Toro 74801 Operator's Manual

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Form No. 3325-900

Z18-52

TimeCutter Z with 52 Side Discharge Mower

Model No. 74801—220000001 and Up

Operator ’s Manual

Domestic English (EN)

Warning

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

Important This engine is not equipped with a spark

arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate this engine on any forest-covered, brush-covered, or grass-covered land. Other states or federal areas may have similar laws.

This spark ignition system complies with Canadian ICES-002.

Ce système d’allumage par étincelle de véhicule est conforme à la norme NMB-002 du Canada.

The enclosed Engine Owner’s Manual is supplied for information regarding The U.S. Environmental Protection Agency (EPA) and the California Emission Control Regulation of emission systems, maintenance and warranty.

Keep this engine Owner’s Manual with your unit. Should this engine Owner’s Manual become damaged or illegible, replace immediately. Replacements may be ordered through the engine manufacturer.

Contents

Page

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

Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safe Operating Practices 3. . . . . . . . . . . . . . . . . . . .

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

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

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

Gasoline and Oil 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Gasoline 12. . . . . . . . . . . . . . . . . . . .

Using Stabilizer/Conditioner 12. . . . . . . . . . . . . . . .

Filling the Fuel Tank 12. . . . . . . . . . . . . . . . . . . . . .

Checking the Engine Oil Level 12. . . . . . . . . . . . . .

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

Think Safety First 13. . . . . . . . . . . . . . . . . . . . . . . . .

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

Parking Brake 13. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting and Stopping the Engine 13. . . . . . . . . . . . .

Operating the Power Take Off (PTO) 14. . . . . . . . . .

The Safety Interlock System 15. . . . . . . . . . . . . . . .

Testing the Safety Interlock System 15. . . . . . . . . . .

Driving Forward or Backward 15. . . . . . . . . . . . . . .

Stopping the Machine 16. . . . . . . . . . . . . . . . . . . . . .

Page

Adjusting the Height of Cut 16. . . . . . . . . . . . . . . . .

Adjusting the Anti-Scalp Rollers 17. . . . . . . . . . . . .

Positioning the Seat 17. . . . . . . . . . . . . . . . . . . . . . .

Adjusting the Motion Control Levers 17. . . . . . . . . .

Pushing the Machine by Hand 18. . . . . . . . . . . . . . .

Side Discharge 18. . . . . . . . . . . . . . . . . . . . . . . . . . .

Tips for Mowing Grass 19. . . . . . . . . . . . . . . . . . . . .

Maintenance 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Maintenance Schedule 20. . . . . . . . .

Engine Oil 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning the Cooling System 22. . . . . . . . . . . . . . . .

Servicing the Air Cleaner 23. . . . . . . . . . . . . . . . . . .

Spark Plug 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Servicing the Battery 25. . . . . . . . . . . . . . . . . . . . . .

Fuse 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Fuel Filter 27. . . . . . . . . . . . . . . . . . .

Draining the Fuel Tank 27. . . . . . . . . . . . . . . . . . . . .

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

Tire Pressure 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cutting Blades 29. . . . . . . . . . . . . . . . . . . . . . . . . . .

Leveling the Mower from Side-to-Side 30. . . . . . . .

Adjusting the Front-to-Rear Blade Slope 31. . . . . . .

Inspecting the Belts 32. . . . . . . . . . . . . . . . . . . . . . .

Replacing the Mower Belt 32. . . . . . . . . . . . . . . . . .

Removing the Mower 33. . . . . . . . . . . . . . . . . . . . . .

Installing the Mower 34. . . . . . . . . . . . . . . . . . . . . .

Washing the Underside of the Mower 34. . . . . . . . .

Replacing the Grass Deflector 35. . . . . . . . . . . . . . .

Wiring Diagram 36. . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning and Storage 37. . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The Toro Total Coverage Guarantee 40. . . . . . . . . . . . .

Introduction

Read this manual carefully to learn how to operate and maintain your product properly. The information in this manual can help you and others avoid injury and product damage. Although Toro designs and produces safe products, you are responsible for operating the product properly and safely.

Whenever you need service, genuine Toro parts, or additional information, contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready. Figure 1 illustrates the location of the model and serial numbers on the product.

 2001 by The Toro Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196

Printed in the USA

Safety

This machine meets or exceeds the B71.1–1998 specifications of the American National Standards Institute, in effect at the time of production. However, improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert symbol, which means CAUTION, WARNING, or DANGER—“personal safety instruction.” Failure to comply with the instruction may result in personal injury or death.

m-5163

Figure 1

1. Model and serial number plate

Write the product model and serial numbers in the space below:

Model No.

Serial No.

This manual identifies potential hazards and has special safety messages that help you and others avoid personal injury and even death. Danger, Warning, and Caution are signal words used to identify the level of hazard. However, regardless of the hazard, be extremely careful.

Danger signals an extreme hazard that will cause serious injury or death if you do not follow the recommended precautions.

Warning signals a hazard that may cause serious injury or death if you do not follow the recommended precautions.

Caution signals a hazard that may cause minor or moderate injury if you do not follow the recommended precautions.

This manual uses two other words to highlight information.

Important calls attention to special mechanical

information and Note: emphasizes general information worthy of special attention.

Safe Operating Practices

The following instructions are from ANSI standard B71.1—1998.

This product is capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death.

General Operation

• Read, understand, and follow all instructions in the

operator’s manual and on the machine before starting.

• Allow only responsible adults who are familiar with the

instructions to operate the machine.

• Clear the area of objects such as rocks, toys, wire, etc.,

which could be picked up and thrown by the blade.

• Be sure the area is clear of other people before mowing.

Stop the machine if anyone enters the area.

• Never carry passengers.

• Do not mow in reverse unless absolutely necessary.

Always look down and behind before and while backing.

• Be aware of the mower discharge direction and do not

point it at anyone. Do not operate the mower without either the entire grass catcher or the guard in place.

• Slow down before turning.

• Never leave a running machine unattended. Always turn

off blades, set parking brake, stop engine, and remove key before dismounting.

• Turn off blades when not mowing.

• Stop the engine before removing the grass catcher or

unclogging the chute.

• Mow only in daylight or good artificial light.

• Do not operate the machine while under the influence

of alcohol or drugs.

• Watch for traffic when operating near or crossing

roadways.

• Use extra care when loading or unloading the machine

into a trailer or truck.

• Keep children out of the mowing area and under the

watchful care of another responsible adult.

• Always wear safety goggles or safety glasses with side

shields when operating mower.

• Data indicates that operators, age 60 years and above,

are involved in a large percentage of riding mower–related injuries. These operators should evaluate their ability to operate the riding mower safely enough to protect themselves and others from serious injury.

Slope Operation

Slopes are a major factor related to loss-of-control and tip-over accidents, which can result in severe injury or death. All slopes require extra caution. If you cannot back up the slope or if you feel uneasy on it, do not mow it.

• Mow up and down slopes, not across.

• Remove obstacles such as rocks, tree limbs, etc.

• Watch for holes, ruts or bumps. Uneven terrain could

overturn the machine. Tall grass can hide obstacles.

• Use slow speed. Choose a low gear so that you will not

have to stop or shift while on the slope.

• Follow Toro’s recommendations for wheel weight or

counterweights to improve stability.

• Use extra care with grass catchers or other attachments.

These can change the stability of the machine.

• Keep all movement on slopes slow and gradual. Do not

make sudden changes in speed or direction.

• Avoid starting or stopping on a slope. If tires lose

traction, disengage the blades and proceed slowly straight down the slope.

• Do not turn on slopes unless necessary, and then, turn

slowly and gradually downhill, if possible.

• Do not mow near drop-offs, ditches, or embankments.

The machine could suddenly turn over if a wheel goes over the edge of a cliff or ditch, or if an edge caves in.

• Do not mow on wet grass. Reduced traction could cause

sliding.

• Do not try to stabilize the machine by putting your foot

on the ground.

• Do not use a grass catcher on steep slopes.

Children

• Be alert and turn the machine off if children enter the

area.

• Before and while backing, look behind and down for

small children.

• Never carry children, even with the blades off. They

may fall off and be seriously injured or interfere with

safe machine operation.

• Never allow children to operate the machine.

• Use extra care when approaching blind corners, shrubs,

trees, the end of a fence or other objects that may

obscure vision.

Service

• Use extra care when handling gasoline and other fuels.

They are flammable and vapors are explosive.

