise,oneturnatatime(Figure54).

4.Removethetractionbeltfromtheengineandthe
hydraulicpumppulleys(Figure53).

5.Installthenewbeltaroundtheengineandthe
hydraulicpumppulleys(Figure53).

6.Pullthespring-loadedidlertothesideandalignthe
belt.

7.Releasethepressureonthespringloadedidler
(Figure53).

1.Pusharm3.Jamnut

2.15–1/8inch(384mm)

Figure54

4.Balljoint

8.Installthemowerbelt.

2.Adjusteachsidethesameamount.Eachpusharm
shouldhavealengthof15–1/8inch(384mm)
(Figure54).

40

Note:Increasethetensionbylengtheningthepush
arms;decreasethetensionbyshorteningthepush
arms.

ControlsSystem
Maintenance

AdjustingtheControlHandle
NeutralPosition

Ifthemotioncontrolleversdonotalignormoveeasily
intotheconsolenotch,adjustmentthem.Adjusteach
lever,spring,androdseparately.

Note:Themotioncontrolleversmustbeinstalled
correctly.SeeInstallingtheMotionControlLeversin
theSetupInstructions.

1.DisengagethePTO,movethemotioncontrollevers
totheneutrallockedposition,andsettheparking
brake.

2.Stoptheengine,removethekey ,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Tilttheseatforward.

4.Beginwitheithertheleftorrightmotioncontrol
lever.

5.Movelevertotheneutralpositionbutnotlocked
(Figure55).

Figure55

1.Neutrallockedposition3.Neutralposition

2.Controllever

6.Pulltheleverbackuntiltheclevispin(onthe
armbelowthepivotshaft)contactstheendofthe
slot(justbeginningtoputpressureonthespring)
(Figure56).

41

HydraulicSystem
Maintenance

ServicingtheHydraulic
System

Figure56

1.Clevispininslot

2.Nut7.Jamnut

3.Nut-Lefthandthread

4.Adjustmentbolt9.Balljoint

5.Pumprod

6.Doublenuts

8.Yoke

7.Checkwherethecontrolleverisrelativetothenotch
intheconsole(Figure55).Itshouldbecentered,
allowingthelevertopivotoutwardtotheneutral
lockposition.

HydraulicOilType:T oro
hydraulicoilorMobil

®

HYPR-OIL

®

115W-50.

™

500

HydraulicSystemOilCapacity:67ounces(2.0l)

Important:Useoilspeciedorequivalent.Other
uidscouldcausesystemdamage.

CheckingtheHydraulicFluid

ServiceInterval:Aftertherst8hours

Every50hours

Note:Therearetwowaysofcheckingthehydraulicoil.
Oneiswhentheoiliswarmandoneiswhentheoilis
cold.Thebafeinsidethetankhastwolevelsdepending
iftheoiliswarmorcold.

1.Positionthemachineonalevelsurfaceandsetthe
parkingbrake.

2.Cleantheareaaroundllerneckofhydraulictank
(Figure57).

3.Removethecapfromthellerneck.Lookinsideto
checkifthereisuidinthereservoir(Figure57).

8.Ifadjustmentisneeded,loosenthenutandjamnut
againsttheyoke(Figure56).

9.Applyslightrearwardpressureonthemotioncontrol
lever,andturntheheadoftheadjustmentboltin
theappropriatedirectionuntilthecontrolleveris
centeredintheneutrallockposition.

Note:Keepingrearwardpressureontheleverwill
keepthepinattheendoftheslotandallowthe
adjustmentbolttomovethelevertotheappropriate
position.

10.Tightenthenutandjamnut(Figure56).

11.Repeatontheoppositesideofmachine.

4.Ifthereisnouid,adduidtothereservoiruntilit
reachesthecoldlevelofthebafe.

5.Runthemachineatlowidlefor15minutestoallow
anyairtopurgeoutofthesystemandwarmthe
uid.RefertoStartingandStoppingtheEnginein
Operation.

6.Rechecktheuidlevelwhiletheuidiswarm.The
uidshouldbebetweencoldandhot.

7.Ifrequired,adduidtothehydraulictank.

Note:Theuidlevelshouldbetothetopofthehot
levelofthebafe,whentheuidishot(Figure57).

8.Installthecaponllerneck.

42

Figure57

1.Cap3.Colduidlevel-full

2.Bafe4.Hotuidlevel-full

Hydraulicuidescapingunderpressurecan
penetrateskinandcauseinjury.