A. Use only an approved container.

B. Never remove the gas cap or add fuel when the

engine is running. Allow the engine to cool before

refueling. Do not smoke. C. Never refuel the machine indoors. D. Never store the machine or fuel container inside

where there is an open flame, such as near a water

heater or furnace.

• Never run a machine inside a closed area.

• Keep nuts and bolts tight, especially the blade

attachment bolts. Keep equipment in good condition.

• Never tamper with safety devices. Check their proper

operation regularly.

• Keep the machine free of grass, leaves, or other debris

build-up. Clean up oil or fuel spillage. Allow the machine to cool before storing.

• Stop and inspect the equipment if you strike an object.

Repair, if necessary, before restarting.

• Grass catcher components are subject to wear, damage

and deterioration, which could expose moving parts or allow objects to be thrown. Frequently check components and replace with manufacturer’s recommended parts, when necessary.

• Mower blades are sharp and can cut. Wrap the blade(s)

or wear gloves, and use extra caution when servicing them.

Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the machine and the mowing activity. Never assume that children will remain where you last saw them.

• Use only genuine Toro replacement parts to ensure that

original standards are maintained.

Toro Riding Mower Safety

The following list contains safety information specific to Toro products or other safety information that you must know that is not included in the ANSI standards.

Warning

Engine exhaust contains carbon monoxide, which is an odorless, deadly poison that can kill you.

Do not run engine indoors or in an enclosed area.

• Stop the engine, disconnect spark plug wire(s) and

remove key before performing any service, repairs, maintenance or adjustments.

• Slow down before turning. Sharp turns on any terrain

may cause loss of control.

• Never leave a running machine unattended. Always turn

off blades, set parking brake, stop engine, and remove the ignition key before dismounting.

• Keep hands, feet, hair, and loose clothing away from

attachment discharge area, underside of mower and any moving parts while engine is running.

• Do not touch equipment or attachment parts which may

be hot from operation. Allow to cool before attempting to maintain, adjust or service.

• Battery acid is poisonous and can cause burns. Avoid

contact with skin, eyes, and clothing. Protect your face, eyes, and clothing when working with a battery.

• Battery gases can explode. Keep cigarettes, sparks and

flames away from battery.

• Use only genuine replacement parts to ensure that

original standards are maintained.

• Use only Toro approved attachments. Warranty may be

voided if used with unapproved attachments.

• Do not mow across slopes exceeding 5 degrees.

• Do not mow down slopes exceeding 15 degrees.

• Do not mow up slopes exceeding 10 degrees.

• If a steep slope must be ascended, back up the hill, and

drive forward down the hill, keeping the machine in gear.

• Avoid turning on slopes. If you must turn, turn slowly

and gradually downhill, if possible.

• Do not use a grass catcher on steep slopes. Heavy grass

bags could cause loss of control or overturn the machine.

• If loading the machine onto a trailer or truck, use a

single, full-width ramp only. The ramp angle should not exceed 15 degrees.

Slope Chart

Safety and Instruction Decals

Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost.

1-633354

1. Fast

2. Slow

3. Neutral

4. Reverse

92-7108

99-3943

98-3798

92-7109

99–3943

1. Explosion hazard

2. No sparks, flame, or smoking

3. Caustic liquid hazard—burns to hand and damage to items

93-1122

104-8008

104-4163

4. Wear eye protection.

5. Read the operator’s manual.

6. Keep bystanders away.

1. Blade height adjustment

104-3641

104-8032

1. Throttle control

2. Choke

3. Fast

4. Variable speed

5. Slow

104-8088

104-8009

6. Headlights—on

7. Headlights—off

8. Engine stop

9. Engine run

10. Engine start

1. Parking brake

104-8014

104-5091

Gasoline and Oil

Recommended Gasoline

Use UNLEADED Regular Gasoline suitable for automotive use (87 pump octane minimum). Leaded regular gasoline may be used if unleaded regular is not available.

Important Never use methanol, gasoline containing

methanol, or gasohol containing more than 10% ethanol because the fuel system could be damaged. Do not mix oil with gasoline.

Danger

In certain conditions, gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline can burn you and others and can damage property.

• Fill the fuel tank outdoors, in an open area,

when the engine is cold. Wipe up any gasoline that spills.

• Do not fill the fuel tank completely full. Add

gasoline to the fuel tank until the level is 1/4 to 1/2 in. (6 to 13 mm) below the bottom of the filler neck. This empty space in the tank allows gasoline to expand.

• Never smoke when handling gasoline, and stay

away from an open flame or where gasoline fumes may be ignited by a spark.

• Store gasoline in an approved container and

keep it out of the reach of children. Never buy more than a 30-day supply of gasoline.

• Always place gasoline containers on the ground

away from your vehicle before filling.

• Do not fill gasoline containers inside a vehicle or

on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge.

• When practical, remove gas–powered

equipment from the truck or trailer and refuel the equipment with its wheels on the ground.

• If this is not possible, then refuel such

equipment on a truck or trailer from a portable container, rather than from a gasoline dispenser nozzle.

• If a gasoline dispenser nozzle must be used, keep

the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete.

Warning

Gasoline is harmful or fatal if swallowed. Long–term exposure to vapors can cause serious injury and illness.

• Avoid prolonged breathing of vapors.

• Keep face away from nozzle and gas tank or

conditioner opening.

• Keep gas away from eyes and skin.

Using Stabilizer/Conditioner

Use a fuel stabilizer/conditioner in the machine to provide the following benefits:

• Keeps gasoline fresh during storage of 90 days or less.

For longer storage it is recommended that the fuel tank be drained.

• Cleans the engine while it runs

• Eliminates gum-like varnish buildup in the fuel system,

which causes hard starting

Important Do not use fuel additives containing

methanol or ethanol. Add the correct amount of gas stabilizer/conditioner to the

gas. Note: A fuel stabilizer/conditioner is most effective when

mixed with fresh gasoline. To minimize the chance of varnish deposits in the fuel system, use fuel stabilizer at all times.

Filling the Fuel Tank

1. Shut the engine off and set the parking brake.

2. Clean around the fuel tank cap and remove the cap. Add

unleaded regular gasoline to the fuel tank until the level is 1/4 to 1/2 in. (6 to 13 mm) below the bottom of the filler neck. This space in the tank allows gasoline to expand. Do not fill the fuel tank completely full.

3. Install the fuel tank cap securely. Wipe up any gasoline

that may have spilled.

Checking the Engine Oil Level

Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking the Oil Level, page 21.

Operation

Note: Determine the left and right sides of the machine from the normal operating position.

Parking Brake

Always set the parking brake when you stop the machine or leave it unattended.

Think Safety First

Please carefully read all of the safety instructions and decals in the safety section. Knowing this information could help you, your family, pets or bystanders avoid injury.

Controls

Become familiar with all of the controls (Fig. 2 and 3) before you start the engine and operate the machine.

1. Ignition switch

2. Throttle/Choke

Figure 2

3. Power take off (PTO)

4. Headlights—optional

Setting the Parking Brake

1. Move the motion control levers (Fig. 3) out to the

neutral lock position.

2. Pull back and up on the parking brake lever to set the

parking brake (Fig. 4). The parking brake lever should stay firmly in the Engaged position.

Important Do not engage the parking brake while the

machine is moving. Damage to the drive system may occur.

m–4121

Figure 4

1. Parking brake—On 2. Parking brake—Off

m–5135

Releasing the Parking Brake

Push forward and down on the parking brake lever to release the parking brake (Fig. 4).

1. Motion control lever

2. Parking brake lever

Figure 3

3. Height-of-cut lever

m–5134

Starting and Stopping the Engine

Starting

1. Open the fuel shut-off valve under the front of the fuel

tank.

2. Sit down on the seat and move the motion controls to

neutral locked position.

3. Set the parking brake; refer to Setting the Parking

Brake, page 13.

4. Move the PTO (power take off) to Off (Fig. 5).

Stopping

m–4201

Figure 5

1. PTO—On 2. PTO—Off

5. Move the throttle lever to Choke (Fig. 6) before starting

a cold engine.

Note: A warm or hot engine may require choking. After the engine starts, move the throttle lever to Fast.

6. Turn the ignition key to Start (Fig. 7) to energize the

starter. When the engine starts, release the key.

Important Do not engage the starter for more than 5

seconds at a time. If the engine fails to start, allow a 15 second cool-down period between attempts. Failure to follow these instructions can burn out the starter motor.

7. After the engine starts, move the throttle lever to

between Fast and Slow (Fig. 6). Allow the engine to warm to 3 to 5 minutes before moving the throttle lever to Fast.

2 3

1. Move the throttle lever to Slow (Fig. 6).

2. Move the PTO to Off (Fig. 5).

3. Turn the ignition key to Off (Fig. 7).

4. Pull the wire off of the spark plug(s) to prevent the

possibility of someone accidentally starting the machine before transporting or storing the machine.

5. Close the fuel shut-off valve under the front of the fuel

tank before transporting or storing the machine.

Important Make sure the fuel shut-off valve is closed

before transporting or storing machine, as fuel leakage may occur.

Operating the Power Take Off (PTO)

The power take off (PTO) switch engages and disengages power to the electric clutch.

Engaging the PTO

1. Release pressure on the traction control levers and place

the machine in neutral.

2. Move the throttle to the Fast position.

3. Pull out on the PTO switch to engage it (Fig. 8).

1. Engine

2. Choke

1. Off

2. Run

m–4201

Figure 6

3. Fast

4. Slow

m–5126

1. PTO—On 2. PTO—Off

Figure 8

Disengaging the PTO

m–4268

Figure 7

3. Start

4. Ignition

Push the PTO switch to Off (Fig. 8).

The Safety Interlock System

Caution

If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury.

• Do not tamper with the interlock switches.

• Check the operation of the interlock switches

daily and replace any damaged switches before operating the machine.

Understanding the Safety Interlock System

The safety interlock system is designed to prevent the engine from starting unless:

• The parking brake is engaged.

• The PTO is disengaged.

Driving Forward or Backward

The throttle control regulates the engine speed as measured in rpm (revolutions per minute). Place the throttle control in the Fast position for best performance. Always operate in the full throttle position.

Caution

The machine can spin very rapidly. The operator may lose control of the machine and cause personal injury or damage to the machine.

• Use caution when making turns.

• Slow the machine down before making sharp

turns.

Forward

1. Release the parking brake; refer to Releasing the

Parking Brake, page 13.

• The motion control levers are in the neutral locked

position.

The safety interlock system also is designed to stop the engine when the traction controls are moved with the parking brake on or if you rise from the seat when the PTO is engaged.

Testing the Safety Interlock System

Test the safety interlock system before you use the machine each time. If the safety system does not operate as described below, have an Authorized Service Dealer repair the safety system immediately.

1. While sitting on the seat, engage the parking brake and

move the PTO to On. Try starting the engine; the engine should not crank.

2. While sitting on the seat, engage the parking brake and

move the PTO to Off. Move either motion control lever (forward or reverse). Try starting the engine; the engine should not crank. Repeat with the other motion control lever.

3. While sitting on the seat, engage the parking brake,

move the PTO to Off, and lock the motion control levers in neutral. Start the engine. While the engine is running, release the parking brake, engage the PTO, and rise slightly from the seat; the engine should stop.

4. While sitting on the seat, engage the parking brake,

move the PTO to Off, and lock the motion control levers in neutral. Start the engine. While the engine is running, center the motion controls and move (forward or reverse); the engine should stop.

2. Move the levers to the center, unlocked position.

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

forward (Fig. 9).

Note: The engine will kill if the traction control levers are moved with the parking brake engaged.

Figure 9

1. Motion control lever—neutral lock position

To go straight, apply equal pressure to both motion control levers (Fig. 9).

To turn, release pressure on the motion control lever toward the direction you want to turn (Fig. 9).

The farther you move the traction control levers in either direction, the faster the machine will move in that direction.

To stop, pull the motion control levers to neutral.

m–2715

2. Center unlock position

3. Forward

4. Backward

Backward

1. Move the levers to the center, unlocked position.

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

rearward (Fig. 9).

To go straight, apply equal pressure to both motion control levers (Fig. 9).

To turn, release the pressure on the motion control lever toward the direction you want to turn (Fig. 9).

To stop, push the motion control levers to neutral.

Stopping the Machine

To stop the machine, move the traction control levers to neutral and separate to lock, disengage the PTO, and turn the ignition key to Off to stop the engine. Also set the parking brake when you leave the machine; refer to Setting the Parking Brake, page 13. Remember to remove the key from the ignition switch.

Important Do not engage the parking brake while the

machine is moving. Damage to the drive system may occur.

Caution

Adjusting the Height of Cut

The height of cut is adjusted from 1-1/2 to 4-1/2 in. (38 to 114 mm) in 1/2 in. (13 mm) increments by relocating the clevis pin in different hole locations.

1. Raise the height-of-cut lever to the transport position

(also the 4-1/2 in. (114 mm) cutting height position) (Fig. 10).

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

the height-of-cut bracket (Fig. 10).

3. Select the hole in the height-of-cut bracket

corresponding to the height-of-cut desired, and insert the clevis pin (Fig. 10).

4. Secure the clevis pin with the hairpin cotter (Fig. 10).

Children or bystanders may be injured if they move or attempt to operate the tractor while it is unattended.

Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes.

Figure 10

1. Height-of-cut lever

2. Clevis pin

5. Lower the height-of-cut lever onto the clevis pin.

3. Hairpin cotter

m-3654

Adjusting the Anti-Scalp Rollers

Whenever you change the height-of-cut it is recommended to adjust the height of the anti-scalp rollers.

1. Disengage the PTO and stop the engine. Move the

controllers to the neutral locked position and apply the parking brake. Remove the key.

2. After adjusting the height-of-cut, remove the nut and

washer while holding the stud with a wrench (Fig. 11).

Note: Do not remove the wheel nut and washer (Fig. 11).

m–5163

Figure 12

1. Adjustment knobs

Adjusting the Motion Control

m–4167

Figure 11

1. Gage wheel

2. Stud

3. Washer

4. Nut

5. Wheel nut and washer. Do not remove.

3. Select a hole so that the gage wheel is positioned to the

nearest corresponding height-of-cut desired (Fig. 11).

4. Install the stud nut and washer (Fig. 11).

5. Repeat the adjustment on the other gage wheels.

Positioning the Seat

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

1. Raise the seat and loosen the adjustment knobs

(Fig. 12).

2. Move the seat to the desired position and tighten the

knobs.

Levers

The motion control levers can be adjusted higher or lower for maximum operator comfort.

1. Remove the 2 screws and curved washers holding the

control lever to the control arm shaft (Fig. 13).

2. Move the control lever to the next set of holes. Secure

the lever with the 2 screws and curved washers. The cupped side of the washer should be toward the control arm shaft (Fig. 13).

3. Repeat the adjustment on the other control lever.

1. Control lever

2. Screw

Figure 13

3. Curved washer

4. Control arm shaft

m–5215

Pushing the Machine by Hand

Side Discharge

Important Always push the machine by hand. Never

tow the machine because damage may occur.

To Push the Machine

1. Disengage the PTO, stop the engine, and remove the

key.

2. Pull the two bypass levers up and push them until the

washer on the rod passes through the slot. Push the levers down to lock them in place (Fig. 14).

3. Disengage the parking brake to push the machine.

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

Danger

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

• Never remove the grass deflector from the

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

• Never put your hands or feet under the mower.

• Never try to clear discharge area or mower

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

m–5139

Figure 14

1. Position for pushing the machine

2. Position for operating the machine

To Operate the Machine

Pull each bypass lever up and pull them completely out. Push the levers down (Fig. 14).

Note: The machine will not drive unless the bypass levers are pulled out.

Tips for Mowing Grass

Fast Throttle Setting

For best mowing and maximum air circulation, operate the engine at Fast. Air is required to thoroughly cut grass clippings, so do not set the height-of-cut so low as to totally surround the mower by uncut grass. Always try to have one side of the mower free from uncut grass, which allows air to be drawn into the mower.

Cutting a Lawn for the First Time

Cut grass slightly longer than normal to ensure that the cutting height of the mower does not scalp any uneven ground. However, the cutting height used in the past is generally the best one to use. When cutting grass longer than six inches tall, you may want to cut the lawn twice to ensure an acceptable quality of cut.

Cut 1/3 of the Grass Blade

It is best to cut only about 1/3 of the grass blade. Cutting more than that is not recommended unless grass is sparse, or it is late fall when grass grows more slowly.

Mowing Direction

Alternate mowing direction to keep the grass standing straight. This also helps disperse clippings which enhances decomposition and fertilization.

Long Grass

If the grass is ever allowed to grow slightly longer than normal, or if it contains a high degree of moisture, raise the cutting height higher than usual and cut the grass at this setting. Then cut the grass again using the lower, normal setting.

When Stopping

If the machine’s forward motion must be stopped while mowing, a clump of grass clippings may drop onto your lawn. To avoid this, move onto a previously cut area with the blades engaged.