•Ifhydraulicuidisinjectedintotheskin
itmustbesurgicallyremovedwithinafew
hoursbyadoctorfamiliarwiththistypeof
injury.Gangrenemayresultifthisisnot
done.

•Keepbodyandhandsawayfrompinhole
leaksornozzlesthatejecthighpressure
hydraulicuid.

•Usecardboardorpapertondhydraulic
leaks.

•Safelyrelieveallpressureinthehydraulic
systembeforeperforminganyworkonthe
hydraulicsystem.

•Makesureallhydraulicuidhosesand
linesareingoodconditionandallhydraulic
connectionsandttingsaretightbefore
applyingpressuretohydraulicsystem.

Usewinterlterbelow32°F(0°C)

1.DisengagethePTO,movethemotioncontrollevers
totheneutrallockedpositionandsettheparking
brake.

2.Stoptheengine,removethekey ,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

Important:Donotsubstituteautomotiveoil
lterorseverehydraulicsystemdamagemay
result.

3.Placeadrainpanunderlter,removetheoldlter
andwipethelteradaptergasketsurfaceclean
(Figure58).

Figure58

1.Hydrauliclter

4.Applyathincoattotherubbergasketonthe
replacementlter(Figure59).

5.Installthereplacementhydrauliclterontothelter
adapter.Donottighten.

6.Fillthehydraulictankwithhydraulicuiduntilthe
uidoverowsthelterandthenturntheoillter
clockwiseuntiltherubbergasketcontactsthelter
adapter,thentightenthelteranadditional1/2turn
(Figure59).

7.Cleanupanyspilleduid.

ReplacingtheHydraulicFilterand
HydraulicOil

ServiceInterval:Aftertherst25hours—Changethe

hydrauliclter.

Every250hours—Changethe
hydraulicltersandhydraulicoil
whenusingMobil

Every500hours—Changethe
hydraulicltersandhydraulicoil
whenusingToro
hydraulicoil.

Usesummerlterabove32°F(0°C)

®

1oil.

®

HYPR-OIL

8.Adduidtothecoldlevelofthebafeinthe
hydraulictank.

9.Starttheengineandletitrunforabouttwominutes
topurgeairfromthesystem.Stoptheengineand
checkforleaks.Ifoneorbothwheelswillnotdrive,
refertoBleedingHydraulicSystem.

10.Rechecktheuidlevelwhiletheuidiswarm.The
uidshouldbebetweencoldandhot.

11.Ifrequired,adduidtothehydraulictank.Donot

™

500

43

overll.

Figure59

1.Hydrauliclter

2.Gasket

3.Adapter

BleedingtheHydraulicSystem

Thetractionsystemisselfbleeding,however,itmaybe
necessarytobleedthesystemifuidischangedorafter
workisperformedonthesystem.

1.Raiserearofthemachinesowheelsareoffthe
groundandsupportwithjackstands.

Hydraulicuidescapingunderpressurecan
penetrateskinandcauseinjury.

•Ifhydraulicuidisinjectedintotheskin
itmustbesurgicallyremovedwithinafew
hoursbyadoctorfamiliarwiththistypeof
injury.Gangrenemayresultifthisisnot
done.

•Keepbodyandhandsawayfrompinhole
leaksornozzlesthatejecthighpressure
hydraulicuid.

•Usecardboardorpapertondhydraulic
leaks.

•Safelyrelieveallpressureinthehydraulic
systembeforeperforminganyworkonthe
hydraulicsystem.

•Makesureallhydraulicuidhosesand
linesareingoodconditionandallhydraulic
connectionsandttingsaretightbefore
applyingpressuretohydraulicsystem.

2.Starttheengineandrunatlowidlespeed.Engage
theleverandtractionononesideandspinthewheel
byhand.

3.Whenthewheelbeginstospinonitsown,keepit
engageduntilwheeldrivessmoothly .(minimum
2minutes)

4.Checkthehydraulicuidlevelandaddasrequired
tomaintainproperlevel.

5.Repeatthisprocedureontheoppositewheel.

CheckingtheHydraulicHoses

ServiceInterval:Every100hours

Checkthehydraulichosesforleaks,loosettings,
kinkedlines,loosemountingsupports,wear,weather
andchemicaldeterioration.Makenecessaryrepairs
beforeoperating.

Note:Keepareasaroundthehydraulicsystemclean
fromgrassanddebrisbuildup.

SettingtheHydraulicPump
NeutralPosition

Note:Adjustthehandleneutralrst.Thatneedstobe

correctbeforethefollowingadjustmentcanbemade.

Thisadjustmentmustbemadewithdrivewheelsturning.