Keep the Underside of the Mower Clean

Clean clippings and dirt from the underside of the mower after each use. If grass and dirt build up inside the mower, cutting quality will eventually become unsatisfactory.

Blade Maintenance

Maintain a sharp blade throughout the cutting season because a sharp blade cuts cleanly without tearing or shredding the grass blades. Tearing and shredding turns grass brown at the edges, which slows growth and increases the chance of disease. Check the cutter blades daily for sharpness, and for any wear or damage. File down any nicks and sharpen the blades as necessary. If a blade is damaged or worn, replace it immediately with a genuine Toro replacement blade.

Mow at Correct Intervals

Normally, mow every four days. But remember, grass grows at different rates at different times. So to maintain the same cutting height, which is a good practice, mow more often in early spring. As the grass growth rate slows in mid summer, mow less frequently. If you cannot mow for an extended period, first mow at a high cutting height; then mow again two days later at a lower height setting.

Cutting Speed

To improve cut quality, use a slower ground speed.

Avoid Cutting Too Low

If the cutting width of the mower is wider than the mower you previously used, raise the cutting height to ensure that uneven turf is not cut too short.

Maintenance

Note: Determine the left and right sides of the machine from the normal operating position.

Recommended Maintenance Schedule

Maintenance Service

Interval

After first use • Change the engine oil.

Each use

Every 5 hours • Check the cutting blades.

Every 25 hours

Every 50 hours • Service the paper air cleaner.

Every 100 hours

Every 200 hours

Every 300 hours • Clean the engine shrouds and cooling fins.

Maintenance Procedure

• Check the engine oil level.

• Check the safety system.

• Clean the air intake screen.

• Clean the mower housing.

• Grease all lubrication points.

• Oil the linkage bushings.

• Service the foam air cleaner.

• Check the belts for wear/cracks.

• Check the battery electrolyte.

• Check the tire pressure.

• Change the engine oil.

• Check the spark plug(s).

• Change the oil filter.

• Replace the fuel filter.

• Replace the paper air cleaner.

• Perform all maintenance procedures listed above before storage.

Before storage

More often in dusty, dirty conditions

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

• Drain the fuel tank.

• Charge the battery and disconnect the battery cables.

• Paint any chipped surfaces.

Caution

If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders.

Remove the key from the ignition and disconnect the wire from the spark plug(s) before you do any maintenance. Set the wire aside so that it does not accidentally contact the spark plug.

Engine Oil

Change the oil after the first 8 operating hours and every 100 operating hours thereafter.

Oil Type: Detergent oil (API service SC, SD, SE, SF, SG, or SH)

Crankcase Capacity: w/filter, 1.6 qt. (1.5 l)

Changing and Draining the Oil

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

warms the oil so that it drains better.

2. Park the machine so that the drain side is slightly lower

than the opposite side to ensure that the oil drains completely. Then disengage the PTO, set the parking brake, stop the engine, and remove the key.

Viscosity: See the table below.

USE THESE SAE VISCOSITY OILS

Checking the Oil Level

1. Park the machine on a level surface, disengage the PTO,

stop the engine, and remove the key.

2. Clean around the oil dipstick (Fig. 15) so that dirt

cannot fall into the filler hole and damage the engine.

3. Unscrew the oil dipstick and wipe the metal end clean

(Fig. 15).

4. Slide the oil dipstick fully into the filler tube, but do not

thread it onto the tube (Fig. 15). Pull the dipstick out and look at the metal end. If the oil level is low, slowly pour only enough oil into the filler tube to raise the level to the “FULL” mark on the dipstick.

Important Do not overfill the crankcase with oil

because the engine may be damaged.

3. Place a pan below the oil drain. Remove the oil drain

cap (Fig. 16).

4. When the oil has drained completely, install the drain

cap.

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

m–5557

Figure 16

1. Oil drain cap

5. Clean around the oil dipstick and unscrew the cap

(Fig. 15).

6. Slowly pour approximately 80% of the specified

amount of oil, page 21, into the filler tube (Fig. 15). Check the oil level; refer to Checking the Oil Level, page 21. Slowly add additional oil to bring the level to the “FULL” mark on the dipstick.

m-4288

1. Oil dipstick

2. Filler tube

Figure 15

3. Dipstick end

m-4291

Changing the Oil Filter

Replace the oil filter every 200 hours or every other oil change.

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

1. Drain the oil from the engine; refer to Changing and

Draining the Oil, page 21.

2. Remove the old filter (Fig. 17).

3. Apply a thin coat of new oil to the rubber gasket on the

replacement filter (Fig. 17).

Cleaning the Cooling System

Clean the air intake screen from grass and debris before each use.

Clean the cooling fins and engine shrouds every 300 hours or yearly, whichever comes first.

1. Disengage the PTO, set the parking brake, stop the

engine, and remove the key.

2. Remove the air intake screen, cylinder covers, and fan

housing.

3. Clean debris and grass from the parts.

4. Install the air intake screen, cylinder covers, and fan

housing.

m-4288

Figure 17

1. Oil filter 2. Adapter

4. Install the replacement oil filter to the adapter. Turn the

oil filter clockwise until the rubber gasket contacts the filter adapter, then tighten the filter an additional 3/4 turn (Fig. 17).

5. Fill the crankcase with the proper type of new oil; refer

to Changing and Draining the Oil, page 21.

1. Air intake screen

2. Fan housing

m–4295

Figure 18

3. Cylinder cover

4. Cylinder cover

Servicing the Air Cleaner

Foam Element: Clean and oil after every 25 operating hours.

Paper Element: Clean after every 100 operating hours. Replace after every 200 operating hours or yearly, whichever comes first.

Note: Service the air cleaner more frequently (every few hours) if operating conditions are extremely dusty or sandy.

Removing the Foam and Paper Elements

1. Disengage the PTO, set the parking brake, stop the

engine, and remove the key.

2. Clean around the air cleaner to prevent dirt from getting

into the engine and causing damage. Unlatch the two side latches and remove the air cleaner cover (Fig. 19).

3. Carefully remove the foam element from the paper

element (Fig. 19).

4. Unscrew the wing nut and remove the paper element

(Fig. 19).

Cleaning the Foam and Paper Elements

1. Foam Element

A. Wash the foam element in liquid soap and warm

water. When the element is clean, rinse it thoroughly.

B. Dry the element by squeezing it in a clean cloth (do

not wring). Allow the element to air dry.

C. Soak the element in new engine oil. (Fig. 20).

Squeeze the element to remove excess oil.

Important Replace the foam element if it is torn or

worn.

Figure 20

1. Foam element 2. Oil

1. Cover

2. Foam element

3. Paper element

3 5

Figure 19

4. Wing nut

5. Air cleaner base

6. Latches

2. Paper Element

A. Lightly tap the element on a flat surface to remove

dust and dirt (Fig. 21).

B. Inspect the element for tears, an oily film, and

damage to the rubber seal.

Important Never clean the paper element with

pressurized air or liquids, such as solvent, gas, or kerosene. Replace the paper element if it is damaged or cannot be cleaned thoroughly.

m-4289

Figure 21

1. Paper element 2. Rubber seal

m–4293

Installing the Foam and Paper Elements

Checking the Spark Plug

Important To prevent engine damage, always operate

the engine with the complete foam and paper air cleaner assembly installed.

1. Carefully slide the foam element into the paper air

cleaner element (Fig. 19).

2. Place the air cleaner assembly onto the air cleaner base

and install the wing nut (Fig. 19).

3. Install the air cleaner cover and latch it (Fig. 19).

Spark Plug

Check the spark plug(s) after every 100 operating hours. Make sure the air gap between the center and side electrodes is correct before installing the spark plug. Use a spark plug wrench for removing and installing the spark plug(s) and a gapping tool/feeler gauge to check and adjust the air gap. Install a new spark plug(s) if necessary.

Type: Champion RCJ8Y (or equivalent) Air Gap: 0.030 in. (0.76 mm)

Removing the Spark Plug(s)

1. Disengage the PTO, set the parking brake, stop the

engine, and remove the key.

1. Look at the center of the spark plug(s) (Fig. 23). If you

see light brown or gray on the insulator, the engine is operating properly. A black coating on the insulator usually means the air cleaner is dirty.

Important Never clean the spark plug(s). Always

replace the spark plug(s) when it has a black coating, worn electrodes, an oily film, or cracks.

2. Check the gap between the center and side electrodes

(Fig. 23). Bend the side electrode (Fig. 23) if the gap is not correct.