Mechanicalorhydraulicjacksmayfailto
supportmachineandcauseaseriousinjury .

•Usejackstandwhensupportingmachine.

•Donotusehydraulicjacks.

Enginemustberunningsomotioncontrol
adjustmentcanbeperformed.Contactwith
movingpartsorhotsurfacesmaycause
personalinjury.

Keephands,feet,face,clothingandotherbody
partsawayfromrotatingparts,muferand
otherhotsurfaces.

44

1.Raisetheframeandblockupthemachinesodrive
wheelscanrotatefreely .

2.Disconnecttheelectricalconnectorfromtheseat
safetyswitch.Temporarilyinstallajumperwire
acrossterminalsinthewiringharnessconnector.

3.Unlatchtheseatandslideseatforward.

4.Disconnecttheseatrodandtilttheseatfullyforward.

2.Starttheengine,openthrottle1/2wayandrelease
parkingbrake.RefertoStartingandStoppingthe
Enginein,page.

Note:Themotioncontrollevermustbeinneutral
whilemakinganyadjustments.

Note:Thefrontnutonthepumprodhasleft-hand
threads.

SettingtheLeft-handHydraulicPump
NeutralPosition

1.Starttheengine,openthethrottle1/2wayand
releaseparkingbrake.RefertoStartingandStopping
theEngineinOperation.

Note:Themotioncontrollevermustbeinneutral
whilemakinganyadjustments.

2.Adjustthepumprodlengthbyrotatingtheknob,in
theappropriatedirection,untilthewheelisstillor
slightlycreepinginreverse(Figure60).

3.Movethemotioncontrolleverforwardandreverse,
thenbacktoneutral.Thewheelmuststopturning
orslightlycreepinreverse.

4.Openthethrottletofast.Makesurewheelremains
stoppedorslightlycreepsinreverse,adjustif
necessary.

3.Adjustthepumprodlengthbyrotatingdoublenuts
ontherod,intheappropriatedirection,untilthe
wheelisstillorslightlycreepsinreverse(Figure61).

4.Movethemotioncontrolleverforwardandreverse,
thenbacktoneutral.Thewheelmuststopturning
orslightlycreepinreverse.

5.Openthethrottletofast.Makesurethewheel
remainsstoppedorslightlycreepsinreverse,adjust
ifnecessary.

6.Tightenthelocknutsattheballjoints(Figure61).

Figure60

1.Trackingknob3.Adjustmentbolt

2.Pumprod

SettingtheRight-handHydraulicPump
NeutralPosition

1.Loosenthelocknutsattheballjointsonthepump
controlrod(Figure61).

Figure61

1.Doublenuts3.Locknut

2.Pumprod4.Balljoint

45

MowerDeck

Electricalsystemwillnotperformpropersafety
shutoffwithjumperwireinstalled.

•Removejumperwirefromwireharness
connectorandplugconnectorintoseat
switchwhenadjustmentiscompleted.

•Neveroperatethisunitwithjumperinstalled
andseatswitchbypassed.

7.Afterbothpumpneutralsareset,shutoffthe
machine.

8.Removethejumperwirefromthewireharness
connectorandplugtheconnectorintotheseat
switch.

9.Installtheseatrodandlowertheseatintoposition.

10.Removethejackstands.

Maintenance

LevelingtheMoweratThree
Positions

Important:Thereareonlythreemeasuring

positionsneededtolevelthemower.

PreparingtheMachine

1.Positionmoweronaatsurface.

2.DisengagethePTO,movethemotioncontrollevers
totheneutrallockedpositionandsettheparking
brake.

3.Stoptheengine,removethekey ,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

4.Checktirepressureofallfourtires.Ifneeded,adjust
to13psi(90kPa)

5.Lowerthemowertothe3inch(76mm)height-of-cut
position.

6.Inspectthefourchains.Thechainsneedtohave
tension.

Note:Adjusttherearchainstothetopoftheslot,
wheretheyareattachedtothemower.

•Ifonerearchainisloose,lower(loosen)thefront
supportarmonthesameside.RefertoAdjusting
theFront-to-RearMowerPitch.

•Ifonefrontchainisloose,raise(tighten)thefront
supportarmforthatchain.RefertoAdjustingthe
Front-to-RearMowerPitch.

LevelingtheMowerSide-to-Side

1.Positiontherightbladefront-to-rear(Figure62).

2.MeasuretherightbladeattheBlocation,froma
levelsurfacetothecuttingedgeofthebladetip
(Figure62).

3.Recordthismeasurement.Thismeasurementneeds
tobe3-1/8to3-1/4inches.