0.030 in.

(0.76 mm)

m–3215

Figure 23

1. Center electrode insulator

2. Side electrode

3. Air gap (not to scale)

2. Pull the wire(s) off of the spark plug(s) (Fig. 22). Clean

around the spark plug(s) to prevent dirt from falling into the engine and potentially causing damage.

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

M-429

Figure 22

1. Spark plug wire installed 2. Spark plug

Installing the Spark Plug(s)

1. Install the spark plug(s). Make sure that the air gap is

set correctly.

2. Tighten the spark plug(s) to 11 ft.-lb. (15 N⋅m).

3. Push the wire(s) onto the spark plug(s) (Fig. 22).

Servicing the Battery

Warning

Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after

handling.

4. Slide the rubber cover up the positive (red) cable.

Disconnect the positive (red) cable from the battery post (Fig. 24).

5. Remove the battery hold-down (Fig. 24) and lift the

battery from the battery tray.

Check the electrolyte level in the battery every 25 hours. Always keep the battery clean and fully charged. Use a paper towel to clean the battery case. If the battery terminals are corroded, clean them with a solution of four parts water and one part baking soda. Apply a light coating of grease to the battery terminals to prevent corrosion.

Voltage: 12 v

Removing the Battery

Warning

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

• When removing or installing the battery, do not

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

• Do not allow metal tools to short between the

battery terminals and metal parts of the tractor.

1. Disengage the PTO, set the parking brake, stop the

engine, and remove the key.

2. Tip the seat forward to see the battery.

3. Disconnect the negative (black) ground cable from the

battery post (Fig. 24).

1. Battery

2. Terminal boot

3. Positive battery cable

4. Negative battery cable

Figure 24

5. Battery hold-down

6. Bolt and washer

7. Nut

m–5143

Installing the Battery

1. Position the battery in the tray with the terminal posts

away from the control panel (Fig. 24).

2. Install the positive (red) battery cable to the positive (+)

battery terminal.

3. Install the negative battery cable to the negative (–)

battery terminal.

4. Secure the cables with 2 bolts (1/4 x 3/4 in.), washers

(1/4 in.), and nuts (1/4 in.) (Fig. 24).

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

battery post.

6. Secure the battery with the hold-down (Fig. 24).

Warning

Incorrect battery cable routing could damage the tractor and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury.

• Always disconnect the negative (black) battery

cable before disconnecting the positive (red) cable.

• Always connect the positive (red) battery cable

before connecting the negative (black) cable.

Checking the Electrolyte Level

Danger

5. Wait five to ten minutes after filling the battery cells.

Add distilled water, if necessary, until the electrolyte level is up to the Upper line (Fig. 25) on the battery case.

Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns.

• Do not drink electrolyte and avoid contact with

skin, eyes or clothing. Wear safety glasses to shield your eyes and rubber gloves to protect your hands.

• Fill the battery where clean water is always

available for flushing the skin.

1. Tip the seat forward to see the battery.

2. Look at the side of the battery. The electrolyte must be

up to the Upper line (Fig. 25). Do not allow the electrolyte to fall below the Lower line (Fig. 25).

m-5004

Figure 25

1. Vent caps

2. Upper line

3. Lower line

6. Reinstall the battery vent caps.

Charging the Battery

Important Always keep the battery fully charged

(1.260 specific gravity). This is especially important to prevent battery damage when the temperature is below 32°F (0°C).

1. Remove the battery from the chassis; refer to Removing

the Battery, page 25.

2. Check the electrolyte level; refer to Checking the

Electrolyte Level, page 26.

3. Make sure that the vent caps are installed in the battery.

Charge the battery for 1 hour at 25 to 30 amps or 6 hours at 4–6 amps. Do not overcharge the battery.

4. When the battery is fully charged, unplug the charger

from the electrical outlet, then disconnect the charger leads from the battery posts (Fig. 26).

3. If the electrolyte is low, add the required amount of

distilled water; refer to Adding Water to the Battery, page 26.

Adding Water to the Battery

The best time to add distilled water to the battery is just before you operate the machine. This lets the water mix thoroughly with the electrolyte solution.

1. Remove the battery from the tractor; refer to Removing

the Battery, page 25.

Important Never fill the battery with distilled water

while the battery installed in the tractor. Electrolyte could be spilled on other parts and cause corrosion.

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

3. Remove the vent caps from the battery (Fig. 25).

4. Slowly pour distilled water into each battery cell until

the electrolyte level is up to the Upper line (Fig. 25) on the battery case.

Important Do not overfill the battery because

electrolyte (sulfuric acid) can cause severe corrosion and damage to the chassis.

m-4970

Figure 26

1. Positive battery post

2. Negative battery post

3. Red (+) charger lead

4. Black (–) charger lead

5. Install the battery in the tractor and connect the battery

cables; refer to Installing the Battery, page 25.

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

Fuse

Service Interval/Specification

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

Fuse: Main F1—30 amp, blade-type

Charge Circuit F2—25 amp, blade-type Optional Headlight Kit—10 amp, blade type

1. Raise the seat to gain access to the fuse holder (Fig. 27).

2. To replace a fuse, pull out on the fuse to remove it

(Fig. 27).

Figure 28

1. Fuel filter

2. Hose clamp

3. Fuel line

Draining the Fuel Tank

Danger

In certain conditions, gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline can burn you and others and can damage property.

m–4294

m–5144

Figure 27

1. Main—30 amp

2. Charge circuit—25 amp

3. For optional Headlight Kit—10 amp

Replacing the Fuel Filter

Replace the fuel filter after every 200 operating hours or yearly, whichever occurs first.

Never install a dirty filter if it is removed from the fuel line.

1. Disengage the PTO, set the parking brake, stop the

engine, and remove the key.

2. Close the fuel shut-off valve located under the front of

the fuel tank.

3. Squeeze the ends of the hose clamps together and slide

them away from the filter (Fig. 28).

4. Remove the filter from the fuel lines.

5. Install a new filter and move the hose clamps close to

the filter (Fig. 28).

6. Open the fuel shut-off valve.

• Drain gasoline from the fuel tank when the

engine is cold. Do this outdoors in an open area. Wipe up any gasoline that spills.

• Never smoke when draining gasoline, and stay

away from an open flame or where a spark may ignite the gasoline fumes.

1. Park the machine on a level surface, to ensure that the

fuel tank drains completely. Then disengage the PTO, set the parking brake, stop the engine, and remove the key.

2. Close the fuel shut-off valve located under the front of

the fuel tank.

3. Loosen the hose clamp at the fuel filter and slide it up

the fuel line away from the fuel filter (Fig. 28).

4. Pull the fuel line off of the fuel filter (Fig. 28).

5. Open the fuel shut-off valve. Allow gasoline to drain

into a gas can or drain pan.

Note: Now is the best time to install a new fuel filter because the fuel tank is empty.

6. Install the fuel line onto the fuel filter. Slide the hose

clamp close to the fuel filter to secure the fuel line (Fig. 28).

Greasing and Lubrication

Lubricate the machine when shown on the Check Service Reference Aid decal (Fig. 29) located beneath the seat. Grease more frequently when operating conditions are extremely dusty or sandy.

Grease with No. 2 general purpose lithium base or molybdenum base grease.

How to Grease

1. Disengage the PTO, stop the engine, and remove the

key.

2. Clean the grease fittings with a rag. Make sure to scrape

any paint off of the front of the fitting(s).

3. Connect a grease gun to the fitting. Pump grease into

the fittings until grease begins to ooze out of the bearings.

4. Wipe up any excess grease.

Where to Add Grease

Lubricate the grease fittings as shown on the Check Service Reference Aid decal (Fig. 29) located beneath the seat.

m–5157

Figure 30

Top View

Tire Pressure

Maintain the air pressure in the front and rear tires as specified. Uneven tire pressure can cause uneven cut. Check the pressure at the valve stem after every 50 operating hours or monthly, whichever occurs first (Fig. 31). Check the tires when they are cold to get the most accurate pressure reading.

Rear Tires: 13 psi (90 kPa) Front Tires (castor wheels): 35 psi (139 kPa)

Figure 29

Greasing the Bearings

The cutting unit must be lubricated regularly; refer to the Recommended Maintenance Schedule, page 20. Grease with No. 2 general purpose lithium base or molybdenum base grease.

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

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

2. Grease the fittings on the three spindle bearings

(Fig. 30).