4.Positiontheleftbladefront-to-rear(Figure62).

5.MeasuretheleftbladeattheClocation(Figure62),
fromalevelsurfacetothecuttingedgeoftheblade
tip.

6.Recordthismeasurement.Thismeasurementneeds
tobe3-1/8to3-1/4inches(79to83mm).

46

Figure62

g012086

1.Measureherefromblade
tohardsurface

2.MeasureatBandC

7.IfthemeasurementsatpositionsBorCarenot
correct,loosentheboltattachingtherearchainto
therearsupportarm(Figure63).

8.Loosenthejamnutundertherearsupportarmand
adjusttheadjustmentbolttogetameasurementof
3-1/8to3-1/4inches(Figure63).

AdjustingtheFront-to-RearMower
Pitch

1.Positiontherightbladefront-to-rear(Figure64).

2.MeasuretherightbladeattheAlocation,froma
levelsurfacetothecuttingedgeofthebladetip
(Figure64).

Figure64

1.Measureherefromblade
tohardsurface

2.MeasureatAandB

Note:Itisrecommendedthatbothsidesofthe
mowerareadjustedthesamedistance.

9.Tightenthejamnutundertherearsupportarm
andtightentheboltsecuringthechaintotherear
supportarm.

10.Adjusttheoppositesideifneeded.

Figure63

1.Rearchain5.Adjustmentbolt

2.Rearsupportarm6.Frontswivel

3.Bolt7.Frontsupportarm

4.JamNut

3.Recordthismeasurement.

4.MeasuretherightbladeattheBlocation,froma
levelsurfacetothecuttingedgeofthebladetip
(Figure64).

5.Recordthismeasurement.

6.Themowerbladeshouldbea1/4to3/8inch
(6to10mm)loweratpositionAthanatposition
B(Figure64).Ifitisnotcorrect,proceedtothe
followingsteps.

Note:Bothofthefrontswivelsneedtobeadjusted
thesameamounttomaintainequalchaintension.

7.Loosenthefrontswiveljamnuts,atthefrontof
therightandleftswivels,approximatelya1/2inch
(13mm)(Figure63).

8.Adjusttheliftnutsonboththeleftandtheright
sideofthemachinetoachieve1/4to3/8inch
(6to10mm)lowerinfrontatAthanintherearat
B(Figure63).

9.Tightenbothswiveljamnutsagainstthefrontswivel
tolocktheheight.

10.Checktomakesurethereisequaltensiononthe
chainsandadjustagainifneeded.

AdjustingtheCompressionSpring

1.Raisethemowerliftlevertothetransportposition.

47

2.Checkthedistancebetweenthetwolargewashers,

g012085

itneedstobe11-1/8inches(28.2cm)for52inch
mowerdecksand10-1/2inches(26.7cm)for60
inchmowerdecks(Figure65).

3.Adjustthisdistance,bylooseningthespringjam
nutandturningthenutinfrontofeachspring
(Figure65).

Note:Turningthenutclockwisewillshortenthe
spring;counter-clockwisewilllengthenthespring.

4.Lockthenutintopositionbytighteningthespring
jamnut(Figure65).

Figure65

1.10-1/2inch(26.7cm)for
60inmowerdecksand

11.125inch(28.2cm)for
52inmowerdecks

2.Frontnut

3.Springjamnut

4.Frontswivel8.Largewasher

5.Swiveljamnut

6.Liftnut

7.Frontsupportarm

Awornordamagedbladecanbreak,anda
pieceofthebladecouldbethrownintothe
operator’sorbystander’sarea,resultingin
seriouspersonalinjuryordeath.

•Inspectthebladeperiodicallyforwearor
damage.

•Replaceawornordamagedblade.

Inspectandcheckthebladesevery8hours.

BeforeInspectingorServicingthe
Blades

Parkthemachineonalevelsurface,disengagetheblade
control(PTO),andsettheparkingbrake.Turnthe
ignitionkeytoOff.Removethekey .

InspectingtheBlades

ServiceInterval:Beforeeachuseordaily

1.Inspectthecuttingedges(Figure66).Iftheedges
arenotsharporhavenicks,removeandsharpenthe
blades.RefertoSharpeningtheBlades.

2.Inspecttheblades,especiallythecurvedarea
(Figure66).Ifyounoticeanydamage,wear,oraslot
forminginthisarea(Figure66),immediatelyinstalla
newblade.

ServicingtheCuttingBlades

Maintainsharpbladesthroughoutthecuttingseason
becausesharpbladescutcleanlywithouttearingor
shreddingthegrassblades.Tearingandshreddingturns
grassbrownattheedges,whichslowsgrowthand
increasesthechanceofdisease.

Checkthecutterbladesdailyforsharpness,andforany
wearordamage.Filedownanynicksandsharpenthe
bladesasnecessary.Ifabladeisdamagedorworn,
replaceitimmediatelywithagenuineTororeplacement
blade.Forconvenientsharpeningandreplacement,you
maywanttokeepextrabladesonhand.

Figure66

1.CuttingEdge3.Wear/slotForming

2.CurvedArea4.Crack

CheckingforBentBlades

1.DisengagethePTO,movethemotioncontrollevers
totheneutrallockedpositionandsettheparking
brake.

2.Stoptheengine,removethekey ,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Rotatethebladesuntiltheendsfaceforwardand
backward(Figure67).Measurefromalevelsurface

48

tothecuttingedge,positionA,oftheblades
(Figure67).Notethisdimension.

Figure67

1.Measureherefromblade
tohardsurface

2.PositionA

4.Rotatetheoppositeendsofthebladesforward.

Contactwithasharpbladecancauseserious
injury.

Wearglovesorwrapsharpedgesoftheblade
witharag.

1.Holdthebladeendusingaragorthickly-padded
glove.

2.Removethebladebolt,springdiskandbladefrom
thespindleshaft(Figure70).

SharpeningtheBlades

Whensharpeningblade,piecesofbladecould
bethrownandcauseseriousinjury.

Wearpropereyeprotectionwhensharpening
blade.

5.Measurefromalevelsurfacetothecuttingedgeof
thebladesatthesamepositionasinstep3above.
Thedifferencebetweenthedimensionsobtainedin
steps3and4mustnotexceed1/8inch(3mm).If
thisdimensionexceeds1/8inch(3mm),theblade
isbentandmustbereplaced;refertoRemovingthe
BladesandInstallingtheBlades.

Abladethatisbentordamagedcouldbreak
apartandcouldseriouslyinjureorkillyouor
bystanders.

•Alwaysreplacebentordamagedbladewith
anewblade.

•Neverleorcreatesharpnotchesinthe
edgesorsurfacesofblade.

RemovingtheBlades

Bladesmustbereplacedifasolidobjectishit,ifthe
bladeisoutofbalanceorisbent.Toensureoptimum
performanceandcontinuedsafetyconformanceof
themachine,usegenuineT ororeplacementblades.
Replacementbladesmadebyothermanufacturersmay
resultinnonconformancewithsafetystandards.

1.Usealetosharpenthecuttingedgeatbothends
oftheblade(Figure68).Maintaintheoriginalangle.
Thebladeretainsitsbalanceifthesameamountof
materialisremovedfrombothcuttingedges.

Figure68

1.Sharpenatoriginalangle

2.Checkthebalanceofthebladebyputtingitona
bladebalancer(Figure69).Ifthebladestaysina
horizontalposition,thebladeisbalancedandcanbe
used.Ifthebladeisnotbalanced,lesomemetaloff
theendofthesailareaonly(Figure70).Repeatthis
procedureuntilthebladeisbalanced.

Figure69

1.Blade2.Balancer

49

InstallingtheBlades

1.Installthebladeontothespindleshaft(Figure70).

Important:Thecurvedpartoftheblademust
bepointingupwardtowardtheinsideofthe
mowertoensurepropercutting.

2.Installthespringdiskandbladebolt.Thespring
diskconemustbeinstalledtowardthebolthead
(Figure70).Torquethebladeboltto85-110ft-lb
(115-150N-m).

2.Placethespacerandspringontograssdeector.
PlacetheLendofspringbehinddeckedge.

Note:MakesuretheLendofthespringisinstalled
behindthedeckedgebeforeinstallingtheboltas
showninFigure71.

3.Installtheboltandnut.PlacetheJhookendofthe
springaroundthegrassdeector(Figure71).

Important:Thegrassdeectormustbeableto
lowerdownintoposition.Liftthedeectorup
totestthatitlowersintothefulldownposition.

Figure70

1.SailAreaofBlade

2.Blade

3.SpringDisk

4.BladeBolt

5.ConeTowardsBoltHead

ReplacingtheGrassDeector

Anuncovereddischargeopeningcouldallow
thelawnmowertothrowobjectsinthe
operator’sorbystander’sdirectionandresult
inseriousinjury.Also,contactwiththeblade
couldoccur.

•Neveroperatethelawnmowerunlessyou
installacoverplate,amulchplate,oragrass
chuteandcatcher.