3. Grease the idler pulley pivot (Fig. 30).

m–1872

Figure 31

1. Valve stem

Cutting Blades

Maintain sharp blades throughout the cutting season because sharp blades cut cleanly without tearing or shredding the grass blades. Tearing and shredding turns grass brown at the edges, which slows growth and increases the chance of disease.

Check the cutter blades daily for sharpness, and for any wear or damage. File down any nicks and sharpen the blades as necessary. If a blade is damaged or worn, replace it immediately with a genuine Toro replacement blade. For convenient sharpening and replacement, you may want to keep extra blades on hand.

Danger

A worn or damaged blade can break, and a piece of the blade could be thrown into the operator’s or bystander’s area, resulting in serious personal injury or death.

• Inspect the blade periodically for wear or

damage.

• Replace a worn or damaged blade.

Checking for Bent Blades

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

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

2. Rotate the blades until the ends face forward and

backward (Fig. 33). Measure from a level surface to the cutting edge of the blades (Fig. 34). Note this dimension.

Front

m–1078

Figure 33

Before Inspecting or Servicing the Blades

Park the machine on a level surface, disengage the PTO, and set the parking brake. Stop the engine, remove the key, and disconnect the spark plug wire(s) from the spark plug(s).

Inspecting the Blades

1. Inspect the cutting edges (Fig. 32). If the edges are not

sharp or have nicks, remove and sharpen the blades; refer to Sharpening the Blades, page 30.

2. Inspect the blades, especially the curved area (Fig. 32).

If you notice any damage, wear, or a slot forming in this area (item 3 in Fig. 32), immediately install a new blade.

1. Cutting edge

2. Curved area

Figure 32

3. Wear/slot forming

m–151

MEASURE FROM

CUTTING EDGE TO A

LEVEL SURFACE

m–2539

Figure 34

3. Rotate the opposite ends of the blades forward. Measure

from a level surface to the cutting edge of the blades at the same position as in step 2 above. The difference between the dimensions obtained in steps 2 and 3 must not exceed 1/8 in. (3 mm). If this dimension exceeds 1/8 in. (3 mm), the blade is bent and must be replaced; refer to Removing the Blades and Installing the Blades, page 30.

Warning

A blade that is bent or damaged could break apart and could seriously injure or kill you or bystanders.

• Always replace bent or damaged blade with a

new blade.

• Never file or create sharp notches in the edges

or surfaces of blade.

Removing the Blades

The blades must be replaced if a solid object is hit, if the blade is out of balance, or the blade is bent. To ensure optimum performance and continued safety conformance of the machine, use genuine Toro replacement blades. Replacement blades made by other manufacturers may result in non-conformance with safety standards.

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

balancer (Fig. 37). If the blade stays in a horizontal position, the blade is balanced and can be used. If the blade is not balanced, file some metal off the end of the sail area only (Fig. 35). Repeat this procedure until the blade is balanced.

Hold the blade end using a rag or thickly-padded glove. Remove the blade bolt, stiffener, and blade from the spindle shaft (Fig. 35).

m–5161

Figure 35

1. Sail area of blade

2. Blade

3. Stiffener

4. Blade bolt

Sharpening the Blades

1. Use a file to sharpen the cutting edge at both ends of the

blade (Fig. 36). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges.

m–1855

Figure 37

1. Blade 2. Balancer

Installing the Blades

1. Install the blade onto the spindle shaft (Fig. 35).

Important The curved part of the blade must be

pointing upward toward the inside of the mower to ensure proper cutting.

2. Install the stiffener and blade bolt (Fig. 35). Torque the

blade bolt to 80–100 ft.-lb. (108–136 N⋅m).

Leveling the Mower from Side-to-Side

The mower blades must be level from side to side. Check the side-to-side level any time you install the mower or when you see an uneven cut on your lawn.

1. Position the mower on a flat surface. Disengage the

PTO, set the parking brake, stop the engine, and remove the key. Disconnect the spark plug wire(s) from the spark plug(s).

1. Sharpen at original angle

Figure 36

m–1854

2. Check the air pressure of all four tires. If needed, adjust

to the recommended inflation; refer to Tire Pressure, page 28.

3. Set the height-of-cut at 3 in. (76 mm).

4. Carefully rotate the blade(s) from side to side (Fig. 38).

Measure between the outside cutting edges and the flat surface (Fig. 38). If both measurements are not within 3/16 in. (4.75 mm), an adjustment is required; refer to steps 5 and 6.

Front

Adjusting the Front-to-Rear Blade Slope

Check the front-to-rear blade level any time you install the mower. If the front of the mower is more than 5/16 in. (7.9 mm) lower than the rear of the mower, adjust the blade level using the following instructions:

1. Position the mower on a flat surface. Disengage the

PTO, set the parking brake, stop the engine, and remove the key. Disconnect the spark plug wire(s) from the spark plug(s).

1078

Figure 38

1. Blades side to side

2. Outside cutting edges

3. Measure here

5. Remove the hairpin cotter and washer from the leveling

bracket (Fig. 39). To level the blade(s), reposition the leveling bracket(s) in a different hole and install the washer and hairpin cotter (Fig. 39). A front hole lowers the blade height and a rear hole raises its height. Adjust both sides as required.

6. Check the front-to-rear blade slope; refer to Adjusting

the Front-to-Rear Blade Slope, page 31.

m–5177

Figure 39

1. Hairpin cotter and washer

2. Leveling bracket

3. Front hole

4. Rear hole

to the recommended inflation; refer to Tire Pressure, page 28.

3. Check and adjust the side-to-side blade level if you

have not checked the setting; refer to Leveling the Mower from Side-to-Side, page 30.

4. Measure the length of the rear trunion rod (Fig. 40). If

the rod length is not 11-1/2 in. (29.2 cm), remove the clevis pin and cotter pin from the end of the rod (Fig. 40), loosen the jam nut, and turn the yoke until the 11-1/2 in. (29.3 cm) dimension is obtained. Then secure the yoke with the clevis pin and cotter pin. Repeat this procedure on the opposite side of the mower.

2. Check the air pressure of all four tires. If needed, adjust

11-1/2 in. (29.2 cm)

m–5177

Figure 40

1. Rear trunion rod

2. Clevis pin and cotter pin

3. Jam nut

4. Yoke

5. Set the height-of-cut at 3 in. (76 mm) and carefully

rotate the blades so they are facing front to rear (Fig. 41).

6. Measure between the tip of the front blade (Fig. 41) and

the tip of the rear blade to the flat surface. If the front blade tip is not 1/16–5/16 in. (1.6–7.9 mm) lower than the rear blade tip, adjust the front trunion rods.

Front

1078

10.When the front-to-rear blade slope is correct, tighten the

jam nuts (Fig. 40 and 42).

11. Recheck the side-to-side level of the mower; refer to

Leveling the Mower from Side-to-Side, page 30.

12.Check the height of the anti-scalp rollers; refer to

Adjusting the Anti-Scalp Rollers, page 17.

Inspecting the Belts

Inspect all belts every 100 hours. Check the belts for cracks, frayed edges, burn marks, or any

other damage. Replace damaged belts.

Figure 41

1. Blade front to rear

2. Measure front blade tip

3. Measure rear blade tip

4. Measure here

7. To adjust the front-to-rear blade slope, remove the

hairpin cotter from the front trunion yokes and loosen the jam nuts (Fig. 42).

m–5178

Figure 42

1. Front trunion rod yoke

2. Hairpin cotter

3. Jam nut

8. Rotate the yokes on the rods to change the adjustment

(Fig. 42). To raise the front of the mower, tighten the yokes (shorten the rods). To lower the front of the mower, loosen the yokes (lengthen the rods).

9. After adjusting both trunion rod yokes evenly, secure

the yokes with the hairpin cotters. Check the front-to-rear level again. Continue adjusting the yokes until the front blade tip is 1/16–5/16 in. (1.6–7.9 mm) lower than the rear blade tip (Fig. 41).

Replacing the Mower Belt

Squealing when the belt is rotating, blades slipping when cutting grass, frayed belt edges, burn marks, and cracks are signs of a worn mower belt. Replace the mower belt if any of these conditions are evident.

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

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

2. Set the height-of-cut at 1-1/2 in. (38 mm).

3. Remove the belt covers over the outside spindles.

4. Loosen the outer nut on the spring eye bolt (Fig. 43)

enough to allow removal of the belt.

m–4197

Figure 43

Top View

1. Outer nut

2. Idler pulley

3. Idler arm

4. Spring eye bolt

5. Spring

6. 9-3/8 in. ± 1/8 in. (238 mm ± 3 mm)

7. Mower belt

5. Remove the belt. Start at the outside pulley and rotate

the belt off (Fig. 44).

Note: Do not remove the spring.

Caution

The spring is under tension when installed and can cause personal injury.

Do not remove the spring from the spring eye bolt.

Removing the Mower

1. Park the machine on a level surface, disengage the PTO,

set the parking brake, stop the engine, and remove the key. Disconnect the spark plug wire(s) from the spark plug(s).

2. Lower the height-of-cut lever to the lowest position.

6. Route the new belt through the idler arm (Fig. 43) and

onto the other pulleys (Fig. 44).

7. Tighten the outer nut on the spring eye bolt (Fig. 43). Note: Check the spring length. The spring should measure

9-3/8 in. ± 1/8 in. (238 mm ± 3 mm) when installed with the height-of-cut set at 1-1/2 in. (38 mm). Adjust it if it does not (Fig. 43).

8. Install the belt covers over the outside spindles.

m–5157

Figure 44

Top View

1. Mower belt

2. Idler arm

3. Outside pulley

4. Spring

5. Idler pulley

3. Remove the hairpin cotter and clevis pin from the front

trunion yokes (Fig. 45).

m–5178

Figure 45

1. Hairpin cotter and clevis pin

2. Front trunion

4. Remove the hairpin cotter and clevis pin from the rear trunion rod (Fig. 46) on each side of the mower.

5. Remove the hairpin cotter and washer at the mower leveling brackets (Fig. 46) on each side of the mower. Note which hole the leveling bracket is mounted in for future installation. Slide the brackets off of the mounting pin.

Figure 46

1. Hairpin cotter and clevis pin

2. Rear trunion rod

3. Hairpin cotter and washer

4. Leveling bracket

6. Slide the mower rearward to remove the mower belt from the engine pulley.

7. Slide the mower out from underneath the tractor.

Note: Retain all parts for future installation.

m–51771

Installing the Mower

1. Park the machine on a level surface, disengage the PTO,

set the parking brake, stop the engine, and remove the key. Disconnect the spark plug wire(s) from the spark plug(s).

2. Slide the mower under the tractor.

3. Lower the height-of-cut lever to the lowest position.

4. Attach the rear trunion rod to the tractor with the clevis

pin and hairpin cotter (Fig. 46) on each side of the mower.

4. Sit on the seat and start the engine. Engage the PTO and

let the mower run for one to three minutes.

5. Disengage the PTO, stop the engine, and remove the

ignition key. Wait for all moving parts to stop.

6. Turn the water off and remove the coupling from the

washout fitting.

Note: If the mower is not clean after one washing, soak it and let it stand for 30 minutes. Then repeat the process.

7. Run the mower again for one to three minutes to

remove excess water.

5. Slide the leveling brackets onto the mounting pins and

secure them with the washers and hairpin cotters (Fig. 46).

6. Attach the front trunion rods to the tractor with the

clevis pins and hairpin cotters (Fig. 45).

7. Install the mower belt onto the engine pulley; refer to

Replacing the Mower Belt, page 32.

Washing the Underside of the Mower

After each use, wash the underside of the mower to prevent grass buildup for improved mulch action and clipping dispersal.

1. Park the machine on a hard level surface, disengage the

PTO, stop the engine, and remove the ignition key.

2. Attach the hose coupling to the end of the mower

washout fitting, and turn the water on high (Fig. 47).

Note: Spread petroleum jelly on the washout fitting o-ring to make the coupling slide on easier and protect the o-ring.

Warning

A broken or missing washout fitting could expose you and others to thrown objects or blade contact. Contact with blade or thrown debris contact will cause injury or death.

• Replace broken or missing washout fitting

immediately, before using mower again.

• Plug any hole(s) in mower with bolts and

locknuts.

• Never put your hands or feet under the mower

or through openings in the mower.

Figure 47

1. Washout fitting

2. Coupling

3. Lower the mower to the lowest height-of-cut.

3. Hose

m–5164

Replacing the Grass Deflector

Warning

An uncovered discharge opening could allow the lawn mower to throw objects in the operator’s or bystander’s direction and result in serious injury. Also, contact with the blade could occur.

Never operate the lawn mower unless you install a cover plate, a mulch plate, or a grass chute and catcher.

1. Remove the locknut, bolt, and spring holding the

deflector to the mower brackets (Fig. 48). Remove the damaged or worn grass deflector.

m-1783

Figure 48

1. Mower bracket

2. Spring hook end

3. Space for spring

4. Grass deflector

5. Bolt

6. Locknut

2. Place the springs into the brackets on the mower with

the hooked ends over the raised back (Fig. 48).

3. Align the grass deflector with the holes in the brackets

and the spring straight ends in the space under the hinge and above the deflector (Fig. 48).

4. Secure the deflector to the mower bracket with the

bolts. The bolts should pass through the grass deflector, springs, and brackets.

Note: It may be helpful to press down near the end of the bolt with a 9/16 in. open end wrench to align the bolts with the second holes on the mower bracket and grass deflector.

5. Lift the grass deflector and check that it is spring loaded

and pivots freely to the full down position.

Important The grass deflector must be spring loaded in

the down position. Lift the deflector up to test that it snaps to the full down position.

Wiring Diagram

OFF NO CONNECTION

ON B I A AND X Y

START B I S

KEY SWITCH PN 88–9830

S B A

SW1

(IGNITION)

Y I

PINKPKREDRTAN

TERMINAL VIEW FROM

BACK OF SWITCH

KEY SW

BU VIOR

WHITE

VIOLET

YELLOW

30A

REGULATOR

FUEL SOLENOID

VIO

25A

VIO

MAGNETO 1

10A

SW6

(SEAT)

OPERATOR

SHOWN WITH

HEADLIGHT

HARNESS

BATTERY+

START

SOLENOID

IN SEAT

(KILL RELAY)

GND

VIO

WIRE COLOR CODES

BROWN

BLACK

BLUEBUGREEN

GREY

ORANGE

SW2

(PTO)

SHOWN IN

OFF POSITION

SW3

(BRAKE)

SHOWN WITH

PARK BRAKE

DISENGAGED

VIO VIO

PTO

CLUTCH

SHOWN WITH

LEVER IN

SW4

(NEUTRAL)

NEUTRAL

POSITION

SHOWN WITH

LEVER IN

NEUTRAL

POSITION

SW5

(NEUTRAL)

Cleaning and Storage

1. Disengage the PTO, set the parking brake, stop the

engine, and remove the key.

2. Remove grass clippings, dirt, and grime from the

external parts of the entire machine, especially the engine. Clean dirt and chaff from the outside of the engine cylinder head fins and blower housing.

Important You can wash the machine with mild

detergent and water. Do not pressure wash the machine. Avoid excessive use of water, especially near the control panel, engine, hydraulic pumps, and motors.

3. Service the air cleaner; refer to Servicing the Air

Cleaner, page 23.

4. Grease and oil the machine; refer to Greasing and

Lubrication, page 28.

5. Change the crankcase oil and filter; refer to Engine Oil,

page 21.

6. Check the tire pressure; refer to Tire Pressure, page 28.

7. Charge the battery; refer to Servicing the Battery,

page 25.

8. Check the condition of the blades; refer to Cutting

Blades, page 29.

9. Prepare the machine for storage when non-use occurs

over 30 days. Prepare the machine for storage as follows.

10.Add a petroleum based stabilizer/conditioner to the fuel

in the tank. Follow the mixing instructions from the stabilizer manufacturer (1 oz. per gallon or 7.8 ml per liter). Do not use an alcohol based stabilizer (ethanol

or methanol).

Note: A fuel stabilizer/conditioner is most effective when

mixed with fresh gasoline and used at all times.

A. Run the engine to distribute the conditioned fuel

through the fuel system (5 minutes).

B. Stop the engine, allow it to cool, and drain the fuel

tank; refer to Draining the Fuel Tank, page 27. C. Restart the engine and run it until it stops. D. Choke or prime the engine. Start and run the engine

until it will not start. Operate the primer, if

equipped, several times to ensure no fuel remains in

the primer system. E. Dispose of fuel properly. Recycle as per local codes.

Important Do not store stabilizer/conditioned gasoline

over 90 days.

11. Remove the spark plug(s) and check its condition; refer

to Spark Plug, page 24. With the spark plug(s) removed from the engine, pour two tablespoons of engine oil into the spark plug hole. Use the starter to crank the engine and distribute the oil inside the cylinder. Install the spark plug(s). Do not install the wire on the spark plug(s).

12.Clean any dirt and chaff from the top of the mower.