•Makesurethegrassdeectorisinthedown
position.

Figure71

1.Bolt

2.Spacer6.GrassDeector

3.Locknut

4.Spring8.Jhookendofspring

5.Springinstalled

7.Lendofspring,place

behinddeckedgebefore
installingbolt

1.Removethelocknut,bolt,springandspacerholding
thedeectortothepivotbrackets(Figure71).
Removethedamagedorworngrassdeector.

50

Cleaning

CleaningUndertheMower

ServiceInterval:Beforeeachuseordaily

Removethegrassbuildupunderthemowerdaily.

1.DisengagethePTO,movethemotioncontrollevers
totheneutrallockedpositionandsettheparking
brake.

2.Stoptheengine,removethekey ,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Raisethemowertothetransportposition.

4.Liftthefrontofthemachineandsupportthe
machineusingjackstands.

WasteDisposal

Engineoil,batteries,hydraulicoil,andenginecoolant
arepollutantstotheenvironment.Disposeofthese
accordingtoyourstateandlocalregulations.

Storage

1.Disengagethepowertakeoff(PTO),settheparking
brake,andturntheignitionkeytoOff.Removethe
key.

2.Removegrassclippings,dirt,andgrimefromthe
externalpartsoftheentiremachine,especiallythe
engineandhydraulicsystem.Cleandirtandchaff
fromtheoutsideoftheenginecylinderheadnsand
blowerhousing.

Important:Youcanwashthemachinewith
milddetergentandwater.Donotpressure
washthemachine.Avoidexcessiveuseof
water,especiallynearthecontrolpanel,engine,
hydraulicpumps,andmotors.

3.Checkthebrake;refertoServicingtheBrakein
Maintenance.

4.Servicetheaircleaner;refertoServicingtheAir
CleanerinMaintenance.

5.Greasethemachine;refertoGreasingand
LubricationinMaintenance.

6.Changethecrankcaseoil;refertoServicingthe
EngineOilinMaintenance.

7.Checkthetirepressure;refertoCheckingtheTire
PressureinMaintenance.

8.Changethehydrauliclter;refertoServicingthe
HydraulicSysteminMaintenance..

9.Chargethebattery;refertoServicingtheBatteryin
Maintenance.

10.Scrapeanyheavybuildupofgrassanddirtfromthe
undersideofthemower,thenwashthemowerwith
agardenhose.

Note:RunthemachinewiththePTOengaged
andtheengineathighidlefor2to5minutesafter
washing.

11.Checktheconditionoftheblades;refertoServicing
theCuttingBladesinMaintenance.

12.Preparethemachineforstoragewhennon-use
occursover30days.Preparethemachineforstorage
asfollows:

A.Addapetroleumbasedstabilizer/conditioner

tofuelinthetank.Followmixinginstructions
fromthestabilizermanufacturer.Donotusean
alcoholbasedstabilizer(ethanolormethanol).

Note:Afuelstabilizer/conditionerismost
effectivewhenmixedwithfreshfuelandused
atalltimes.

B.Runtheenginetodistributeconditionedfuel

throughthefuelsystem(5minutes).

51

C.Stoptheengine,allowittocool,anddrainthe

fueltank;refertoServicingtheFuelTankin
Maintenance.

D.Restarttheengineandrunituntilitstops.

E.Disposeoffuelproperly.Recycleasperlocal

codes.

Important:Donotstore
stabilizer/conditionedfuelover90days.

13.Checkandtightenallbolts,nuts,andscrews.Repair
orreplaceanypartthatisdamaged.

14.Paintallscratchedorbaremetalsurfaces.Paintis
availablefromyourAuthorizedServiceDealer.

15.Storethemachineinaclean,drygarageorstorage
area.Removethekeyfromtheignitionswitchand
keepitoutofreachofchildrenorotherunauthorized
users.Coverthemachinetoprotectitandkeepit
clean.

52

Troubleshooting

Problem

Starterdoesnotcrank

Enginewillnotstart,startshard,orfails
tokeeprunning.

Enginelosespower.

PossibleCauseCorrectiveAction

1.Bladecontrol(PTO)isengaged.1.Movethebladecontrol(PTO)to

2.Parkingbrakeisnoton.

3.Operatorisnotseated.3.Sitontheseat.

4.Batteryisdead.

5.Electricalconnectionsarecorrodedor
loose.

6.Fuseisblown.

7.Relayorswitchisdefective.7.ContactanAuthorizedServiceDealer.

1.Fueltankisempty .

2.Aircleanerisdirty .

3.Dirtinthefuellter.3.Replacethefuellter.

4.Dirt,water,orstalefuelisinthefuel
system.

1.Engineloadisexcessive.1.Reducethegroundspeed.

2.Aircleanerisdirty .

3.Oillevelinthecrankcaseislow.

4.Coolingnsandairpassagesabove
theengineareplugged.

5.Ventholeinthefuelcapisplugged.5.Cleanorreplacethefuelcap.

6.Dirtinthefuellter.6.Replacethefuellter.

7.Dirt,water,orstalefuelisinthefuel
system.

disengaged.

2.Settheparkingbrake.

4.Chargethebattery.

5.Checktheelectricalconnectionsfor
goodcontact.

6.Replacethefuse.

1.Fillthefueltankwithfuel.

2.Cleanorreplacetheaircleaner
element.

4.ContactanAuthorizedServiceDealer.

2.Cleantheaircleanerelement.

3.Addoiltothecrankcase.

4.Removetheobstructionfromthe
coolingnsandairpassages.

7.ContactanAuthorizedServiceDealer.

Engineoverheats.

Machinedoesnotdrive.

Abnormalvibration.

1.Engineloadisexcessive.1.Reducethegroundspeed.

2.Oillevelinthecrankcaseislow.

3.Coolingnsandairpassagesabove
theengineareplugged.

1.Bypassvalveisnotclosedtight.1.Tightenthebypassvalve.

2.Driveorpumpbeltisworn,looseor
broken.

3.Driveorpumpbeltisoffapulley.3.Changethebelt.

4.Brokenormissingidlerspring.4.Replacethespring.

5.Hydraulicuidlevelislowortoohot.5.Addhydraulicuidtoreservoirorletit

1.Cuttingblade(s)is/arebentor
unbalanced.

2.Blademountingboltisloose.2.Tightentheblademountingbolt.

3.Enginemountingboltsareloose.3.Tightentheenginemountingbolts.

4.Looseenginepulley,idlerpulley,or
bladepulley .

5.Enginepulleyisdamaged.

6.Bladespindleisbent.

7.Motormountislooseorworn.

2.Addoiltothecrankcase.

3.Removetheobstructionfromthe
coolingnsandairpassages.

2.Changethebelt.

cooldown.

1.Installnewcuttingblade(s).

4.Tightentheappropriatepulley.

5.ContactanAuthorizedServiceDealer.

6.ContactanAuthorizedServiceDealer.

7.ContactanAuthorizedServiceDealer.

53

Problem

PossibleCauseCorrectiveAction

Unevencuttingheight.

Bladesdonotrotate.

1.Blade(s)notsharp.1.Sharpentheblade(s).

2.Cuttingblade(s)is/arebent.2.Installnewcuttingblade(s).

3.Mowerisnotlevel.

4.Undersideofmowerisdirty .4.Cleantheundersideofthemower .

5.Tirepressureisnotcorrect.5.Adjustthetirepressure.

6.Bladespindlebent.

1.Drivebeltisworn,looseorbroken.

2.Drivebeltisoffpulley .

3.Deckbeltisworn,looseorbroken.3.Installanewdeckbelt.

4.Deckbeltisoffpulley.

5.Brokenormissingidlerspring.5.Replacethespring.

3.Levelthemowerfromside-to-sideand
front-to-rear.

6.ContactanAuthorizedServiceDealer.

1.Checkthebelttension.

2.Installthedrivebeltandcheck
adjustingshaftsandbeltguidesfor
correctposition.

4.Installthedeckpulleyandcheckthe
idlerpulley,idlerarmandspringfor
correctpositionandfunction.

54

Schematics

WireDiagram(Rev.A)

55

Preliminary

TheToroTotalCoverageWarranty

ALimitedWarranty(seewarrantyperiodsbelow)

Landscape
Contractor
Equipment(LCE)

ConditionsandProductsCovered

TheToroCompanyanditsafliate,ToroWarrantyCompany,pursuantto
anagreementbetweenthem,jointlypromisetotheoriginalpurchaser
torepairtheToroProductslistedbelowifdefectiveinmaterialsor
workmanship.

Thefollowingtimeperiodsapplyfromthedateofpurchasebytheoriginal
owner:

ProductsWarrantyPeriod

AllMowers

•Engine**

•Battery1year

•Attachments1year

Mid-SizeWalk-BehindMowers
GrandStand

•Frame
ZMaster

•Engine

•Frame

ZMaster

•Frame

*Whicheveroccursrst.

**SomeenginesusedonT oroLCEProductsarewarrantedbytheenginemanufacturer.

***LifetimeFrameWarranty-Ifthemainframe,consistingofthepartsweldedtogethertoformthe

tractorstructurethatothercomponentssuchastheenginearesecuredto,cracksorbreaksin

normaluse,itwillberepairedorreplacedunderwarrantyatnocostforpartsandlabor .Frame

failureduetomisuseorabuseandfailureorrepairrequiredduetorustorcorrosionarenotcovered.

Thiswarrantyincludesthecostofpartsandlabor,butyoumustpay
transportationcosts.

TM

Mowers5yearsor1,200hours*

®

Z400,Z500Mowers

®

G3Mowers5yearsor1,200hours*

2years

2years

Lifetime(originalowneronly)***
4yearsor1,200hours*
2years**
Lifetime(originalowneronly)***

Lifetime(originalowneronly)***

InstructionsforObtainingWarrantyService

IfyouthinkthatyourT oroProductcontainsadefectinmaterialsor
workmanship,followthisprocedure:

1.ContactanyAuthorizedToroServiceDealertoarrangeserviceattheir
dealership.Tolocateadealerconvenienttoyou,refertotheY ellow
Pagesofyourtelephonedirectory(lookunder“LawnMowers”)or
accessourwebsiteatwww.Toro.com.Y oumayalsocallthenumbers
listedinitem#3tousethe24-hourToroDealerlocatorsystem.

2.Bringtheproductandyourproofofpurchase(salesreceipt)tothe
ServiceDealer.Thedealerwilldiagnosetheproblemanddetermine
ifitiscoveredunderwarranty.

3.IfforanyreasonyouaredissatisedwiththeServiceDealer’s
analysisorwiththeassistanceprovided,contactusat:

RLCCustomerCareDepartment
ToroW arrantyCompany
811 1LyndaleAvenueSouth
Bloomington,MN55420-1196
888-865-5676(U.S.Customers)
888-865-5691(Canadacustomers)

OwnerResponsibilities

YoumustmaintainyourT oroProductbyfollowingthemaintenance
proceduresdescribedintheOperator’sManual.Suchroutine
maintenance,whetherperformedbyadealerorbyyou,isatyourexpense.

ItemsandConditionsNotCovered

Thereisnootherexpresswarrantyexceptforspecialemission
systemandenginewarrantycoverageonsomeproducts.
Thisexpresswarrantydoesnotcoverthefollowing:

•Costofregularmaintenanceserviceorwearparts,suchaslters,

fuel,lubricants,tune-upparts,bladesharpening,brakeandclutch
adjustments.

•Anyproductorpartwhichhasbeenalteredormisusedandrequires

replacementorrepairduetonormalwear,accidents,orlackof
propermaintenance.

•Repairsnecessaryduetoimproperfuel,contaminantsinthefuel

system,orfailuretoproperlypreparethefuelsystempriortoany
periodofnon-useoverthreemonths.

•Pickupanddeliverycharges.

GeneralConditions

Allrepairscoveredbythesewarrantiesmustbeperformedbyan
AuthorizedToroServiceDealerusingToroapprovedreplacementparts.

NeitherTheToroCompanynorToroWarrantyCompanyisliablefor
indirect,incidentalorconsequentialdamagesinconnectionwiththe
useoftheT oroProductscoveredbythiswarranty,includingany
costorexpenseofprovidingsubstituteequipmentorserviceduring
reasonableperiodsofmalfunctionornon-usependingcompletion
ofrepairsunderthiswarranty.

Allimpliedwarrantiesofmerchantability(thattheproductistfor
ordinaryuse)andtnessforuse(thattheproductistforaparticular
purpose)arelimitedtothedurationoftheexpresswarranty

Somestatesdonotallowexclusionsofincidentalorconsequential
damages,orlimitationsonhowlonganimpliedwarrantylasts,so
theaboveexclusionsandlimitationsmaynotapplytoyou.

Thiswarrantygivesyouspeciclegalrights,andyoumayalsohaveother
rightswhichvaryfromstatetostate.

CountriesOtherthantheUnitedStatesorCanada

CustomerswhohavepurchasedToroproductsoutsidetheUnitedStatesorCanadashouldcontacttheirToroDistributor(Dealer)toobtainguarantee
policiesforyourcountry,province,orstate.IfforanyreasonyouaredissatisedwithyourDistributor’sserviceorhavedifcultyobtainingguarantee
information,contacttheToroimporter.Ifallotherremediesfail,youmaycontactusatT oroWarrantyCompany.

374-0252RevA