13.Scrape any heavy buildup of grass and dirt from the

underside of the mower, then wash the mower with a garden hose.

14.Check the condition of the drive and mower belts.

15.Check and tighten all bolts, nuts, and screws. Repair or

replace any part that is worn or damaged.

16.Paint all scratched or bare metal surfaces. Paint is

available from your Authorized Service Dealer.

17.Store the machine in a clean, dry garage or storage area.

Remove the key from the ignition switch and keep it in a memorable place. Cover the machine to protect it and keep it clean.

Troubleshooting

Problem Possible Causes Corrective Action

The engine overheats.

1. The engine load is excessive. 1. Reduce ground speed.

2. The oil level in the crankcase is low.

3. The cooling fins and air passages under the engine blower housing are plugged.

4. The air cleaner is dirty. 4. Clean or replace the air cleaner

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

2. Add oil to the crankcase.

3. Remove the obstruction from the cooling fins and air passages.

element.

5. Contact an Authorized Service Dealer.

Problem Corrective ActionPossible Causes

The starter does not crank.

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

6. The blade control (PTO) is engaged.

7. The parking brake is not on. 7. Set the parking brake.

8. The operator is not seated. 8. Sit on the seat.

9. The battery is dead. 9. Charge the battery.

10.The electrical connections are corroded or loose.

11.A fuse is blown. 11.Replace the fuse.

12.A relay or switch is damaged. 12.Contact an Authorized Service

1. The fuel tank is empty. 1. Fill the fuel tank.

2. The fuel valve turned off. 2. Open the fuel valve.

3. The choke is not on. 3. Move the choke lever to On.

4. The air cleaner is dirty. 4. Clean or replace the air cleaner

5. The spark plug wire(s) is loose or disconnected.

6. The spark plug(s) is pitted, fouled, or the gap is incorrect.

6. Move the PTO to Disengaged.

10.Check the electrical connections for good contact.

Dealer.

element.

5. Install the wire(s) on the spark plug.

6. Install a new, correctly gapped spark plug(s).

The engine loses power.

7. There is dirt in fuel filter. 7. Replace the fuel filter.

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

9. There is incorrect fuel in the fuel tank.

10.The oil level in the crankcase is low.

1. The engine load is excessive. 1. Reduce ground speed.

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

3. The oil level in the crankcase is low.

4. The cooling fins and air passages under the engine blower housing are plugged.

5. The spark plug(s) is pitted, fouled, or the gap is incorrect.

6. The vent in the fuel cap is closed.

7. There is dirt in the fuel filter. 7. Replace the fuel filter.

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

8. Contact an Authorized Service Dealer.

9. Drain the tank and replace the fuel with the proper type.

10.Add oil to the crankcase.

3. Add oil to the crankcase.

4. Remove the obstruction from the cooling fins and air passages.

5. Install a new, correctly gapped spark plug(s).

6. Open the vent in the fuel cap.

8. Contact an Authorized Service Dealer.

9. There is incorrect fuel in the fuel tank.

9. Drain the tank and replace the fuel with the proper type.

Problem Corrective ActionPossible Causes

The machine does not drive.

There is abnormal vibration.

Uneven cutting height.

1. The traction belt is worn, loose, or broken.

2. The traction belt is off of the pulley.

1. The engine mounting bolts are loose.

2. The engine pulley, idler pulley, or blade pulley is loose.

3. The engine pulley is damaged. 3. Contact an Authorized Service

4. The cutting blade(s) is/are bent or unbalanced.

5. A blade mounting bolt is loose. 5. Tighten the blade mounting

6. A blade spindle is bent. 6. Contact an Authorized Service

1. The blade(s) is not sharp. 1. Sharpen the blade(s).

2. A cutting blade(s) is/are bent. 2. Install a new cutting blade(s).

3. The mower is not level. 3. Level the mower from

1. Contact an Authorized Service Dealer.

2. Contact an Authorized Service Dealer.

1. Tighten the engine mounting bolts.

2. Tighten the appropriate pulley.

Dealer.

4. Install a new cutting blade(s).

bolt.

Dealer.

side-to-side and front-to-rear.

The blades do not rotate.

4. An anti-scalp wheel is not set correctly.

5. The underside of the mower is dirty.

6. The tire pressure is incorrect. 6. Adjust the tire pressure.

7. A blade spindle is bent. 7. Contact an Authorized Service

1. The drive belt is worn, loose or broken.

2. The drive belt is off of the pulley.

3. The mower belt is worn, loose, or broken.

4. Adjust the anti-scalp wheel height.

5. Clean the underside of the mower.

Dealer.

1. Install a new drive belt.

2. Install the drive belt and check the adjusting shafts and belt guides for the correct position.

3. Install a new mower belt.

Consumer Riding Products

The Toro Total Coverage Guarantee

A Two-Year Full Warranty

(Limited Warranty for Commercial Use)

Conditions and Products Covered

The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair any Toro Product used for normal residential purposes* if defective in materials or workmanship. The following time periods apply from the date of purchase:

Products

• All Products 2 year full warranty

• 300 and 5xi Series Tractors:

Frame 5 year full warranty Front Axle 5 year full warranty Drive Shaft (5xi Series Only) 5 year full warranty

• All Batteries 1 year full warranty

This warranty covers both the cost of parts and labor, and transportation within a fifteen mile radius of the servicing dealer.

This warranty applies to all consumer riding products and their attachments.

* Normal residential purposes means use of the product on the

same lot as your home. Use at more than one location is considered commercial use, and the commercial use warranty would apply.

Warranty Period

Limited Warranty for Commercial Use

Toro Consumer Products and attachments used for commercial, institutional, or rental use are warranted against defects in materials or workmanship for the following time periods from the date of purchase:

Products

• 300 and 5xi Series Tractors Liquid Cooled Gas Engines 1 year limited warranty Air Cooled Gas and Diesel

Engines All other items 1 year limited warranty

• All other Riding Products 90 day limited warranty

Warranty Period

2 year limited warranty

Instructions for Obtaining Warranty Service

If you think that your T oro Product contains a defect in materials or workmanship, follow this procedure:

1. Contact any Toro Authorized or Master Service Dealer to arrange service at their dealership. To locate a dealer convenient to you, refer to the Y ellow Pages of your telephone directory (look under “Lawn Mowers”) or access our website at www.Toro.com. U.S. Customers may also call 800-421-9684 to use our 24-hour Toro dealer locator system.

2. Bring the product and your proof of purchase (sales receipt) to the Service Dealer.

If for any reason you are dissatisfied with the Service Dealer’s analysis or with the assistance provided, contact us at:

Customer Care Department, Consumer Division Toro Warranty Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196 800-348-2424 (U.S. customers) 877-484-9255 (Canada customers)

Owner Responsibilities

You must maintain your Toro Product by following the maintenance procedures described in the operator’s manual. Such routine maintenance, whether performed by a dealer or by you, is at your expense.

Items and Conditions Not Covered

There is no other express warranty except for special emission system coverage on some products. This express warranty does not cover:

• Cost of regular maintenance service or parts, such as filters, fuel, lubricants, tune-up parts, blade sharpening, brake and clutch adjustments.

• Any product or part which has been altered or misused or required replacement or repair due to normal wear, accidents, or lack of proper maintenance.

• Repairs necessary due to improper fuel, contaminants in the fuel system, or failure to properly prepare the fuel system prior to any period of non-use over three months.

• Pickup and delivery charges for distances beyond a fifteen mile radius from an Authorized Toro Service Dealer.

All repairs covered by this warranty must be performed by an Authorized T oro Service Dealer using Toro approved replacement parts.

General Conditions

Repair by an Authorized Toro Service Dealer is your sole remedy under this warranty.

Neither The Toro Company nor Toro Warranty Company is liable for indirect, incidental or consequential damages in connection with the use of the Toro Products covered by this warranty, including any cost or expense of providing substitute equipment or service during reasonable periods of malfunction or non-use pending completion of repairs under this warranty.

Some states do not allow exclusions of incidental or consequential damages, or limitations on how long an implied warranty lasts, so the above exclusions and limitations may not apply to you.

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

Countries Other than the United States or Canada

Customers who have purchased Toro products exported from the United States or Canada should contact their Toro Distributor (Dealer) to obtain guarantee policies for your country, province, or state. If for any reason you are dissatisfied with your Distributor’s service or have difficulty obtaining guarantee information, contact the Toro importer. If all other remedies fail, you may contact us at Toro Warranty Company.

Part No. 374-0045 Rev. –

Toro 74801 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual