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Toro
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74904
Operator's Manual
80 pgs61.85 Mb0
Operator's Manual
76 pgs3.63 Mb0
Operator's Manual
72 pgs4.92 Mb0
Operator's Manual [es]
80 pgs3.68 Mb0
Operator's Manual [es]
88 pgs5.68 Mb0
Operator's Manual [es]
76 pgs3.79 Mb0
Operator's Manual [es]
76 pgs4.97 Mb0
Operator's Manual [fr]
80 pgs3.67 Mb0
Operator's Manual [fr]
88 pgs5.67 Mb0
Operator's Manual [fr]
76 pgs4.96 Mb0
Parts Catalogue
60 pgs2.13 Mb0
Parts Catalogue
52 pgs1.93 Mb0
Service Manual
46 pgs132.19 Mb0
Service Manual
188 pgs391.85 Mb0
Setup Instructions
16 pgs119.7 Mb0
Software Guide
12 pgs4.88 Mb0
Warranty
1 pgs5.92 Mb0
Warranty
1 pgs10.3 Mb0
Table of contents
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Toro 74904, 74906, 74918, 74926, 74930 Operator's Manual

...
Download
FormNo.3424-649RevA
ZMaster
®
Professional5000or
6000SeriesRidingMower
with48in,52in,60in,or72inTURBOFORCE SideorRearDischargeMower
®
Registeratwww.T oro.com. OriginalInstructions(EN)
*3424-649*A
ItisaviolationofCaliforniaPublicResourceCode Section4442or4443touseoroperatetheengineon anyforest-covered,brush-covered,orgrass-covered landunlesstheengineisequippedwithaspark arrester,asdenedinSection4442,maintainedin effectiveworkingorderortheengineisconstructed, equipped,andmaintainedforthepreventionofre.
GrossorNetTorque:Thegrossornettorque ofthisenginewaslaboratoryratedbytheengine manufacturerinaccordancewiththeSocietyof AutomotiveEngineers(SAE)J1940orJ2723.As conguredtomeetsafety,emission,andoperating requirements,theactualenginetorqueonthisclass ofmowerwillbesignicantlylower.
Pleaserefertotheenginemanufacturer’sinformation includedwiththemachine.
WARNING
CALIFORNIA
Proposition65Warning
Theengineexhaustfromthisproduct
containschemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orotherreproductiveharm.
Batteryposts,terminals,andrelated
accessoriescontainleadandlead
compounds,chemicalsknownto
theStateofCaliforniatocause
cancerandreproductiveharm.Wash
handsafterhandling.
Useofthisproductmaycauseexposure
tochemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orotherreproductiveharm.
Introduction
Thisrotary-blade,ridinglawnmowerisintendedtobe usedbyprofessional,hiredoperators.Itisdesigned primarilyforcuttinggrassonwell-maintainedlawnson residentialorcommercialproperties.Itisnotdesigned forcuttingbrushorforagriculturaluses.
Readthisinformationcarefullytolearnhowtooperate andmaintainyourproductproperlyandtoavoid injuryandproductdamage.Youareresponsiblefor operatingtheproductproperlyandsafely .
YoumaycontactT orodirectlyatwww.Toro.com forproductsafetyandoperationtrainingmaterials, accessoryinformation,helpndingadealer,orto registeryourproduct.
FortheOperator’sManual,thecompletewarranty details,ortoregisteryourproduct,usetheQR codeorvisitwww.Toro.com.Y oumayalsocallus at1-888-384-9939torequestawrittencopyofthe productwarranty.
Wheneveryouneedservice,genuineToroparts,or additionalinformation,contactanAuthorizedService DealerorToroCustomerServiceandhavethemodel andserialnumbersofyourproductready.Figure1 identiesthelocationofthemodelandserialnumbers ontheproduct.Writethenumbersinthespace provided.
Important:Withyourmobiledevice,youcan
scantheQRcode(ifequipped)ontheserial numberdecaltoaccesswarranty,parts,andother productinformation.
©2018—TheToro®Company 8111LyndaleAvenueSouth Bloomington,MN55420
1.Modelandserialnumberlocation
2
g233771
Figure1
Contactusatwww.Toro.com.
PrintedintheUSA
AllRightsReserved
ModelNo.
SerialNo.
Thismanualidentiespotentialhazardsandhas safetymessagesidentiedbythesafety-alertsymbol (Figure2),whichsignalsahazardthatmaycause seriousinjuryordeathifyoudonotfollowthe recommendedprecautions.
Figure2
Safety-alertsymbol
Thismanualuses2wordstohighlightinformation. Importantcallsattentiontospecialmechanical informationandNoteemphasizesgeneralinformation worthyofspecialattention.
Contents
Safety.......................................................................4
GeneralSafety...................................................4
SlopeIndicator...................................................5
SafetyandInstructionalDecals..........................6
ProductOverview...................................................14
Controls...........................................................14
Specications..................................................16
MachineswithSideDischarge..........................16
MachineswithRearDischarge.........................16
BeforeOperation.................................................17
BeforeOperationSafety...................................17
AddingFuel......................................................18
PerformingDailyMaintenance..........................18
BreakinginaNewMachine..............................18
UsingtheRollover-ProtectionSystem
(ROPS).........................................................19
UsingtheSafety-InterlockSystem....................20
PositioningtheSeat..........................................21
UnlatchingtheSeat..........................................21
ChangingtheSeatSuspension.........................21
AdjustingtheMyRide™Suspension
System..........................................................22
DuringOperation.................................................23
DuringOperationSafety...................................23
EnteringtheOperator’sPosition.......................24
OperatingtheParkingBrake.............................25
OperatingtheMowerBlade-ControlSwitch
(PTO)............................................................25
OperatingtheThrottle.......................................25
StartingtheEngine...........................................26
ShuttingOfftheEngine.....................................26
UsingtheMotion-ControlLevers.......................27
DrivingtheMachine..........................................27
UsingtheSideDischarge.................................28
AdjustingtheHeightofCut...............................29
AdjustingtheAnti-ScalpRollers........................30
AdjustingtheAnti-ScalpRollers........................30
AdjustingtheSkid(s).........................................31
AdjustingtheFlowBafeCamLocks................32
PositioningtheFlowBafe................................32
OperatingTips.................................................33
AfterOperation....................................................34
AfterOperationSafety......................................34
UsingtheFuel-ShutoffValve.............................34
g000502
UsingtheDrive-Wheel-ReleaseValves............34
TransportingtheMachine.................................35
Maintenance...........................................................37
RecommendedMaintenanceSchedule(s)...........37
Pre-MaintenanceProcedures..............................38
MaintenanceSafety..........................................38
Lubrication..........................................................38
GreasingtheMachine.......................................38
AddingLightOilorSprayLubrication................39
GreasingtheMowerDeck................................39
LubricatingtheCaster-WheelHubs..................41
EngineMaintenance...........................................42
EngineSafety...................................................42
ServicingtheAirCleaner..................................42
ServicingtheEngineOil....................................43
ServicingtheSparkPlug...................................45
CheckingtheSparkArrester.............................47
FuelSystemMaintenance...................................47
ServicingtheElectronicFuel-Injection
System..........................................................47
ReplacingtheLow-PressureFuel
Filter..............................................................47
ServicingtheHigh-PressureFuelFilter.............48
ServicingtheFuelT ank.....................................48
ElectricalSystemMaintenance...........................48
ElectricalSystemSafety...................................48
ServicingtheBattery.........................................48
ServicingtheFuses..........................................50
Jump-StartingtheMachine...............................50
DriveSystemMaintenance..................................52
CheckingtheSeatBelt.....................................52
CheckingtheRoll-BarKnobs............................52
AdjustingtheTracking......................................53
CheckingtheTirePressure...............................53
CheckingtheWheelLugNuts...........................53
CheckingtheWheel-HubSlottedNut................53
AdjustingtheCaster-PivotBearing...................54
UsingtheClutchShim......................................54
CoolingSystemMaintenance..............................56
CleaningtheEngineScreenandEngine-Oil
Cooler...........................................................56
CleaningtheEngine-CoolingFinsand
Shrouds........................................................57
3
CheckingandCleaningtheHydraulic-Unit
Shrouds........................................................57
BrakeMaintenance.............................................58
AdjustingtheParkingBrake..............................58
BeltMaintenance................................................59
InspectingtheBelts..........................................59
ReplacingtheMowerBeltforSide-Discharge
MowerDecks................................................59
ReplacingtheMowerBeltforRear-Discharge
MowerDecks................................................60
ReplacingtheHydraulicPump-Drive
Belt................................................................61
ControlsSystemMaintenance.............................62
AdjustingtheControl-HandlePosition..............62
AdjustingtheMotion-ControlLinkage...............63
AdjustingtheMotion-ControlDamper...............64
AdjustingtheMotion-ControlNeutral-Lock
Pivot..............................................................64
HydraulicSystemMaintenance...........................65
HydraulicSystemSafety...................................65
ServicingtheHydraulicSystem........................65
MowerDeckMaintenance....................................67
LevelingtheMowerDeck..................................67
ServicingtheCuttingBlades.............................69
RemovingtheMowerDeck...............................72
ReplacingtheGrassDeector..........................73
Cleaning..............................................................74
CleaningundertheMowerDeck.......................74
CleaningtheSuspensionSystem.....................74
DisposingofWaste...........................................74
Storage...................................................................75
StorageSafety..................................................75
CleaningandStorage.......................................75
Troubleshooting......................................................76
Schematics.............................................................79
Safety
Thismachinehasbeendesignedinaccordancewith ANSIB71.4-2012.

GeneralSafety

Thisproductiscapableofamputatinghandsand feetandofthrowingobjects.Alwaysfollowallsafety instructionstoavoidseriouspersonalinjury.
Usingthisproductforpurposesotherthanitsintended usecouldprovedangeroustoyouandbystanders.
•Alwayskeeptherollbarinthefullyraisedand
lockedpositionandusetheseatbelt.
•Donotoperatethemachineneardrop-offs,
ditches,embankments,water,orotherhazards,or onslopesgreaterthan15degrees.
•Readandunderstandthecontentsofthis
Operator’sManualbeforestartingtheengine.
•Donotputyourhandsorfeetnearmoving
componentsofthemachine.
•Donotoperatethemachinewithoutallguards
andothersafetyprotectivedevicesinplaceand workingonthemachine.
•Keepchildrenandbystandersoutoftheoperating
area.Neverallowchildrentooperatethemachine.
•Stopthemachine,shutofftheengine,andremove
thekeybeforeservicing,fueling,orunclogging themachine.
Improperlyusingormaintainingthismachinecan resultininjury.T oreducethepotentialforinjury, complywiththesesafetyinstructionsandalwayspay attentiontothesafety-alertsymbol,whichmeans Caution,Warning,orDanger—personalsafety instruction.Failuretocomplywiththeseinstructions mayresultinpersonalinjuryordeath.
Youcanndadditionalsafetyinformationwhere neededthroughoutthismanual.
4
SlopeIndicator
Figure3
Youmaycopythispageforpersonaluse.
1.Themaximumslopeyoucanoperatethemachineonis15degrees.Usetheslopecharttodeterminethedegreeofslopeof hillsbeforeoperating.Donotoperatethismachineonaslopegreaterthan15degrees.Foldalongtheappropriateline tomatchtherecommendedslope.
2.Alignthisedgewithaverticalsurface,atree,building,fencepole,etc.
3.Exampleofhowtocompareslopewithfoldededge
5
g011841
SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyarea ofpotentialdanger.Replaceanydecalthatisdamagedormissing.
BatterySymbols
Someorallofthesesymbolsareonyourbattery .
decal93-7818
93-7818
decalbatterysymbols
1.Warning—readtheOperator'sManualforinstructionson torquingthebladebolt/nutto1 15to149N∙m(85to110 ft-lb).
1.Explosionhazard
6.Keepbystandersasafe distanceawayfromthe battery.
2.Nore,opename,or smoking
7.Weareyeprotection; explosivegasescan causeblindnessandother injuries.
3.Causticliquid/chemical burnhazard
8.Batteryacidcancause blindnessorsevereburns.
4.Weareyeprotection.9.Flusheyesimmediately withwaterandgetmedical helpfast.
5.ReadtheOperator's
Manual.
10.Containslead;donot discard
Manufacturer'sMark
1.Thismarkindicatesthatthebladeisidentiedasapart fromtheoriginalmachinemanufacturer.
decal99-8936
99-8936
1.Machinespeed4.Neutral
decaloemmarkt
2.Fast5.Reverse
3.Slow
decal58-6520
58-6520
1.Grease
1.Warning-donottouchorapproachmovingbelts;remove
106-2655
decal106-2655
theignitionkeyandreadtheinstructionsbeforeservicing orperformingmaintenance.
6
1.Warning—donottouchthehotsurface.
decal106-5517
106-5517
decal109-6036
109-6036
MachineswithRearDischargeOnly
1.ReadtheOperator’sManual.
2.Removethekeyfromthekeyswitchandreadthe instructionsbeforeservicingorperformingmaintenance.
3.Heightofcut
decal107-3069
107-3069
1.Warning–thereisnorolloverprotectionwhentherollbaris down.
2.Toavoidinjuryordeathfromarolloveraccident,keepthe rollbarintheraisedandlockedpositionandweartheseat belt.Lowertherollbaronlywhenabsolutelynecessary;do notweartheseatbeltwhentherollbarisdown.
3.ReadtheOperator'sManual;driveslowlyandcarefully .
decal110-2067
110-2067
decal110-2068
110-2068
1.ReadtheOperator'sManual.
7
112-9028
1.Warning—stayawayfrommovingparts;keepallguards andshieldsinplace.
115-9625
MachineswithMyRide™Only
decal112-9028
decal115-9625
1.Parking brake—disengaged
133-8062
116-5988
MachineswithoutMyRide™Only
1.Parkingbrake—engaged2.Parking
2.Parkingbrake—engaged
decal117-0346
117-0346
1.Fuelleakhazard—readtheOperator'sManual;donot attempttoremovetherollbar;donotweld,drill,ormodify therollbarinanyway.
decal133-8062
decal117-3848
117-3848
decal116-5988
brake—disengaged
1.Thrownobjecthazard—keepbystandersasafedistance awayfromthemachine.
2.Thrownobjecthazard,mower-donotoperatethemachine withoutthedeector ,dischargecover,orgrasscollection systeminplace.
3.Cutting/dismembermentofhandorfoot—stayawayfrom movingparts;keepallguardsandshieldsinplace.
116-8726
1.ReadtheOperator’sManualfortherecommendedhydraulic uid.
decal116-8726
8
decal119-6807
119-6807
1.Warning—nostep
decal117-3864
117-3864
1.ReadtheOperator’s Manual.
2.Filltobottomofllerneck; warning—donotoverll thetank.
decal125-9383
125-9383
1.Checkthehydraulicuidevery50operatinghours.3.Checkthetirepressureevery50operatinghours.
2.ReadtheOperator’sManualforinformationonlubricating themachine.
decal126-2055
4.ReadtheOperator’sManualbeforeservicingorperforming maintenance.
126-2055
1.Wheellugnuttorque129N∙m(95ft-lb)(4x)
2.Wheelhubnuttorque319N∙m(235ft-lb)
3.ReadandunderstandtheOperator’sManualbefore performinganymaintenance,checktorqueafterrst100 hoursthenevery500hoursthereafter.
9
decal126-7875
126-7875
1.Fuselocation4.Auxiliary,15A
2.Relaylocation
5.Startrelay
3.Main,20A6.Notused
decal126-4398
126-4398
1.ReadtheOperator’s Manual.
2.Lock
126-4659
1.Warning—hotpulley;allowtocool.
3.Unlock
decal127-0326
127-0326
decal126-4659
1.ReadtheOperator's
2.Height-of-cut
MachineswithSideDischargeOnly
Manual.
3.Removethekeyfromthe keyswitchandreadthe Operator'sManualbefore performingmaintenance orservicingthemachine.
126-5641
1.PTO4.Operator-presenceswitch
2.Parkingbrake
3.Neutral
5.Seeuser’sguidefor operatingconditioncode
g224114
decal127-6661
127-6661
Rear-DischargeMachinesOnly
1.Attention—readtheOperator'sManualforinformationon removingtheblade.
10
decal127-6663
127-6663
1.Warning—readthe Operator'sManual.
2.Crushinghazard—1) Engagetheparkingbrake, shutofftheengine,and removethekey;2)Jack themachineusinga manufacturer-approved jack,andalwaysusea jackstand.
decal136-5508
136-5508
Side-DischargeMachinesOnly
1.Beltrouting
132-5063
MachineswithMyRide™Only
1.Camlock2.Camunlock
decal132-5063
11
132-0871
Note:Thismachinecomplieswiththeindustrystandardstabilitytestinthestaticlateralandlongitudinaltestswiththemaximum
recommendedslopeindicatedonthedecal.ReviewtheinstructionsforoperatingthemachineonslopesintheOperator’sManualas wellastheconditionsinwhichyouwouldoperatethemachinetodeterminewhetheryoucanoperatethemachineinthoseconditions onthatdayandatthatsite.Changesintheterraincanresultinachangeinslopeoperationforthemachine.Ifpossible,keepthe cuttingunitsloweredtothegroundwhileoperatingthemachineonslopes.Raisingthecuttingunitswhileoperatingonslopescan causethemachinetobecomeunstable.
decal132-0871
1.Warning—readtheOperator’sManual;donotoperatethis machineunlessyouaretrained;wearhearingprotection.
4.Ramphazard—whenloadingontoatrailer,donotusedual ramps;onlyuseasingularrampwideenoughforthemachine andthathasaninclinelessthan15°;backuptheramp(in reverse)anddriveforwardofftheramp.
2.Cutting,dismembering,andentanglementhazard—keep handsawayfrommovingparts;keepallguardsandshieldsin
5.Bodilyharmhazard—donotcarrypassengers;lookbehind youwhenmowinginreverse.
place.
3.Thrownobjecthazard—keepbystandersaway .6.Tippinghazardonslopes—donotuseonslopesnearopen water;donotuseonslopesgreaterthan15°.
132-5067
MachineswithMyRide™Only
decal132-5067
12
1.Fast4.Engine—stop
2.Slow
3.PTO
decal136-5522
136-5522
Rear-DischargeMachinesOnly
decal137-9208
137-9208
5.Engine—run
6.Engine—start
1.Beltrouting;readtheOperator’sManualforgreasing
information.
13
ProductOverview
Figure4
1.Grassdeector
(side-dischargemachines)
2.Height-of-cutdeck-lift
pedal
3.Parking-brakelever10.Fuelcap
4.Transportlock11.Mowerdeck
5.Controls12.Casterwheel
6.Motion-controllevers13.Front-shockassembly
7.Rollbar
8.Rear-shockassembly
9.Seatbelt
(machineswithMyRide only)
(machineswithMyRide only)
Controls
Becomefamiliarwithallthecontrolsbeforeyoustart theengineandoperatethemachine.
ControlPanel
g232246
g029631
1.Blade-controlswitch (powertakeoff)
2.Throttlecontrol4.Keyswitch
HourMeter
Thehourmeterrecordsthenumberofhoursthe enginehasoperated.Itoperateswhentheengine isrunning.Usethesetimesforschedulingregular maintenance(Figure6).
Thehourmeterdisplayswhenyouareoperating themachineandmomentarilywhenyoushutoffthe engine.Thedisplayturnsoffafter5minutes.
Figure5
3.Hour meter/Safety-interlock display
RefertotheSoftwareGuideformoreinformation.
Figure6
1.Safety-interlockindicators3.Informationscreen
2.LEDstatuslight
g231075
14
FuelGauge
Fuel-ShutoffValve
Whenthefuel-tanklevelislow,theLEDstatuslight ashesaredlightandthefuel-levelsymbolonthe screenashes.
RefertotheSoftwareGuideformoreinformation.
Safety-InterlockIndicators
Therearesymbolsonthehourmeterthatindicatewith ablackbarthattheinterlockcomponentispositioned correctly(Figure6).
ThrottleControl
Thethrottlecontrolstheenginespeed,andithasa continuous-variablesettingfromtheSLOWtoFAST position(Figure5).
ChokeControl
Usethechokecontroltostartacoldengine.
Blade-ControlSwitch(Power
Closethefuel-shutoffvalvewhentransportingor storingthemachine;refertoUsingtheFuel-Shutoff
Valve(page34).
Attachments/Accessories
AselectionofToroapprovedattachmentsand accessoriesisavailableforusewiththemachine toenhanceandexpanditscapabilities.Contact yourAuthorizedServiceDealerorauthorizedT oro distributororgotowww.Exmark.comforalistofall approvedattachmentsandaccessories.
Toensureoptimumperformanceandcontinuedsafety certicationofthemachine,useonlygenuineT oro replacementpartsandaccessories.Replacement partsandaccessoriesmadebyothermanufacturers couldbedangerous,andsuchusecouldvoidthe productwarranty.
Takeoff)
Theblade-controlswitch,representedbya power-takeoff(PTO)symbol,engagesand disengagespowertothemowerblades(Figure5).
KeySwitch
Thekeyswitch,usedtostartandshutofftheengine, has3positions:OFF,RUN,andSTART.Referto
StartingtheEngine(page26).
Motion-ControlLevers
Usethemotion-controlleverstodrivethemachine forward,reverse,andturneitherdirection(Figure4).
Neutral-LockPosition
UsetheNEUTRAL-LOCKpositionwiththe safety-interlocksystemtoengageandtodetermine theNEUTRALposition.
15
Specications
Note:Specicationsanddesignaresubjecttochangewithoutnotice.

MachineswithSideDischarge

Width:
48-inch Deck
Without Deck
Deector Up
Deector Down
116cm116cm135cm150cm
(46 inches)
137cm146cm157cm187cm
(54 inches)
161cm172cm192cm222cm
(64 inches)
Length:
48-inch Deck
Roll Bar—Up
Roll Bar—Down
201cm201cm211cm219cm
(79 inches)
206cm206cm215cm223cm
(81 inches)
Height:
RollBar—UpRollBar—Down
179.1cm(70.5inches)118.9cm(46.8inches)
52-inch Deck
(46 inches)
(58 inches)
(68 inches)
52-inch Deck
(79 inches)
(81 inches)

MachineswithRearDischarge

Width:
60-inch Deck
(53 inches)
(62 inches)
(76 inches)
60-inch Deck
(83 inches)
(85 inches)
72-inch Deck
WithoutMower
(59 inches)
(74 inches)
(88 inches)
72-inch Deck
Deck
WithMowerDeck
Length:
RollBar-Up
RollBar-Down
60-inchMower Deck
134.6cm150.1cm
(53.0inches)(59.1inches)
168.4cm199.0cm
(66.3inches)(78.3inches)
60-inchMower Deck
221.6cm(87.25 inches)
226.0cm(88.95 inches)
72-inchMower Deck
72-inchMower Deck
221.6cm(87.25 inches)
226.0cm(88.95 inches)
Height:
(86 inches)
(88 inches)
RollBar-UpRollBar-Down
179.1cm(70.5inches)118.9cm(46.8inches)
Weight:
ModelWeight
60-inchMowerDeck
72-inchMowerDeck
577kg(1,271lb)
606kg(1,335lb)
Weight:
ModelWeight
48-inchMowerDeck
52-inchMowerDeck
60-inchMowerDeck
72-inchMowerDeck
508kg(1,120lb)
533kg(1,174lb)
569kg(1,255lb)
612kg(1,350lb)
16
Operation
Note:Determinetheleftandrightsidesofthe
machinefromthenormaloperatingposition.
BeforeOperation

BeforeOperationSafety

•Donotllcontainersinsideavehicleoronatruck
ortrailerbedwithaplasticliner.Alwaysplace containersontheground,awayfromyourvehicle beforelling.
•Removetheequipmentfromthetruckortrailer
andrefuelitwhileitisontheground.Ifthisisnot possible,thenrefuelfromaportablecontainer ratherthanafuel-dispensernozzle.
•Donotoperatethemachinewithouttheentire
exhaustsysteminplaceandinproperworking condition.

GeneralSafety

•Neverallowchildrenoruntrainedpeopleto
operateorservicethemachine.Localregulations mayrestricttheageoftheoperator.Theowner isresponsiblefortrainingalloperatorsand mechanics.
•Becomefamiliarwiththesafeoperationofthe
equipment,operatorcontrols,andsafetysigns.
•Knowhowtostopthemachineandshutoffthe
enginequickly.
•Checkthatoperator-presencecontrols,safety
switches,andshieldsareattachedandfunctioning properly.Donotoperatethemachineunlessthey arefunctioningproperly.
•Beforemowing,alwaysinspectthemachineto
ensurethattheblades,bladebolts,andcutting assembliesareingoodworkingcondition. Replacewornordamagedbladesandboltsinsets topreservebalance.
•Inspecttheareawhereyouwillusethemachine
andremoveallobjectsthatthemachinecould throw.
•Keepthefuel-dispensernozzleincontactwith
therimofthefueltankorcontaineropeningat alltimesuntilfuelingiscomplete.Donotusea nozzlelock-opendevice.
•Ifyouspillfuelonyourclothing,changeyour
clothingimmediately.Wipeupanyfuelthatspills.
•Neveroverllthefueltank.Replacethefuelcap
andtightenitsecurely.
•Storefuelinanapprovedcontainerandkeepit
outofthereachofchildren.Neverbuymorethan a30-daysupplyoffuel.
•Donotllthefueltankcompletelyfull.Addfuelto
thefueltankuntilthelevelis6to13mm(1/4to 1/2inch)belowthebottomofthellerneck.This emptyspaceinthetankallowsfueltoexpand.
–Avoidprolongedbreathingofvapors.
–Keepyourfaceawayfromthenozzleandfuel
tankopening.
–Avoidcontactwithskin;washoffspillswith
soapandwater.
•Evaluatetheterraintodeterminetheappropriate
equipmentandanyattachmentsoraccessories requiredtooperatethemachineproperlyand safely.

FuelSafety

•Toavoidpersonalinjuryorpropertydamage,use
extremecareinhandlingfuel.Fuelvaporsare ammableandexplosive.
•Extinguishallcigarettes,cigars,pipes,andother
sourcesofignition.
•Useonlyanapprovedfuelcontainer.
•Donotremovethefuelcaporaddfueltothefuel
tankwhiletheengineisrunningorwhilehot.
•Donotrefuelthemachineindoors.
•Donotstorethemachineorfuelcontainerwhere
thereisanopename,spark,orpilotlight,such asonawaterheateroronotherappliances.
17

AddingFuel

RecommendedFuel

•Forbestresults,useonlyclean,fresh(lessthan
30daysold),unleadedgasolinewithanoctane ratingof87orhigher((R+M)/2ratingmethod).
•Ethanol:Gasolinewithupto10%ethanol
(gasohol)or15%MTBE(methyltertiarybutyl ether)byvolumeisacceptable.Ethanoland MTBEarenotthesame.Gasolinewith15% ethanol(E15)byvolumeisnotapprovedforuse.
Neverusegasolinethatcontainsmorethan 10%ethanolbyvolume,suchasE15(contains
15%ethanol),E20(contains20%ethanol),orE85 (containsupto85%ethanol).Usingunapproved gasolinemaycauseperformanceproblemsand/or enginedamagewhichmaynotbecoveredunder warranty.
•Donotusegasolinecontainingmethanol.
•Donotstorefueleitherinthefueltankorfuel
containersoverthewinterunlessyouuseafuel stabilizer.
•Donotaddoiltogasoline.

UsingStabilizer/Conditioner

Usefuelstabilizer/conditionerinthemachineatall timestokeepthefuelfreshlongerwhenusedas directedbythefuel-stabilizermanufacturer.
Important:Donotusefueladditivescontaining
methanolorethanol.
Addtheamountoffuelstabilizer/conditionertofresh fuelasdirectedbythefuel-stabilizermanufacturer.

FillingtheFuelTank

1.Parkthemachineonalevelsurface.
2.Engagetheparkingbrake.
3.Shutofftheengineandremovethekey.
4.Cleanaroundthefuel-tankcap.
5.Fillthefueltankuntilthefuelgaugereadsatthe fullmark(Figure7).
Note:Donotllthefueltankcompletelyfull.
Theemptyspaceinthetankallowsthefuelto expand.
g027726
Figure7

PerformingDaily Maintenance

Beforestartingthemachineeachday ,performthe EachUse/DailyprocedureslistedinMaintenance
(page37).

BreakinginaNewMachine

Newenginestaketimetodevelopfullpower.Mower decksanddrivesystemshavehigherfrictionwhen new,placingadditionalloadontheengine.Allow 40to50hoursofbreak-intimefornewmachinesto developfullpowerandbestperformance.
18

Usingthe Rollover-ProtectionSystem (ROPS)

WARNING
Toavoidinjuryordeathfromrollover,keep therollbarinthefullyraised,lockedposition andusetheseatbelt.
Ensurethattheseatissecuredtothe machine.
WARNING
Thereisnorolloverprotectionwhentheroll barisinthedownposition.
•Lowertherollbaronlywhenabsolutely necessary.
•Donotweartheseatbeltwhentherollbar isinthedownposition.
•Driveslowlyandcarefully.
•Raisetherollbarassoonasclearance permits.
•Checkcarefullyforoverheadclearances (i.e.,branches,doorways,electricalwires) beforedrivingunderanyobjectsanddo notcontactthem.

LoweringtheRollBar

Important:Lowertherollbaronlywhen
absolutelynecessary.
1.T olowertherollbar,applyforwardpressureto theupperpartoftherollbar.
2.Pullbothknobsoutandrotatethem90degrees sotheyarenotengaged(Figure8).
3.Lowertherollbartothedownposition(Figure
8).
Figure8
1.Rollbarintheupright position
2.ROPSknobinthelatched position
3.PulltheROPSknobout.6.Rollbarinthefolded
4.RotatetheROPSknob90 degrees.
5.ROPSknobinthe unlatchedposition
position

RaisingtheRollBar

Important:Alwaysusetheseatbeltwiththeroll
barintheraisedposition.
1.Raisetherollbartotheoperatingpositionand rotatetheknobsuntiltheymovepartiallyinto thegrooves(Figure8).
g228804
2.Raisetherollbartothefulluprightpositionwhile pushingontheupperrollbarsothatthepins snapintopositionwhentheholesalignwiththe pins(Figure8).
3.Pushontherollbarandensurethatbothpins areengaged.
19

UsingtheSafety-Interlock System

TestingtheSafety-Interlock System

ServiceInterval:Beforeeachuseordaily
WARNING
Ifthesafety-interlockswitchesare disconnectedordamaged,themachinecould operateunexpectedly,causingpersonal injury.
•Donottamperwiththeinterlockswitches.
•Checktheoperationoftheinterlock switchesdailyandreplaceanydamaged switchesbeforeoperatingthemachine.

Understandingthe Safety-InterlockSystem

Thesafety-interlocksystemisdesignedtopreventthe enginefromstartingunless:
•Theparkingbrakeisengaged.
•Theblade-controlswitch(PTO)isdisengaged.
•Themotion-controlleversareintheNEUTRAL-LOCK
position.
Thesafety-interlocksystemalsoisdesignedtoshut offtheenginewhenthemotion-controlleversare movedfromtheNEUTRAL-LOCKpositionwiththe parkingbrakeengagedorifyourisefromtheseat whenthePTOisengaged.
Thehourmeterhassymbolstonotifytheuserwhen theinterlockcomponentisinthecorrectposition. Whenthecomponentisinthecorrectposition,ablack bardisplaysbelowthecorrespondingicon.
Testthesafety-interlocksystembeforeyouusethe machineeachtime.Ifthesafetysystemdoesnot operateasdescribedbelow,haveanAuthorized ServiceDealerrepairthesafetysystemimmediately .
1.Sitontheseat,engagetheparkingbrake,and movetheblade-controlswitch(PTO)totheON position.Trystartingtheengine;theengine shouldnotstart.
2.Sitontheseat,engagetheparkingbrake,and movetheblade-controlswitch(PTO)totheOFF position.Moveeithermotion-controlleverout oftheNEUTRAL-LOCKposition.Trystartingthe engine;theengineshouldnotstart.Repeatfor theothercontrollever.
3.Sitontheseat,engagetheparkingbrake, movetheblade-controlswitch(PTO)totheOFF position,andmovethemotion-controllevers totheNEUTRAL-LOCKposition.Nowstartthe engine.Whiletheengineisrunning,disengage theparkingbrake,engagetheblade-control switch(PTO),andriseslightlyfromtheseat;the engineshouldshutoff.
4.Sitontheseat,engagetheparkingbrake, movetheblade-controlswitch(PTO)totheOFF position,andmovethemotion-controllevers totheNEUTRAL-LOCKposition.Nowstartthe engine.Whiletheengineisrunning,center eithermotioncontrolandmove(forwardor reverse);theengineshouldshutoff.Repeatfor othermotioncontrol.
5.Sitontheseat,disengagetheparkingbrake, movetheblade-controlswitch(PTO)totheOFF position,andmovethemotion-controllevers totheNEUTRAL-LOCKposition.Trystartingthe engine;theengineshouldnotstart.
Figure9
1.Blackbarsdisplaywhentheinterlockcomponentsarein thecorrectposition
g231781
20

PositioningtheSeat

Theseatcanmoveforwardandbackward.Position theseatwhereyouhavethebestcontrolofthe machineandaremostcomfortable(Figure10).

MachineswithoutMyRide™ SuspensionSystem

Tounlatchtheseat,pushtheseatlatchforward (Figure12).

UnlatchingtheSeat

MachineswithMyRide™ SuspensionSystem

Figure10
g019754
1.Seatlatch2.Seat
Figure12
g008956

ChangingtheSeat Suspension

MachineswithoutMyRide™ SuspensionSystemOnly
Theseatisadjustabletoprovideasmoothand comfortableride.Positiontheseatwhereyouare mostcomfortable.
Toadjustit,turntheknobinfronteitherdirectionto providethebestcomfort(Figure13).
Figure11
g019768
g204507
1.Seat-suspensionknob
21
Figure13

AdjustingtheMyRide™ SuspensionSystem

MachineswithMyRide™ SuspensionSystemOnly
TheMyRide™suspensionsystemadjuststoprovide asmoothandcomfortableride.Youcanadjustthe rear2-shockassembliestoquicklyandeasilychange thesuspensionsystem.Positionthesuspension systemwhereyouaremostcomfortable.

AdjustingtheRear-Shock Assemblies

Theslotsfortherear-shockassemblieshave detentpositionsforreference.Youcanpositionthe rear-shockassembliesanywhereintheslot,notjust inthedetentpositions.
Thefollowinggraphicshowsthepositionforasoftor rmrideandthedifferentdetentpositions(Figure14).
Adjusttherear-shockassemblies(Figure15).
g030024
Figure14
1.Firmestposition3.Detentsintheslots
2.Softestposition
Note:Ensurethattheleftandrightrear-shock
assembliesarealwaysadjustedtothesamepositions.
g030065
g030019
Figure15
22
DuringOperation

DuringOperationSafety

GeneralSafety

•Theowner/operatorcanpreventandisresponsible
foraccidentsthatmaycausepersonalinjuryor propertydamage.
•Wearappropriateclothing,includingeye
protection;longpants;slip-resistant,substantial footwear;andhearingprotection.Tiebacklong hairanddonotwearloosejewelry .
•Useyourfullattentionwhileoperatingthe
machine.Donotengageinanyactivitythat causesdistractions;otherwise,injuryorproperty damagemayoccur.
•Donotoperatethemachinewhileill,tired,or
undertheinuenceofalcoholordrugs.
•Nevercarrypassengersonthemachineandkeep
bystandersandpetsawayfromthemachine duringoperation.
•Operatethemachineonlyingoodvisibilitytoavoid
holesorhiddenhazards.
•Avoidmowingonwetgrass.Reducedtraction
couldcausethemachinetoslide.
•Ensurethatalldrivesareinneutral,theparking
brakeisengaged,andyouareintheoperating positionbeforeyoustarttheengine.
•Keepyourhandsandfeetawayfromthecutting
units.Keepclearofthedischargeopeningatall times.
•Lookbehindanddownbeforebackinguptobe
sureofaclearpath.
•Usecarewhenapproachingblindcorners,shrubs,
trees,orotherobjectsthatmayobscureyour vision.
•Donotmowneardrop-offs,ditches,or
embankments.Themachinecouldsuddenlyroll overifawheelgoesovertheedgeoriftheedge givesway.
•Stopthebladeswheneveryouarenotmowing.
•Stopthemachine,shutofftheengine,remove
thekey,andinspectthebladesafterstrikingan objectorifthereisanabnormalvibrationinthe machine.Makeallnecessaryrepairsbefore resumingoperation.
•Slowdownandusecautionwhenmakingturns
andcrossingroadsandsidewalkswiththe machine.Alwaysyieldtheright-of-way.
•Disengagethedrivetothecuttingunit,shutoffthe
engine,andremovethekeybeforeadjustingthe heightofcut(unlessyoucanadjustitfromthe operatingposition).
•Neverrunanengineinanareawhereexhaust
gasesareenclosed.
•Neverleavearunningmachineunattended.
•Beforeleavingtheoperatingposition(including
toemptythecatchersortounclogthechute),do thefollowing:
–Stopthemachineonlevelground. –Disengagethepowertakeoffandlowerthe
attachments. –Engagetheparkingbrake. –Shutofftheengineandremovethekey. –Waitforallmovingpartstostop.
•Donotoperatethemachinewhenthereistherisk
oflightning.
•Donotusethemachineasatowingvehicleunless
ithasahitchinstalled.
•Donotchangethegovernorspeedoroverspeed
theengine.
•Useonlyaccessoriesandattachmentsapproved
byToro.
•Thismachineproducessoundlevelsinexcess
of85dBAattheoperator’searandcancause hearinglossthroughextendedperiodsof exposure.
g229846
Figure16
1.Wearhearingprotection.

RolloverProtectionSystem (ROPS)Safety

•Donotremovetherollbarfromthemachine.
•Ensurethattheseatbeltisattachedandthatyou
canreleaseitquicklyinanemergency.
•Alwayswearyourseatbeltwhentherollbarisup.
•Checkcarefullyforoverheadobstructionsanddo
notcontactthem.
•Keeptherollbarinsafeoperatingconditionby
thoroughlyinspectingitperiodicallyfordamage andkeepingallthemountingfastenerstight.
•Replaceadamagedrollbar.Donotrepairoralter
it.

SlopeSafety

•Slopesareamajorfactorrelatedtolossofcontrol
androlloveraccidents,whichcanresultinsevere
23
injuryordeath.Theoperatorisresponsiblefor safeslopeoperation.Operatingthemachineon anysloperequiresextracaution.Beforeusingthe machineonaslope,dothefollowing:
–Reviewandunderstandtheslopeinstructions
inthemanualandonthemachine.
–Useanangleindicatortodeterminethe
approximateslopeangleofthearea.
–Neveroperateonslopesgreaterthan15
degrees.
–Evaluatethesiteconditionsofthedayto
determineiftheslopeissafeformachine operation.Usecommonsenseandgood judgmentwhenperformingthisevaluation. Changesintheterrain,suchasmoisture,can quicklyaffecttheoperationofthemachineon aslope.
•Identifyhazardsatthebaseoftheslope.Do
notoperatethemachineneardrop-offs,ditches, embankments,water,orotherhazards.The machinecouldsuddenlyrolloverifawheelgoes overtheedgeortheedgecollapses.Keepasafe distance(twicethewidthofthemachine)between themachineandanyhazard.Useawalk-behind machineorahandtrimmertomowthegrassin theseareas.
1.SafeZone—usethe machinehereonslopes lessthan15degreesor atareas.
2.DangerZone—usea walk-behindmowerand/or ahandtrimmeronslopes greaterthan15degrees andneardrop-offsor water.
3.Water
g221745
Figure17
4.W=widthofthemachine
5.Keepasafedistance (twicethewidthofthe machine)betweenthe machineandanyhazard.
•Avoidstarting,stopping,orturningthemachineon
slopes.Avoidmakingsuddenchangesinspeedor direction;turnslowlyandgradually.
•Donotoperateamachineunderanyconditions
wheretraction,steering,orstabilityisinquestion. Beawarethatoperatingthemachineonwet grass,acrossslopes,ordownhillmaycausethe machinetolosetraction.Lossoftractiontothe drivewheelsmayresultinslidingandalossof brakingandsteering.Themachinecanslideeven ifthedrivewheelsarestopped.
•Removeormarkobstaclessuchasditches,holes,
ruts,bumps,rocks,orotherhiddenhazards.T all grasscanhideobstacles.Uneventerraincould overturnthemachine.
•Useextracarewhileoperatingwithaccessoriesor
attachments,suchasgrass-collectionsystems. Thesecanchangethestabilityofthemachine andcausealossofcontrol.Followdirectionsfor counterweights.
•Ifpossible,keepthedeckloweredtotheground
whileoperatingonslopes.Raisingthedeckwhile operatingonslopescancausethemachineto becomeunstable.

EnteringtheOperator’s Position

Usethemowerdeckasasteptogetintothe operator’sposition(Figure18).
g029797
Figure18
24
OperatingtheParking
OperatingtheMower
Brake
Alwaysengagetheparkingbrakewhenyoustopthe machineorleaveitunattended.

EngagingtheParkingBrake

Parkthemachineonalevelsurface.
Figure19

DisengagingtheParkingBrake

Blade-ControlSwitch(PTO)
Theblade-controlswitch(PTO)startsandstopsthe mowerbladesandanypoweredattachments.

EngagingtheBlade-Control Switch(PTO)

Note:Engagingtheblade-controlswitch(PTO)with
thethrottlepositionathalforlesscausesexcessive weartothedrivebelts.
g027334
g008945
Figure21
DisengagingtheBlade-Control
Figure20
Switch(PTO)
g009174
g027335
Figure22

OperatingtheThrottle

YoucanmovethethrottlecontrolbetweenFASTand SLOWpositions(Figure23).
AlwaysusetheFASTpositionwhenengagingthePTO.
g008946
Figure23
25

StartingtheEngine

Important:Donotengagestarterformorethan5
secondsatatime.Iftheenginefailstostart,wait 15secondsbetweenattempts.Failuretofollow theseinstructionscanburnoutthestartermotor.
Note:Youmayneedmultipleattemptstostartthe
enginethersttimeafteraddingfueltoanemptyfuel system.

ShuttingOfftheEngine

CAUTION
Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethemachinewhile itisunattended.
Alwaysremovethekeyandengagethe parkingbrakewhenleavingthemachine unattended.
Figure24
g032328
g027337
Figure25
Important:Makesurethatthefuel-shutoffvalve
isclosedbeforetransportingorstoringthe machine,asfuelleakagemayoccur.Engagethe parkingbrakebeforetransporting.Makesurethat youremovethekeyasthefuelpumpmayrunand causethebatterytolosecharge.
26
UsingtheMotion-Control
WARNING
Levers
Themachinecanspinveryrapidly.You maylosecontrolofthemachineandcause personalinjuryordamagetothemachine.
•Usecautionwhenmakingturns.
•Slowthemachinedownbeforemaking sharpturns.

DrivingForward

Note:Theengineshutsoffwhenyoumovethe
traction-controlwiththeparkingbrakeengaged.
Tostopthemachine,pullthemotion-controllevers totheNEUTRALposition.
1.Disengagetheparkingbrake;referto
DisengagingtheParkingBrake(page25).
2.Movetheleverstothecenter,unlockedposition.
3.T ogoforward,slowlypushthemotion-control leversforward(Figure27).
Figure26
1.Motion-control lever—NEUTRAL-LOCK position
2.Center,unlockedposition5.Frontofmachine
3.Forward
4.Backward

DrivingtheMachine

Thedrivewheelsturnindependently,poweredby hydraulicmotorsoneachaxle.Youcanturn1side inreversewhileyouturntheotherforward,causing themachinetospinratherthanturn.Thisgreatly improvesthemachinemaneuverabilitybutmay requiresometimeforyoutoadapttohowitmoves.
Thethrottlecontrolregulatestheenginespeedas measuredinrpm(revolutionsperminute).Place thethrottlecontrolintheFASTpositionforbest performance.Alwaysoperateinthefullthrottle positionwhenmowing.
g004532
g008952
Figure27
27

DrivingBackward

1.Movetheleverstothecenter,unlockedposition.
2.T ogobackward,slowlypullthemotion-control
leversrearward(Figure28).

UsingtheSideDischarge

MachineswithSideDischarge Only
Themowerhasahingedgrassdeectorthat dispersesclippingstothesideanddowntowardthe turf.
DANGER
Withoutagrassdeector,dischargecover,or acompletegrass-catcherassemblymounted inplace,youandothersareexposedtoblade contactandthrowndebris.Contactwith rotatingmowerblade(s)andthrowndebris willcauseinjuryordeath.
•Neverremovethegrassdeectorfromthe mowerdeckbecausethegrassdeector routesmaterialdowntowardtheturf.Ifthe grassdeectoriseverdamaged,replaceit immediately.
Figure28
g008953
•Neverputyourhandsorfeetunderthe mowerdeck.
•Nevertrytoclearthedischargearea ormowerbladesunlessyoumovethe blade-controlswitch(PTO)totheOFF position,rotatethekeyswitchtotheOFF position,andremovethekeyfromthekey switch.
•Makesurethatthegrassdeectorisinthe downposition.
28

AdjustingtheHeightofCut

UsingtheTransportLock

Thetransportlockhas2positions,andisusedwith thedeck-liftpedal.ThereisaLOCKpositionand anUNLOCKpositionforthetransportpositionofthe mowerdeck(Figure29).

AdjustingtheHeight-of-CutPin

Theheight-of-cutisadjustedfrom25to140mm(1 to5-1/2inches)in6mm(1/4inch)incrementsby relocatingtheclevispinintodifferentholelocations.
1.Movethetransportlocktothelockposition.
2.Pushonthedeck-liftpedalwithyourfoot,and raisethemowerdecktothetransportposition (alsothe140mm(5-1/2inches)cuttingheight position)asshowninFigure30.
3.T oadjust,rotatethepin90degreesandremove thepinfromtheheight-of-cutbracket(Figure
30).
4.Selectaholeintheheight-of-cutbracket correspondingtotheheight-of-cutdesired,and insertthepin(Figure30).
5.Pushonthedecklift,pullbackonthetransport lock,andslowlylowerthemowerdeck.
Figure29
Transport-LockPositions
1.Transportlockknob3.UNLOCKposition—The
2.LOCKposition—The mowerdecklocksintothe transportposition.
mowerdeckdoesnotlock intothetransportposition.
g027343
Figure30
1.Deck-liftpedal
2.Cut-of-heightpin
g229103
29
3.Transportlock

AdjustingtheAnti-Scalp Rollers

ForMachineswithSideDischarge
Wheneveryouchangetheheight-of-cut,adjustthe heightoftheanti-scalprollers.
1.Parkthemachineonalevelsurface,disengage
theblade-controlswitch,andengagetheparking brake.
2.Shutofftheengine,removethekey ,andwait
forallmovingpartstostopbeforeleavingthe operatingposition.
3.Adjusttheanti-scalprollersasshowninFigure
31,Figure32,andFigure33.
Figure31
1.Anti-scalproller4.Flangenut
2.Spacer
3.Bushing
5.Bolt
g029957
Figure33
1.Anti-scalproller4.Flangenut
2.Spacer
3.Bushing
5.Bolt

AdjustingtheAnti-Scalp Rollers

ForMachineswithRearDischarge
Wheneveryouchangetheheightofcut,itis recommendedtoadjusttheheightoftheanti-scalp
g029955
rollers.
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch,andengagetheparking brake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
Figure32
1.Anti-scalproller3.Flangenut
2.Bushing4.Bolt
3.Adjusttheanti-scalprollersasshowninFigure
34andFigure35.
g029956
30

AdjustingtheSkid(s)

ForMachineswithRearDischarge
Mounttheskidsinthelowerpositionwhenoperating inheightofcutshigherthan64mm(2-1/2inches)and inthehigherpositionwhenoperatinginheightofcuts lowerthan64mm(2-1/2inches).
Note:Whentheskidsbecomeworn,switchtheskid
totheoppositesidesofthemower,ippingthem over.Thisallowsyoutousetheskidslongerbefore replacingthem.
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch,andengagetheparking brake.
Figure34
1.Flangenut3.Bushing
2.Anti-scalproller4.Bolt
Figure35
1.Bolt3.Anti-scalproller
2.Bushing4.Flangenut
g024242
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Removethecarriageboltsandnutsfromeach skid(Figure36).
g024244
Figure36
1.Carriagebolt
g024243
2.Skid
3.Nut
4.Moveeachskidtothedesiredpositionand securethemwiththecarriageboltsandnuts.
Note:Onlyusethetoporcentersetsofholes
toadjusttheskids.Thebottomholesareused whenswitchingsidesonthemowerdeck,at whichtimetheybecomethetopholesonthe othersideofthemower.
5.T opreventdamagingtheskid,torquethe carriageboltsandnutsforeachskidto12.4to
14.7N∙m(110to130in-lb).
31
AdjustingtheFlowBafe
PositioningtheFlowBafe
CamLocks
ForMachineswithSideDischarge
Thisprocedureisapplicableonlytomachineswiththe ow-bafelocks.Certainmodelshavenutsandbolts inplaceoftheow-bafelocksandcanbeadjusted thesame.
Youcanadjustthemower-dischargeowfordifferent typesofmowingconditions.Positionthecamlocks andbafetogivethebestqualityofcut.
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch,andengagetheparking brake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.T oadjustthecamlocks,swingtheleverupto loosenthecamlock(Figure37).
4.Adjustthebafeandcamlocksintheslotsto thedesireddischargeow.
5.Swingtheleverbackovertotightenthebafe andcamlocks(Figure37).
ForMachineswithSideDischarge
Thefollowingguresareonlyrecommendations foruse.Adjustmentsvarybygrasstype,moisture content,andtheheightofthegrass.
Note:Iftheenginepowerdrawsdownandthe
mowergroundspeedisthesame,openupthebafe.

PositionA

Thisisthefullrearposition.Thesuggestedusefor thispositionisasfollows:
•Short,lightgrassmowingconditions
•Dryconditions
•Smallergrassclippings
•Propelsgrassclippingsfartherawayfromthe
mower
6.Ifthecamlocksdonotlockthebafeintoplace oritistootight,loosentheleverandthenrotate thecamlock.
Note:Adjustthecamlockuntilthedesired
lockingpressureisachieved.
Figure37
g005832
Figure38
g027727
32

PositionB

Usethispositionwhenbagging.Alwaysalignitwith thebloweropening.
Figure39
OperatingTips
UsingtheFastThrottleSetting
Forbestmowingandmaximumaircirculation,operate theengineattheFASTposition.Airisrequiredto thoroughlycutgrassclippings,sodonotsetthe height-of-cutsolowastototallysurroundthemower deckinuncutgrass.Alwaystrytohave1sideofthe mowerdeckfreefromuncutgrass,whichallowsair tobedrawnintothemowerdeck.
CuttingaLawnfortheFirstTime
Cutgrassslightlylongerthannormaltoensurethat thecuttingheightofthemowerdeckdoesnotscalp anyunevenground.However,thecuttingheight
g005833
usedinthepastisgenerallythebestonetouse. Whencuttinggrasslongerthan15cm(6inches)tall, youmaywanttocutthelawntwicetoensurean acceptablequalityofcut.

PositionC

Thisisthefullopenposition.Thesuggestedusefor thispositionisasfollows:
•Tall,densegrassmowingconditions
•Wetconditions
•Lowerstheengine-powerconsumption
•Allowsincreasedgroundspeedinheavyconditions
CuttingaThirdoftheGrassBlade
Itisbesttocutonlyaboutathirdofthegrassblade. Cuttingmorethanthatisnotrecommendedunless grassissparse,oritislatefallwhengrassgrows moreslowly.
AlternatingtheMowingDirection
Alternatethemowingdirectiontokeepthegrass standingstraight.Thisalsohelpsdisperseclippings, whichenhancesdecompositionandfertilization.
MowingatCorrectIntervals
Grassgrowsatdifferentratesatdifferenttimesof theyear.T omaintainthesamecuttingheight,mow moreofteninearlyspring.Asthegrassgrowthrate slowsinmidsummer,mowlessfrequently.Ifyou cannotmowforanextendedperiod,rstmowata highcuttingheight,thenmowagain2dayslaterata lowerheightsetting.
Figure40
UsingaSlowerCuttingSpeed
g005834
Toimprovecutquality,useaslowergroundspeed incertainconditions.
AvoidingCuttingTooLow
Whenmowinguneventurf,raisethecuttingheight toavoidscalpingtheturf.
33
StoppingtheMachine
UsingtheFuel-Shutoff
Ifyoumuststoptheforwardmotionofthemachine whilemowing,aclumpofgrassclippingsmay dropontoyourlawn.T oavoidthis,moveontoa previouslycutareawiththebladesengagedoryou candisengagethemowerdeckwhilemovingforward.
KeepingtheUndersideofthe MowerDeckClean
Cleanclippingsanddirtfromtheundersideofthe mowerdeckaftereachuse.Ifgrassanddirtbuildup insidethemowerdeck,cuttingqualitywilleventually becomeunsatisfactory.
MaintainingtheBlade(s)
Maintainasharpbladethroughoutthecuttingseason becauseasharpbladecutscleanlywithouttearingor shreddingthegrassblades.T earingandshredding turnsgrassbrownattheedges,whichslowsgrowth andincreasesthechanceofdisease.Checkthe mowerbladesaftereachuseforsharpness,and foranywearordamage.Filedownanynicksand sharpenthebladesasnecessary.Ifabladeis damagedorworn,replaceitimmediatelywitha genuineT ororeplacementblade.
Valve
Thefuel-shutoffvalveislocatedundertheseat.Move theseatforwardtoaccessit.
Closethefuel-shutoffvalvefortransport,maintenance, andstorage.
Ensurethatthefuel-shutoffvalveisopenwhen startingtheengine.
g008948
Figure41
1.ONposition2.OFFposition
AfterOperation

AfterOperationSafety

GeneralSafety

•Cleangrassanddebrisfromthecuttingunits,
mufers,andenginecompartmenttohelpprevent res.Cleanupoilorfuelspills.
•Shutoffthefuelandremovethekeybeforestoring
ortransportingthemachine.
•Disengagethedrivetotheattachmentwhenever
youaretransportingornotusingthemachine.
•Allowtheenginetocoolbeforestoringthemachine
inanyenclosure.
•Neverstorethemachineorfuelcontainerwhere
thereisanopename,spark,orpilotlight,such asonawaterheateroronotherappliances.

Usingthe Drive-Wheel-Release Valves

WARNING
Handsmaybecomeentangledintherotating drivecomponentsbelowtheenginedeck, whichcouldresultinseriousinjury.
Shutofftheengine,removethekey,andallow allmovingpartstostopbeforeaccessingthe drive-wheel-releasevalves.
WARNING
Theengineandhydraulic-driveunitscan becomeveryhot.Touchingahotengineor hydraulic-driveunitscancausesevereburns.
Allowtheengineandhydraulic-driveunits tocoolcompletelybeforeaccessingthe drive-wheel-releasevalves.
34
Thedrive-wheel-releasevalvesarelocatedinthe backofeachhydraulic-driveunit,undertheseat.
Note:Makesurethatthereleasevalvesareinthe
fullyhorizontalpositionwhenoperatingthemachine; otherwise,severedamagetothehydraulicsystem canoccur.
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch,andengagetheparking brake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Rotatetherelease-valveleversverticallytopush themachine(Figure42).
Note:Thisallowshydraulicuidtobypassthe
pump,enablingthewheelstoturn.
4.Disengagetheparkingbrakebeforepushing themachine.

TransportingtheMachine

Useaheavy-dutytrailerortrucktotransportthe machine.Useafull-widthramp.Ensurethatthetrailer ortruckhasallthenecessarybrakes,lighting,and markingasrequiredbylaw.Pleasecarefullyreadall thesafetyinstructions.Knowingthisinformationcould helpyouorbystandersavoidinjury.Refertoyour localordinancesfortrailerandtie-downrequirements.
WARNING
Drivingonthestreetorroadwaywithout turnsignals,lights,reectivemarkings,ora slow-moving-vehicleemblemisdangerous andcanleadtoaccidents,causingpersonal injury.
Donotdrivethemachineonapublicstreet orroadway.

SelectingaTrailer

Figure42
1.Verticaltopushthe
machine
5.Rotatethereleasevalvelevershorizontallyto runthemachine(Figure42).
2.Horizontaltorunthe machine
WARNING
Loadingamachineontoatrailerortruck increasesthepossibilityoftip-overandcould causeseriousinjuryordeath(Figure43).
•Useonlyafull-widthramp;donotuse individualrampsforeachsideofthe machine.
•Donotexceeda15-degreeanglebetween therampandthegroundorbetweenthe rampandthetrailerortruck.
g024246
•Ensurethatthelengthoframpisatleast4 timesaslongastheheightofthetraileror truckbedtotheground.Thisensuresthat rampangledoesnotexceed15degreeson atground.
35
1.Ifusingatrailer,connectittothetowingvehicle andconnectthesafetychains.
2.Ifapplicable,connectthetrailerbrakesand lights.
3.Lowertheramp,ensuringthattheangle betweentherampandthegrounddoesnot exceed15degrees(Figure43).
4.Backthemachineuptheramp(Figure44).
Figure44
g028043
1.Full-widthrampinstowed position
2.Sideviewoffull-width rampinloadingposition
3.Notgreaterthan 15degrees

LoadingtheMachine

Figure43
4.Rampisatleast4times aslongastheheightof thetrailerortruckbedto theground
5.H=heightofthetraileror truckbedtotheground
6.Trailer
1.Backthemachineupthe ramp.
2.Drivethemachineforward downtheramp.
5.Shutofftheengine,removethekey,andengage theparkingbrake.
6.Tiedownthemachinenearthefrontcaster wheelsandtherearbumperwithstraps,chains, cable,orropes(Figure45).Refertolocal regulationsfortie-downrequirements.
g027996
WARNING
Loadingamachineontoatrailerortruck increasesthepossibilityoftip-overandcould causeseriousinjuryordeath.
•Useextremecautionwhenoperatinga machineonaramp.
•Backthemachineuptherampanddriveit forwarddowntheramp.
•Avoidsuddenaccelerationordeceleration whiledrivingthemachineonarampas thiscouldcausealossofcontrolora tip-oversituation.
g027338
Figure45
1.Tie-downloops

UnloadingtheMachine

1.Lowertheramp,ensuringthattheangle betweentherampandthegrounddoesnot exceed15degrees(Figure43).
2.Drivethemachineforwarddowntheramp (Figure44).
36
Maintenance
RecommendedMaintenanceSchedule(s)
MaintenanceService
Interval
Aftertherst100hours
Aftertherst250hours
Beforeeachuseordaily
Every50hours
Every100hours
Every150hours
MaintenanceProcedure
•Checkthewheellug-nuttorque.
•Checkthewheel-hubslotted-nuttorque.
•Checktheparkingbrakeadjustment.
•Changethehydraulicltersandhydraulicuidwhenusinganytypeofuid.
•Checkthesafetysystem.
•Checktheengine-oillevel.
•Checktheseatbelt.
•Checktherollbarknobs.
•Cleantheenginescreenandtheoilcooler.
•Checkandcleanthehydraulic-unitshrouds.
•Inspecttheblades.
•Cleanthemowerdeck.
•Cleanthesuspensionsystem.
•Checkthesparkarrester(ifequipped).
•Checkthetirepressure.
•Inspectthebeltsforcracksandwear.
•Checkthehydraulic-uidlevel.
•Lubricatethemowerdeck-liftpivots.
•Changetheengineoil(moreoftenindirtyordustyconditions).
•Checkandcleanengine-coolingnsandshrouds.
•Inspecttheprimarylter.
Every200hours
Every250hours
Every300hours
Every500hours
Every600hours
Yearlyorbeforestorage
•Changetheengine-oillter(moreoftenindirtyordustyconditions).
•Replacethefuellter(moreoftenindirtyordustyconditions).
•ChangethehydraulicltersandhydraulicuidwhenusingMobil®1uid(more oftenindirtyordustyconditions).
•Replacetheprimaryairlter(moreoftenindustyorsandyconditions).
•Checktheinnerairlter.
•Check,cleanandregapthesparkplug.
•Checkthewheellug-nuttorque.
•Checkthewheel-hubslotted-nuttorque.
•Adjustthecaster-pivotbearing.
•Checktheparkingbrakeadjustment.
•ChangethehydraulicltersandhydraulicuidwhenusingToro®HYPR-OIL™500 hydraulicuid(moreoftenindirtyordustyconditions).
•Replacetheinnerairlter.
Monthly
Yearly
•Checkthebatterycharge.
•Greasethepump-belt-idlerarm.
•Greasethefrontcasterpivots(moreoftenindirtyordustyconditions).
•Repackthefrontcaster-wheelbearings(moreoftenindirtyordustyconditions).
•Lubricatethecaster-wheelhubs.
•Paintchippedsurfaces.
•Checkallmaintenanceprocedureslistedabovebeforestorage.
Important:Refertoyourengineowner'smanualforadditionalmaintenanceprocedures.
37
CAUTION
Ifyouleavethekeyintheswitch,someonecouldaccidentlystarttheengineandseriously injureyouorotherbystanders.
Shutofftheengineandremovethekeyfromtheswitchbeforeyouperformanymaintenance.
Pre-Maintenance Procedures

MaintenanceSafety

•Beforerepairingthemachinedothefollowing:
–Disengagethedrives.
–Engagetheparkingbrake.
–Shutofftheengineandremovethekey.
–Disconnectthespark-plugwire.
•Parkthemachineonalevelsurface.
•Cleangrassanddebrisfromthecuttingunit,
drives,mufers,andenginetohelppreventres.
•Cleanupoilorfuelspills.
•Donotallowuntrainedpersonneltoservicethe
machine.
•Usejackstandstosupportthemachineand/or
componentswhenrequired.
•Carefullyreleasepressurefromcomponentswith
storedenergy.
•Disconnectthebatteryorremovethespark-plug
wirebeforemakinganyrepairs.Disconnectthe negativeterminalrstandthepositiveterminal last.Connectthepositiveterminalrstand negativelast.
•Usecarewhencheckingtheblades.Wrapthe
blade(s)orwearthicklypaddedgloves,anduse cautionwhenservicingthem.Onlyreplaceblades; donotstraightenorweldthem.
•Keepyourhandsandfeetawayfrommoving
parts.Ifpossible,donotmakeadjustmentswith theenginerunning.
•Keepallpartsingoodworkingcondition
andallhardwaretightened,especiallythe blade-attachmentbolts.Replaceallwornor damageddecals.
•Neverinterferewiththeintendedfunctionofa
safetydeviceorreducetheprotectionprovided byasafetydevice.Checktheirproperoperation regularly.
•UseonlygenuineTororeplacementparts.
•Checktheparkingbrakeoperationfrequently.
Adjustandserviceasrequired.
Lubrication

GreasingtheMachine

Greasemorefrequentlywhenoperatingconditions areextremelydustyorsandy.
GreaseType:No.2lithiumormolybdenumgrease
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch,andengagetheparking brake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Cleanthegreasettingswitharag.
Note:Makesurethatyouscrapeanypaintoff
thefrontofthetting(s).
4.Connectagreaseguntothetting.
5.Pumpgreaseintothettingsuntilgreasebegins tooozeoutofthebearings.
6.Wipeupanyexcessgrease.
38
AddingLightOilorSpray

GreasingtheMowerDeck

Lubrication
ServiceInterval:Every100hours
Lubricatethedeck-liftpivots.
MachinewithSideDischargeShown
ServiceInterval:Yearly—Greasethepump-belt-idler
arm.
Yearly—Greasethefrontcasterpivots(more oftenindirtyordustyconditions).
Yearly—Repackthefrontcaster-wheelbearings (moreoftenindirtyordustyconditions).
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch,andengagetheparking brake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Greasethemowerdeckidler-pulleypivotuntil greasecomesoutthebottom(Figure48or
Figure49).
g017028
Figure46
Figure47
g185957
Figure48
MachinewithSideDischargeShown
g017050
39
Figure49
MachinewithRearDischargeShown
g024207
Figure51
g192516
MachineswithRearDischargeOnly
6.Removethedustcapandadjustthecaster pivots.
4.Greasethedrive-beltidlerarms(Figure50).
Figure50
5.Greasethedeck-beltidlerarms(reardischarge machinesonly)asshowninFigure51.
Note:Keepthedustcapoffuntilgreasingis
done.
7.Removethehexplug.
8.Threadagreasettingintothehole.
9.Pumpgreaseintothettinguntilitoozesout aroundthetopbearing.
10.Removethegreasettinginthehole.
11.Installthehexpluganddustcap(Figure52).
g009030
Figure52
12.Greasethecaster-wheelbearings(Figure52).
40
g027339

Lubricatingthe Caster-WheelHubs

ServiceInterval:Yearly
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch,andengagetheparking brake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
12.Inserttheassemblednutandaxleintothewheel onthesideofthewheelwiththenewsealand bearing.
13.Withtheopenendofthewheelfacingup,ll theareainsidethewheelaroundtheaxlefullof general-purposegrease.
14.Insertthesecondbearingandnewsealintothe wheel.
15.Applyathread-lockingadhesivetothesecond spacernut,andthreaditontotheaxlewiththe wrenchatsfacingoutward.
16.T orquethenutto8to9N∙m(75to80in-lb), loosen,thentorqueto2to3N∙m(20to25in-lb).
Note:Makesurethattheaxledoesnotextend
beyondeithernut.
17.Installthesealguardsoverthewheelhub,and insertthewheelintothecasterfork.
18.Installthecasterboltandtightenthenutfully.
Figure53
1.Sealguard2.Spacernutwithwrench ats
3.Raisethemowerforaccess.
4.Removethecasterwheelfromthecasterforks.
5.Removethesealguardsfromthewheelhub.
6.Removeaspacernutfromtheaxleassemblyin
thecasterwheel.
Note:Thread-lockingadhesivehasbeen
appliedtolockthespacernutstotheaxle.
7.Removetheaxle(withtheotherspacernutstill
assembledtoit)fromthewheelassembly.
8.Pryoutsealsandinspectbearingsforwearor
damageandreplaceifnecessary.
9.Packthebearingswithageneral-purpose
grease.
10.Insert1bearingand1newsealintothewheel.
g006115
Important:T opreventsealandbearingdamage,
checkthebearingadjustmentoften.Spinthe castertire.Thetireshouldnotspinfreely(more than1or2revolutions)orhaveanysideplay.If thewheelspinsfreely,adjustthetorqueonthe spacernutuntilthereisaslightamountofdrag. Applyanotherlayerofthread-lockingadhesive.
Note:Replacetheseals.
11.Iftheaxleassemblyismissingbothspacernuts, applyathread-lockingadhesiveto1spacernut andthreaditontotheaxlewiththewrenchats facingoutward.
Note:Donotthreadthespacernutallof
thewayontotheendoftheaxle.Leave approximately3mm(1/8inch)fromtheouter surfaceofthespacernuttotheendoftheaxle insidethenut.
41
EngineMaintenance

EngineSafety

•Shutofftheenginebeforecheckingtheoilor
addingoiltothecrankcase.
•Keepyourhands,feet,face,clothing,andother
bodypartsawaythemuferandotherhotsurfaces.

ServicingtheAirCleaner

ServiceInterval:Every150hours—Inspectthe
primarylter.
Every300hours/Y early(whichevercomes rst)—Replacetheprimaryairlter(moreoften industyorsandyconditions).
Every300hours—Checktheinnerairlter.
Every600hours—Replacetheinnerairlter.
Note:Checktheltersmorefrequentlyifthe
operatingconditionsareextremelydustyorsandy .
RemovingtheFilters
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch(PTO),andengagethe parkingbrake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Releasethelatchesontheaircleanerand pulltheair-inletcoverofftheair-cleanerbody (Figure54).
4.Cleantheair-inletscreenandcover.
5.Installtheair-inletcoverandsecureitwiththe latches(Figure54).
6.Releasethelatchesontheaircleanerandpull theair-cleanercoverofftheair-cleanerbody (Figure55).
7.Cleantheinsideoftheair-cleanercoverwith compressedair.
8.Gentlyslidetheprimarylteroutofthe air-cleanerbody(Figure55).
Note:Avoidknockingthelterintothesideof
thebody.
9.Removetheinnerlteronlyifyouintendto replaceit.
Important:Neverattempttocleantheinner
lter.Ifthesafetylterisdirty,thenthe primarylterisdamaged.Replaceboth lters.
g012997
Figure55
Figure54
1.Air-inletcover3.Air-cleanerbody
2.Air-inletscreen4.Latch
1.Innerlter
2.Primarylter
3.Air-cleanercover
10.Inspecttheprimarylterfordamagebylooking intothelter,whileshiningabrightlightonthe outsideofthelter.
4.Latch
5.Air-cleanerbody
Note:Holesinthelterwillappearasbright
spots.Ifthelterisdamaged,discardit.
InspectingtheFilters
g012996
1.Inspecttheinnerlter.Ifitisdirty ,replaceboth theinnerandprimarylters.
Important:Donotattempttocleanthe
innerlter.Iftheinnerlterisdirty,thenthe primarylterisdamaged.
42
2.Inspecttheprimarylterfordamagebylooking intothelterwhileshiningabrightlightonthe outsideofthelter.Iftheprimarylterisdirty , bent,ordamaged,replaceit.
Note:Holesinthelterappearasbrightspots.
Donotcleantheprimarylter.
InstallingtheFilters
Important:Topreventenginedamage,always
operatetheenginewithbothairltersandthe coverinstalled.
1.Ifyouareinstallingnewlters,checkeachlter forshippingdamage.
Note:Donotuseadamagedlter.
2.Ifyouarereplacingtheinnerlter,carefullyslide itintothelterbody(Figure55).
3.Carefullyslidetheprimarylteroverthesafety lter(Figure55).
Note:Ensurethattheprimarylterisfully
seatedbypushingontheouterrimwhile installingit.
CheckingtheEngine-OilLevel
ServiceInterval:Beforeeachuseordaily
Note:Checktheoilwhentheengineiscold.
Important:Ifyouoverllorunderlltheengine
crankcasewithoilandruntheengine,youmay damagetheengine.
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch(PTO),andengagethe parkingbrake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
Note:Ensurethattheengineiscoolsothatthe
oilhashadtimetodrainintothesump.
3.T okeepdirt,grassclippings,etc.,outofthe engine,cleantheareaaroundtheoil-llcapand dipstickbeforeremovingit(Figure57).
Important:Donotpressonthesoft,inside
areaofthelter.
4.Installtheair-cleanercoverandsecurethe latches(Figure55).

ServicingtheEngineOil

EngineOilSpecications
OilCapacity:withalterchange—1.9L(64oz);
withoutalterchange—1.6L(54oz)
Viscosity:Seethetablebelow.
Figure56
g194611
g017552
43
Figure57
ChangingtheEngineOil
ServiceInterval:Every100hours(moreoftenindirty
ordustyconditions).
Note:Disposeoftheusedoilatarecyclingcenter.
1.Starttheengineandletitrunfor5minutes.
Note:Thiswarmstheoilsothatitdrainsbetter.
2.Parkthemachinesothatthedrainsideisslightly lowerthantheoppositesidetoensurethatthe oildrainscompletely.
3.Disengagetheblade-controlswitch(PTO)and engagetheparkingbrake.
4.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
5.Draintheoilfromtheengine(Figure58).
6.Slowlypourapproximately80%ofthespecied oilintothellertubeandslowlyaddthe additionaloiltobringittotheFullmark(Figure
59).
g008804
Figure59
g027660
7.Starttheengineanddrivetoaatarea.
8.Checktheoillevelagain.
Figure58
g027734
44
ChangingtheEngine-OilFilter

ServicingtheSparkPlug

ServiceInterval:Every200hours—Changethe
engine-oillter(moreoftenindirty ordustyconditions).
1.Draintheoilfromtheengine;refertoChanging
theEngineOil(page44).
2.Changetheengine-oillter(Figure60).
ServiceInterval:Every500hours—Check,clean
andregapthesparkplug.
Ensurethattheairgapbetweenthecenterandside electrodesiscorrectbeforeinstallingthesparkplug. Useasparkplugwrenchforremovingandinstalling thesparkplug(s)andagappingtool/feelergaugeto checkandadjusttheairgap.Installanewspark plug(s)ifnecessary.
Type:Champion
AirGap:0.76mm(0.030inch)
®
XC12YC,orequivalent
RemovingtheSparkPlug
1.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
2.DisengagethePTO,movethemotion-control leverstotheNEUTRAL-LOCKposition,and engagetheparkingbrake.
3.Removethelefthydraulic-unitshroudinthe orderlistedwithFigure61.Thisgivesyou accesstothefrontsparkplug.
Figure60
Note:Ensurethattheoil-ltergaskettouches
theengine,andthenturntheoillteranextra 3/4turn.
3.Fillthecrankcasewiththepropertypeofnew oil(Figure59).
g027477
45
5.Installthelefthydraulic-unitshroud(Figure61).
CheckingtheSparkPlug
Important:Replacethesparkplug(s)whenit
has:ablackcoating,wornelectrodes,anoilylm, cracksorreuseisquestionable.
g009922
Ifyouseelightbrownorgrayontheinsulator,the engineisoperatingproperly.Ablackcoatingonthe insulatorusuallymeansthattheaircleanerisdirty.
Setthegapto0.76mm(0.030inches).
g027479
Figure63
1.Pullthistabouttothe
sideinthedirectionofthe arrow
2.Pulltheshroudoffthis
frametabinthedirection ofthearrow
4.Removethesparkplug.
Figure61
3.Pulltheshroudoffthis
4.Shroud
frametabinthedirection ofthearrow
InstallingtheSparkPlug
g009919
g008803
Tightenthesparkplug(s)to24.4to29.8N-m(18to 22ft-lb).
g028109
Figure64
Figure62
g027478
46
CheckingtheSpark
FuelSystem
Arrester
ForMachineswithaSpark Arrester
ServiceInterval:Every50hours
WARNING
Hotexhaust-systemcomponentsmayignite fuelvaporsevenafteryoushutofftheengine. Hotparticlesexhaustedduringengine operationmayigniteammablematerials, resultinginpersonalinjuryorproperty damage.
Donotrefuelorruntheengineunlessthe sparkarresterisinstalled.
1.Parkthemachineonalevelsurface,disengage thePTO,andengagetheparkingbrake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Waitforthemufertocool.
4.Ifyouseeanybreaksinthescreenorwelds, replacethearrester.
Maintenance
WARNING
Fuel-systemcomponentsareunderhigh pressure.Theuseofimpropercomponents canresultinsystemfailure,fuelleakage,and possibleexplosion.
Useonlyapprovedfuellinesandfuellters.

ServicingtheElectronic Fuel-InjectionSystem

Thismachinecontainsanelectronicfuel-injection system.Itcontrolsthefuelowunderdifferent operatingconditions.
Theelectronic-controlunit(ECU)continuously monitorstheoperationoftheEFIsystem.
Ifaproblemorfaultwithinthesystemisdetected,the malfunction-indicatorlight(MIL)illuminates.TheMIL istheredlightlocatedintherightconsolepanel.
OncetheMILilluminates,makeinitialtroubleshooting checks;refertotheMILsectionunderTroubleshooting
(page76).
5.Ifthescreenisplugged,removethearrester, shakelooseparticlesoutofthearrester,and cleanthescreenwithawirebrush(soakthe screeninsolventifnecessary).
6.Installthearresterontheexhaustoutlet.
Ifthesechecksdonotcorrecttheproblem,further diagnosisandservicingbyanAuthorizedService Dealerisnecessary.

Replacingthe Low-PressureFuelFilter

ServiceInterval:Every200hours/Yearly(whichever
comesrst)
Thefuellterislocatedneartheengineonthefront orrearsideoftheengine.
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch,andengagetheparking brake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Waitforthemachinetocooldown.
4.Closethefuel-shutoffvalveundertheseat (Figure65).
47
Figure65
ElectricalSystem Maintenance

ElectricalSystemSafety

•Disconnectthebatterybeforerepairingthe
machine.Disconnectthenegativeterminalrst andthepositivelast.Connectthepositiveterminal rstandthenegativelast.
•Chargethebatteryinanopen,well-ventilated
area,awayfromsparksandames.Unplugthe chargerbeforeconnectingordisconnectingthe battery.Wearprotectiveclothinganduseinsulated
g008963
tools.
1.Fuellter
2.Hoseclamp
5.Squeezetheendsofthehoseclampstogether andslidethemawayfromthelter(Figure65).
6.Removethelterfromthefuellines.
7.Installanewlterandmovethehoseclamps closetothelter(Figure65).
8.Openthefuel-shutoffvalve.
Important:Installthefuellinehosesandsecure
withplastictiesthesameastheywereoriginally installedatthefactorytokeepthefuellineaway fromcomponentsthatcancausefuellinedamage.
3.Fuelline

Servicingthe High-PressureFuelFilter

Donotattempttoservicethehigh-pressurefuel lter.Thehigh-pressurelterisintegratedwithin thefuel-pumpmodule.Thefuellterandother componentsinsidethefuel-pumpmodulearenot serviceable.
Important:Donotattempttoopenthefuel-pump
module.

ServicingtheBattery

ServiceInterval:Monthly
RemovingtheBattery
WARNING
Batteryterminalsormetaltoolscouldshort againstmetalmachinecomponentscausing sparks.Sparkscancausethebatterygasses toexplode,resultinginpersonalinjury.
•Whenremovingorinstallingthebattery, donotallowthebatteryterminalstotouch anymetalpartsofthemachine.
•Donotallowmetaltoolstoshortbetween thebatteryterminalsandmetalpartsofthe machine.
WARNING
Incorrectlyremovingthecablesfrombattery coulddamagethemachineandcables, causingsparks.Sparkscancausethebattery gassestoexplode,resultinginpersonal injury.
EnsurethatanAuthorizedServiceDealerreplaces thefuel-pumpmodulewiththehigh-pressurefuellter.

ServicingtheFuelTank

Donotattempttodrainthefueltank.Ensurethatan AuthorizedServiceDealerdrainsthefueltankand servicesanycomponentsofthefuelsystem.
•Alwaysdisconnectthenegative(black) batterycablebeforedisconnectingthe positive(red)cable.
•Alwaysconnectthepositive(red)battery cablebeforeconnectingthenegative (black)cable.
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch(PTO),andengagethe parkingbrake.
48
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.RemovethebatteryasshowninFigure66.
ChargingtheBattery
WARNING
Chargingthebatteryproducesgassesthat canexplode.
Neversmokenearthebatteryandkeepsparks andamesawayfromthebattery.
Important:Alwayskeepthebatteryfullycharged
(1.265specicgravity).Thisisespecially importanttopreventbatterydamagewhenthe temperatureisbelow0°C(32°F).
1.Removethebatteryfromthechassis;referto
RemovingtheBattery(page48).
2.Chargethebatteryfor10to15minutesat25to 30Aorfor30minutesat10A.
Note:Donotoverchargethebattery.
Figure66
g027728
3.Whenthebatteryisfullycharged,unplug thechargerfromtheelectricaloutlet,then disconnectthechargerleadsfromthebattery posts(Figure67).
4.Installthebatteryinthemachineandconnect thebatterycables;refertoInstallingtheBattery
(page50).
Note:Donotrunthemachinewiththebattery
disconnected;electricaldamagemayoccur.
Figure67
1.Positive(+)batterypost3.Red(+)chargerlead
2.Negative(–)batterypost4.Black(–)chargerlead
49
g000960
InstallingtheBattery
Note:Positionthebatteryinthetraywiththeterminal
postsoppositefromthehydraulictank(Figure66).

Jump-StartingtheMachine

1.Checkandcleancorrosionfromthebattery terminalsbeforejump-starting.Ensurethatthe connectionsaretight.
CAUTION
Corrosionorlooseconnectionscan causeunwantedelectricalvoltagespikes atanytimeduringthejump-starting procedure.
Donotattempttojump-startthemachine withlooseorcorrodedbatteryterminals, ordamagetotheengineorEFImay occur.
DANGER
Figure68

ServicingtheFuses

Theelectricalsystemisprotectedbyfuses.Itrequires nomaintenance,however,ifafuseblowscheckthe component/circuitforamalfunctionorshort.The fusesarelocatedontheconsoletotherightofthe seat(Figure69).
Toreplacethefuses,removethecover,pulloutonthe fusetoremoveit,andinstallanewfuse.
g032526
Jump-startingaweakbatterythatis crackedorfrozenorhasalowelectrolyte leveloranopen/shortedbatterycellcan causeanexplosion,resultinginserious personalinjury .
Donotjump-startaweakbatteryifthese conditionsexist.
2.Makesurethattheboosterbatteryisagood andfullychargedlead-acidbatteryat12.6Vor greater.
Note:Useproperlysizedjumpercableswith
shortlengthstoreducevoltagedropbetween systems.Makesurethatthecablesarecolor codedorlabeledforthecorrectpolarity.
CAUTION
Connectingthejumpercablesincorrectly (wrongpolarity)canimmediatelydamage theEFIsystem.
Becertainofbattery-terminalpolarity andjumper-cablepolaritywhenhooking upthebatteries.
1.Auxiliary,15A
2.Main,20A
Figure69
3.Startrelay
4.Open
WARNING
Batteriescontainacidandproduce explosivegases.
•Shieldyoureyesandfacefromthe
g231345
50
batteriesatalltimes.
•Donotleanoverthebatteries.
Note:Ensurethattheventcapsaretightand
level.Placeadampcloth,ifavailable,overany ventcapsonbothbatteries.Alsoensurethatthe
machinesdonottouchandthatbothelectrical systemsareoffandatthesameratedsystem voltage.Theseinstructionsarefornegative groundsystemsonly.
3.Connectthepositive(+)cabletothepositive(+) terminalofthedischargedbatterythatiswired tothestarterorsolenoidasshowninFigure70.
g024213
Figure70
1.Positive(+)cableon
dischargedbattery
2.Positive(+)cableon
boosterbattery
3.Negative(–)cableonthe
boosterbattery
4.Negative(–)cableonthe
engineblock
5.Boosterbattery
6.Dischargedbattery
7.Engineblock
4.Connecttheotherendofthepositivecableto thepositiveterminaloftheboosterbattery.
5.Connecttheblacknegative(–)cabletotheother terminal(negative)oftheboosterbattery.
6.Makethenalconnectionontheengineblockof thestalledmachine(nottothenegativebattery post),awayfromthebattery,andstandback (Figure71).
g012785
g013117
Figure71
1.Engineblock
2.Negative(–)cable
7.Startthemachineandremovethecablesin thereverseorderofconnection(disconnectthe negativecablefromtheengineblockrst).
51
DriveSystem Maintenance

CheckingtheSeatBelt

ServiceInterval:Beforeeachuseordaily
Inspecttheseatbeltforwear,cuts,andproper operationoftheretractorandbuckle.Replacethe seatbeltifitisdamaged.

CheckingtheRoll-Bar Knobs

ServiceInterval:Beforeeachuseordaily
WARNING
Toavoidinjuryordeathfromrollover,keep therollbarinthefullyraised,lockedposition andusetheseatbelt.
Ensurethattheseatissecuredtothe machine.
•Checkthatboththemountinghardwareandthe
knobsareingoodworkingcondition.
•Makesurethattheknobsarefullyengagedwith
therollbarintheraisedposition.
Note:Theupperhoopoftherollbarmayneed
tobepushedforwardorpulledrearwardtofully engagebothknobs(Figure72andFigure73).
1.Rollbarintheupright
position
2.Roll-barknobinthe
latchedposition
3.Pulltheroll-barknobout
androtateit90degrees.
g228804
Figure72
4.Rotatetheroll-barknob90 degrees.
5.Roll-barknobinthe unlatchedposition
6.Rollbarinthefolded position
Figure73
1.Engaged2.Partiallyengaged—donot operatewiththerollbarin thisposition.
52
g228981

AdjustingtheTracking

CheckingtheTirePressure

1.Disengagetheblade-controlswitch(PTO).
2.Drivetoanopenatarea,movethe motion-controlleverstotheNEUTRAL-LOCK position.
3.Movethethrottlemidwaybetweenfastandslow.
4.Movebothmotion-controlleversalltheway forwarduntiltheybothhitthestopsintheT-slot.
5.Checkwhichwaythemachinetracks.
•Ifittrackstotheright,loosentheboltsand
adjusttheleftstopplaterearwardonthe leftT-slotuntilthemachinetracksstraight (Figure74).
•Ifittrackstotheleft,loosentheboltsand
adjusttherightstopplaterearwardonthe rightT-slotuntilthemachinetracksstraight (Figure74).
6.Tightenthestopplate(Figure74).
ServiceInterval:Every50hours/Monthly(whichever
comesrst)
Maintaintheairpressureinthefrontandreartires at90kPa(13psi).Uneventirepressurecancause unevencut.Checkthetireswhentheyarecoldtoget themostaccuratepressurereading.
g001055
Figure75
Figure74
Leftcontrollevershown

CheckingtheWheelLug Nuts

Checkandtorquethewheellugnutsto122to129 N∙m(90to95ft-lb).

CheckingtheWheel-Hub SlottedNut

ServiceInterval:Aftertherst100hours
Every500hours
Checkandensurethatthetorqueoftheslottednutis 286to352N∙m(211to260ft-lb).
Note:Donotuseanti-seizecompoundonwheelhub.
g010153
1.Controllever3.Stopplate
2.Bolt
53
Figure77
g001297
Figure76
1.Slottednut

AdjustingtheCaster-Pivot Bearing

ServiceInterval:Every500hours/Yearly(whichever
comesrst)
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch(PTO),andengagethe parkingbrake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Removethedustcapfromcasterandtighten thelocknut(Figure77).
1.Springwashers
2.Locknut
g024121
3.Dustcap

UsingtheClutchShim

Somelatermodelyearunitshavebeenbuiltwith clutchesthatcontainabrakeshim.Whentheclutch brakehasworntothepointwheretheclutchnolonger engagesconsistently,youcanremovetheshimto extendtheclutchlife.
4.Tightenthelocknutuntilthespringwashersare at,andthenbackoffa1/4turntoproperlyset thepreloadonthebearings(Figure77).
Important:Makesurethatthespring
washersareinstalledcorrectlyasshownin
Figure77.
5.Installthedustcap(Figure77).
g010869
Figure78
1.Armature5.Brakespacer
2.Fieldshell6.Re-gapshim
3.Rotor7.Brakepole
4.Brake-mountingbolt
RemovingtheClutchShim
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch(PTO),andengagethe parkingbrake.
54
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Usinganaircompressor,blowoutanydebris fromunderthebrakepoleandaroundthebrake spacers(Figure79).
Figure79
4.Checktheconditionofthewire-harnessleads, connectors,andterminals.
Note:Cleanorrepairasnecessary.
5.Verifythat12Vispresentattheclutchconnector whentheblade-controlswitch(PTO)switchis engaged.
6.Measurethegapbetweentherotorand armature.Ifthegapisgreaterthan1mm(0.04 inch),dothefollowingsteps:
A.Loosenbothbrake-mountingbolts1/2to1
fullturnasshowninFigure80.
Note:Donotdiscardtheshimuntilthe
clutchisfunctioningproperly.
g010871
Figure81
1.Shim
C.Usingapneumaticline,blowoutanydebris
g010868
fromunderthebrakepoleandaroundthe brakespacers.
D.T orqueeachbolt(M6x1)to12.3to13.7
N∙m(9.5to10.5ft-lb).
E.Usinga0.25mm(0.01inch)thickfeeler
gauge,verifythatagapispresentbetween therotorandthearmaturefaceonboth sidesofthebrakepoleasshowninFigure
82andFigure83.
Note:Duetothewaytherotorandthe
armaturefaceswear(peaksandvalleys)it issometimesdifculttomeasurethegap accurately.
Note:Donotremovethebrakepolefrom
theeldshell/armature.Thebrakepole hasworntomatchthearmatureandneeds tocontinuetomatchafteryouremovethe shimtoensureproperbraketorque.
Figure80
1.Brake-mountingbolt
B.Usingneedle-nosepliers,orbyhand,hold
thetabandremovetheshim(Figure81).
g010872
Figure82
1.Feelergauge
g010870
55
CoolingSystem Maintenance

CleaningtheEngineScreen andEngine-OilCooler

1.Feelergauge
•Ifthegapislessthan0.25mm(0.01
inch),theninstalltheshim;referto
UsingtheClutchShim(page54).
•Ifthegapissufcient,proceedtothe
safetycheckinstepF.
F.Performthefollowingsafetycheck:
i.Sitontheseatandstarttheengine.
ii.Makesurethatthebladesdonot
engagewiththeblade-controlswitch (PTO)intheOFFposition,andthat theclutchisdisengaged.
Iftheclutchdoesnotdisengage, installtheshimagain;refertoUsing
theClutchShim(page54).
iii.Engageanddisengagethe
blade-controlswitch(PTO)10 consecutivetimestoensurethatthe clutchisfunctioningproperly.
Figure83
g010873
ServiceInterval:Beforeeachuseordaily
Removeanybuildupofgrass,dirt,orotherdebris fromtheoilcoolerandtheenginescreen(Figure84).
g008804
g009191
Figure84
Removeanybuildupofgrass,dirt,orotherdebris fromtheenginescreen.Thishelpsensureadequate coolingandcorrectenginespeedandreducesthe possibilityofoverheatingandmechanicaldamageto theengine(Figure81).
56
Cleaningthe
CheckingandCleaningthe Engine-CoolingFinsand Shrouds
ServiceInterval:Every100hours/Yearly(whichever
comesrst)
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch(PTO),andengagethe parkingbrake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Removetheair-intakescreen,therecoilstarter, andthefanhousing(Figure85).
4.Cleanthedebrisandgrassfromtheengine parts.
5.Installtheair-intakescreen,therecoilstarter, andthefanhousing(Figure85).
Hydraulic-UnitShrouds
ServiceInterval:Beforeeachuseordaily
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch(PTO),andengagethe parkingbrake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Movetheseatforward.
4.Cleanthedebrisandgrassfromthe hydraulic-unitshrouds(Figure86).
5.Positiontheseat.
g009922
Figure85
1.Engineguard4.Fanhousing
2.Engineair-intakescreen
3.Bolt
g015117
Figure86
1.Hydraulic-unitshrouds
g004218
5.Screw
57
BrakeMaintenance

AdjustingtheParking Brake

ServiceInterval:Aftertherst100hours
Every500hoursthereafter
Note:Performthisprocedureattherecommended
serviceintervalorwhenabrakecomponenthasbeen removedorreplaced.
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch(PTO),andengagethe parkingbrake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Raisethebackofthemachineandsupportthe machinewithjackstands.
Figure87
LeftSideShown
1.L-bracket4.Rearlinkageassembly
2.Linkagestop
3.Gap
5.Caliper
6.Wheelhub
g026961
CAUTION
Raisingthemachineforservice ormaintenancerelyingsolelyon mechanicalorhydraulicjackscouldbe dangerous.Themechanicalorhydraulic jacksmaynotbeenoughsupportormay malfunctionallowingthemachinetofall, whichcouldcauseinjury .
Donotrelysolelyonmechanical orhydraulicjacksforsupport.Use adequatejackstandsorequivalent support.
4.Removethereartiresfromthemachine.
5.Removeanydebrisfromthebrakearea.
6.Rotatethedrive-wheelreleasehandleto thereleasedposition;refertoUsingthe
Drive-Wheel-ReleaseValves(page34).
7.Checktoseeifthereisavisiblegapbetween theL-bracketandthelinkagestop(Figure87).
8.Disengagetheparkingbrake,thelevershould beinthedownposition.
9.Turnthewheelhubbyhandinbothdirections relativetothecaliper;thewheelhubshould movefreelybetweenthecaliper.
10.Ifagapisneededorthewheelhubdoesnot movefreely:
A.Disengagetheparkingbrake.
B.Disconnectandne-tunetherearlinkage
assembly:
•Shortenthelinktocreateagap.
•Lengthenthelinktoallowwheelhub
movement.
C.Connecttherearlinkageassembly.
11.Engagetheparkingbrakeandcheckthegap.
12.Repeatsteps8through12untilavisiblegapis achievedandthewheelhubrotatesfreely.
13.Repeatthisprocedureforthebrakeonthe oppositeside.
14.Rotatethedrive-wheelreleasehandleto theoperatingposition;refertoUsingthe
Drive-Wheel-ReleaseValves(page34).
15.Installthereartiresandtorquethelugnuts; refertoCheckingtheWheelLugNuts(page53).
16.Removethejackstands.
58
BeltMaintenance

InspectingtheBelts

ServiceInterval:Every50hours
Replacethebeltifitisworn.Thesignsofawornbelt includesquealingwhilethebeltisrotating;theblades slippingwhilecuttinggrass;andfrayededges,burn marks,andcracksonthebelt.

ReplacingtheMowerBelt forSide-DischargeMower Decks

1.Parkthemachineonalevelsurface,disengage theblade-controlswitch(PTO),andengagethe parkingbrake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Lowerthemowertothe76mm(3inch) height-of-cut.
4.Removethebeltcovers(Figure88).
Figure89
1.Clutchpulley5.Squareholeintheidler
2.Mowerbelt
3.Spring-loadedidlerpulley
4.Ratchet
armfortheratchet
6.Idler-greasetting
7.Beltguide
g009038
Figure88
1.Pushthetabdown2.Removethebeltcover
5.Usearatchetinthesquareholeintheidlerarm toremovetensionontheidlerspring(Figure89).
6.Removethebeltfromthemower-deckpulleys.
7.Removethebeltguideonthespring-loaded idlerarm(Figure89).
8.Removetheexistingbelt.
9.Installthenewbeltaroundthemowerpulleys andtheclutchpulleyundertheengine(Figure
89).
10.Installthebeltguideontheidlerarm(Figure89).
11.Usingtheratchetinthesquarehole,installthe idlerspring(Figure89).
g027729
Note:Makesurethatthespringendsare
seatedintheanchorgrooves.
12.Installthebeltcovers(Figure90).
59
Figure90
g027730
1.Positionthebeltcover3.Ensurethatthetabis underthemetalcatch
2.Slidethebeltcoverunder
thesidecatches

ReplacingtheMowerBelt forRear-DischargeMower Decks

ReplacingtheCounter-Rotating Belt
1.Parkthemachineonalevelsurface,disengage
theblade-controlswitch(PTO),andengagethe parkingbrake.
2.Shutofftheengine,removethekey ,andwait
forallmovingpartstostopbeforeleavingthe operatingposition.
3.Lowerthemowertothe76mm(3inches)height
ofcut.
4.Lifttheoorpanuptogainaccesstothecenter
pulley.
5.Removetheplasticbeltcover(Figure92).
6.Removethe3boltsholdingthemetalbeltcover
inplaceandremovethemetalbeltcover.
g024145
Figure91
1.Idlerspring4.Idlerpulley
2.Counter-rotatingbelt5.Squareholeintheidler armfortheratchet
3.Doublepulley
7.Usearatchetinthesquareholeintheidlerarm
toremovetensionontheidlerspring(Figure91).
8.Removethebeltfromthemowerdeckpulley
(Figure91).
9.Removethebeltfromtheremainingpulleys
(Figure91).
10.Routethenewbeltaboundthemowerpulleys.
11.Usingtheratchetinthesquarehole,removethe tensiononthespring,andguidethenewbelt aroundtheidlerpulley(Figure91).
ReplacingtheMowerBelt
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch(PTO),andengagethe parkingbrake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Lowerthemowertothe76mm(3inches)height ofcut.
4.Removethebeltcovers(Figure92).
60
Figure92
5.Removethecounter-rotatingbelt;referto
ReplacingtheCounter-RotatingBelt(page60).
6.Usearatchetinthesquareholeintheidlerarm toremovetensionontheidlerspring(Figure93).
7.Removethebeltfromthemower-deckpulleys andtheclutchpulley.
8.Installthenewbeltaroundthemowerpulleys andtheclutchpulleyundertheengine(Figure
93).
9.Rotateandensurethebelt-guidetabhitsagainst thepivothub(Figure93).
10.Usingtheratchetinthesquarehole,installthe beltaroundthespring-loadedidlerpulley(Figure
93).Seatthespringendsintheanchorgrooves.
11.Installthebeltcovers(Figure94).
g027729
g027730
Figure94
Figure93
1.Clutchpulley
2.Mowerbelt
3.Spring-loadedidlerpulley7.Squareholeintheidler
4.Ensurethatthebelt-guide tabhitsagainstthepivot hub.
5.Beltguide
6.Spring-loadedidlerpulley
armfortheratchet
8.Spring

ReplacingtheHydraulic Pump-DriveBelt

1.Parkthemachineonalevelsurface,disengage theblade-controlswitch(PTO),andengagethe parkingbrake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Removethemowerbelt;refertoReplacingthe
MowerBeltforSide-DischargeMowerDecks (page59)orReplacingtheMowerBeltfor Rear-DischargeMowerDecks(page60).
4.Raisethemachineandsupportitwithjack stands(Figure95).
g024146
61
Figure95
1.Idlerpulley
2.Clutchpulley6.Squareholeintheidler
3.Pump-drivebelt7.Idlerspring
4.Righthydraulic-pump pulley
5.Lefthydraulic-pumppulley
arm
ControlsSystem Maintenance

Adjustingthe Control-HandlePosition

Thereare2heightpositionsforthecontrol levers—highandlow.Removetheboltstoadjustthe heightfortheoperator.
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch(PTO),andengagethe parkingbrake.
2.Shutofftheengine,removethekey ,andwait
g009039
forallmovingpartstostopbeforeleavingthe operatingposition.
3.Loosentheboltsandangenutsinstalledinthe levers(Figure96).
4.Aligntheleversinthefront-to-rearpositionby bringingtheleverstogethertotheNEUTRAL position,andslidethemuntiltheyarealigned, thentightenthebolts(Figure97).
5.Usearatchetinthesquareholeintheidlerarm toremovetheidlerspring(Figure95).
6.Unhooktheidlerspringfromtheframe(Figure
95).
7.Removethebeltfromthehydraulic-unit-drive pulleysandtheenginepulley.
8.Installthenewbeltaroundenginepulleyand the2drivepulleys.
9.Usingaratchetinthesquareholeintheidler arm,installtheidlerspringtotheframe(Figure
95).
10.Installthemowerbelt;refertoReplacingthe
MowerBeltforSide-DischargeMowerDecks (page59)orReplacingtheMowerBeltfor Rear-DischargeMowerDecks(page60).
Figure96
1.Bolt
2.Handle4.Nut
g009040
3.Controllever
62
4.Lowerdecktotheground.
5.Raisetherearofmachineupandsupportitwith jackstands(orequivalentsupport).
Note:Raisethemachinejusthighenoughto
allowthedrivewheelstoturnfreely.
6.Removetheelectricalconnectionfromtheseat safetyswitch,locatedunderthebottomcushion oftheseat.
Note:Theswitchisapartoftheseatassembly.
7.T emporarilyinstallajumperwireacrossthe terminalsintheconnectorofthemainwire harness.
8.Starttheengineandrunitatfullthrottleand disengagethebrake.
Figure97
5.Iftheendsofthelevershitagainsteach other,refertoAdjustingtheMotion-Control
Neutral-LockPivot(page64).
6.Repeattoadjustthecontrollevers.

Adjustingthe Motion-ControlLinkage

Locatedoneithersideofthemachine,belowtheseat, arethepump-controllinkages.Rotatingtheendnut witha1/2-inchdeepsocketwrenchallowsnetuning adjustmentssothatthemachinedoesnotmovein neutral.Anyadjustmentsshouldbemadeforneutral positioningonly.
WARNING
Theenginemustberunningandthedrive wheelsturningsothatyoucanperformthe adjustments.Contactwithmovingpartsor hotsurfacesmaycausepersonalinjury .
g009195
Note:Beforestartingtheengine,ensurethat
theparkingbrakeisengagedandthatthe motion-controlleversareout.Y oudonothave tobeintheseat.
9.Runthemachineforatleast5minuteswiththe driveleversatfullforwardspeedtobringthe hydraulicuiduptotheoperatingtemperature.
Note:Themotion-controlleversmust
beinneutralwhilemakinganynecessary adjustments.
10.Bringthemotion-controlleversintotheNEUTRAL position.
11.Adjustthepumpcontrolrodlengthsbyrotating thedoublenutsontherodintheappropriate directionuntilthewheelsslightlycreepin reverse(Figure98).
Keepyourngers,hands,andclothingclear ofrotatingcomponentsandhotsurfaces.
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch(PTO),andengagethe parkingbrake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Pushthedeck-liftpedal,andremovethe height-of-cutpin.
63
1.Doublenuts
Figure98
g008620
Figure99
RightMotionControlShown
1.Torquethelocknutto23N∙m(17ft-lb).Theboltmust protrudepasttheendofthelocknutaftertorquing.
2.Mostresistance(rmestfeel)
3.Damper
4.Mediumresistance(mediumfeel)
g027409
5.Leastresistance(softestfeel)
12.Movethemotion-controlleverstotheREVERSE positionandwhileapplyingslightpressureto thelever,allowthereverse-indicatorspringsto bringtheleversbacktoneutral.
Note:Thewheelsmuststopturningorslightly
creepinreverse.
13.Shutoffthemachine.
14.Removethejumperwirefromthewireharness andplugtheconnectorintotheseatswitch.
15.Removethejackstands.
16.Raisethedeckandinstalltheheight-of-cutpin.
17.Checkthatthemachinedoesnotcreepin neutralwiththeparkbrakesdisengaged.

Adjustingthe Motion-ControlDamper

Youcanadjustthetopdamper-mountingbolttoobtain thedesiredmotion-controlleverresistance.Referto
Figure99formountingoptions.

Adjustingthe Motion-Control Neutral-LockPivot

Youcanadjusttheangednuttoobtainthedesired motion-controlleverresistancewhenmovingitto theNEUTRAL-LOCKposition.SeeFigure100for adjustmentoptions.
1.Loosenthejamnut.
2.Tightenorloosentheangednuttothedesired feel.
•Formoreresistance,tightentheangednut.
•Forlessresistance,loosentheangednut
3.Tightenthejamnut.
Figure100
1.Flangednut2.Jamnut
64
g008621
HydraulicSystem
6.Remove1dipstickfromthehydraulicreservoir (Figure101).
Maintenance

HydraulicSystemSafety

•Seekimmediatemedicalattentionifuidisinjected
intoskin.Injecteduidmustbesurgicallyremoved withinafewhoursbyadoctor.
•Ensurethatallhydraulic-uidhosesandlinesare
ingoodconditionandallhydraulicconnections andttingsaretightbeforeapplyingpressureto thehydraulicsystem.
•Keepyourbodyandhandsawayfrompinhole
leaksornozzlesthatejecthigh-pressurehydraulic uid.
•Usecardboardorpapertondhydraulicleaks.
•Safelyrelieveallpressureinthehydraulicsystem
beforeperforminganyworkonthehydraulic system.

ServicingtheHydraulic System

7.Wipethedipstickoffandthreadthedipstickinto thereservoir.
8.Removethedipstickandlookattheend(Figure
101).
Important:Donotoverllthehydraulic
unitswithuid,asdamagemayoccur.Do notrunthemachinewithuidbelowtheadd mark.
9.Iftheuidlevelisattheaddmark,slowlypour onlyenoughuidintothehydraulicreservoirto raisetheleveltothefullorHline.
10.Installthedipstick.
11.Repeattheprocedurefortheoppositedipstick.
Hydraulic-FluidSpecications
Hydraulic-FluidT ype:Toro
hydraulicuidorMobil
®
®
HYPR-OIL
115W-50.
Important:Usethespecieduid.Otheruids
coulddamagethehydraulicsystem.
EachHydraulic-SystemFluidCapacity:1.5L(52
oz)persidewithlterchange
™
500
CheckingtheHydraulicFluid
ServiceInterval:Every50hours—Checkthe
hydraulic-uidlevel.
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch(PTO),andengagethe parkingbrake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Allowtheengineandthehydraulicsystemto coolfor10minutes.
Note:Theoillevelonthedipstickisincorrect
whentheoilischeckedandthemachineishot.
g015459
Figure101
Eitherdipstickisusedinthemachine
1.Full3.H—meanshighlevel
2.Add4.Dipsticklocationsunder seat
4.Movetheseatforward.
5.Cleantheareaaroundthedipsticksof hydraulic-systemreservoirs(Figure101).
65
ReplacingtheHydraulicFluidand Filters
ServiceInterval:Aftertherst250hours—Change
thehydraulicltersandhydraulic uidwhenusinganytypeofuid.
5.Placeadrainpanunderthelter,removetheold lter,andwipethesurfaceclean(Figure103).
Every250hours—Changethehydrauliclters andhydraulicuidwhenusingMobil
®
1uid
(moreoftenindirtyordustyconditions).
Every500hours—Changethehydraulic ltersandhydraulicuidwhenusingT oro HYPR-OIL
™
500hydraulicuid(moreoftenin
dirtyordustyconditions).
Toreplacethehydraulicuid,theltersneedtobe removed.Replacebothatthesametime;referto
Hydraulic-FluidSpecications(page65)fortheoil
specications.
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch,andengagetheparking brake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Raisethemachineandsupportitwithjack stands(Figure102).
®
g008968
Figure103
Bottomviewofthemachine
1.Filterlocations
2.Hydrauliclter
6.Applyathincoatofhydraulicuidtotherubber gasketonthereplacementlter(Figure103).
Figure102
1.Jackstands
4.Removeboththemowerbeltandthepump-drive belt;refertoReplacingtheMowerBeltfor
Side-DischargeMowerDecks(page59)or ReplacingtheMowerBeltforRear-Discharge MowerDecks(page60),andrefertoReplacing theHydraulicPump-DriveBelt(page61).
7.Installthereplacementhydrauliclter.
8.Installthepump-drivebeltandthemowerbelt.
9.Removethejackstandsandlowerthemachine (Figure102).
10.Adduidtothehydraulicreservoirandcheck foranyleaks.
11.Cleanupanyspilleduid.
12.Starttheengineandletitrunforabout2minutes topurgeairfromthesystem.
13.Shutofftheengineandcheckforleaks.
g008970
14.Checktheuidlevelwhiletheuidiscold.
15.Ifrequired,adduidtothehydraulicreservoir.
Note:Donotoverll.
Note:Thispreventsoilfromgettingonthe
belts.
66

MowerDeck Maintenance

LevelingtheMowerDeck

LevelingtheDeck
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch(PTO),andengagethe parkingbrake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Checkthetirepressureinthedrivetires;referto
CheckingtheTirePressure(page53).
4.Positionthetransportlockinthelatching position.
5.Pushthedeck-liftpedalallthewayforward andthedecklatchesatthe14cm(5-1/2inch) transportposition(Figure104).
9.Onbothsidesofthedeck,measurefromthe levelsurfacetothefronttipoftheblade(Postion A)asshowninFigure105.
Note:Themeasurementshouldread7.6mm
(3inches)
Figure105
1.7.6cm(3inch)atposition
Aiscorrect
2.8.3cm(3-1/4inch)at
positionBiscorrect
3.Measureherefromthe bladetiptothehard surface
4.MeasureatpositionAand Bonbothsides
g009196
Figure104
1.Deck-liftpedal
2.Height-of-cutpin
6.Inserttheheight-adjustmentpinintothe7.6cm (3inches)cutting-heightlocation.
3.Transportlock
10.Fine-tunetheadjustmentnutonthefront deck-liftassemblybyturningit(Figure106or
Figure107).
Note:Toincreasetheheight,turnthe
adjustmentnutclockwise;todecreasethe height,turnthenutcounterclockwise.
Note:Ifthefrontdecklinksdonothaveenough
adjustmenttoachieveaccuratecutheight,the single-pointadjustmentcanbeutilizedtogain moreadjustment.
g027343
7.Releasethetransportlockandallowthedeckto lowertothecuttingheight.
8.Forside-dischargemachines,raisethe dischargechute.
67
Figure106
5000SeriesMachines
1.Adjustmentnut3.Reardeckadjustment
2.Jamnut4.Frontdeckadjustment
holesforfurtheradjustmentwhenlevelingthe mowerdeck.
g010251
g027345
Figure108
1.Boltsatthebottomoftheheight-of-cutplate
Figure107
6000SeriesMachines
1.Adjustmentnut3.Reardeckadjustment
2.Jamnut4.Frontdeckadjustment
11.T oadjustthesingle-pointsystem,loosenthe 2boltsatthebottomoftheheight-of-cutplate (Figure108).
Note:Forrear-dischargemachines,themower
deckisattachedinthebackholesatthefactory. RefertoFigure109.Ifneeded,usethefront
g025558
Figure109
g027344
1.Mowerdeck3.Backhole
2.Fronthole
Rear-DischargeMachinesOnly
12.Ifthedeckistoolow,tightenthe single-point-adjustmentboltbyrotatingit clockwise.Ifthedeckistoohigh,loosen thesingle-point-adjustmentboltbyrotatingit counterclockwise(Figure110).
Note:Loosenortightenthesingle-point
adjustmentboltenoughtomovethe height-of-cutplatemountingboltsatleast1/3 thelengthoftheavailabletravelintheirslots.
68
Thisregainssomeupanddownadjustmenton eachofthe4decklinks.

ServicingtheCutting Blades

Toensureasuperiorqualityofcut,keeptheblades sharp.Forconvenientsharpeningandreplacement, youmaywanttokeepextrabladesonhand.
BladeSafety
Awornordamagedbladecanbreak,andapieceof thebladecouldbethrowntowardyouorbystanders, resultinginseriouspersonalinjuryordeath.Tryingto repairadamagedblademayresultindiscontinued safetycerticationoftheproduct.
Figure110
1.Single-pointadjustmentbolt
13.Tightenthe2boltsatthebottomofthe height-of-cutplate(Figure108).
Note:Inmostconditions,thebackbladetip
shouldbeadjusted6.4mm(1/4inch)higher thanthefront.
14.T orquethe2boltsto37to45N∙m(27to33ft-lb).
15.Onbothsidesofthedeck,measurefromthe levelsurfacetothebacktipoftheblade(postion B)asshowninFigure105.
Note:Themeasurementshouldread8.3cm
(3-1/4inches)
16.Finetunethescrewadjusterbyturningittoget
8.3mm(3-1/4inches)height(Figure107).
Toincreasetheheight,turntheadjustmentnut clockwise;todecrease,turncounterclockwise.
17.Measureuntilall4sidesarethecorrectheight.
18.Tightenallofthenutsonthedeck-lift-arm assemblies.
19.Forside-dischargemachines,lowerthe dischargechute.
g017036
•Inspectthebladesperiodicallyforwearordamage.
•Usecarewhencheckingtheblades.Wrapthe
bladesorweargloves,andusecautionwhen servicingtheblades.Onlyreplaceorsharpenthe blades;neverstraightenorweldthem.
•Onmulti-bladedmachines,takecareasrotating1
bladecancauseotherbladestorotate.
BeforeInspectingorServicingthe Blades
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch(PTO),andengagethe parkingbrake.
2.Shutofftheengine,removethekey,and disconnectthespark-plugwiresfromthespark plugs.
InspectingtheBlades
ServiceInterval:Beforeeachuseordaily
1.Inspectthecuttingedges(Figure111).
2.Iftheedgesarenotsharporhavenicks,remove andsharpentheblade;refertoSharpeningthe
Blades(page71).
3.Inspecttheblades,especiallyinthecurvedarea.
4.Ifyounoticeanycracks,wear,oraslotforming inthisarea,immediatelyinstallanewblade (Figure111).
69
Figure111
1.Cuttingedge3.Wear/slotforming
2.Curvedarea4.Crack
CheckingforBentBlades
1.Rotatethebladesuntiltheendsfaceforward andbackward.
2.Measurefromalevelsurfacetothecutting edge,positionA,oftheblades(Figure112).
RemovingtheBlades
Side-DischargeMachines
Replacethebladesiftheyhitasolidobject,orifthe bladeisoutofbalanceorbent.
1.Holdthebladeendusingaragorthicklypadded glove.
g006530
2.Removethebladebolt,curvedwasher,and bladefromthespindleshaft(Figure113).
Figure112
1.Measureherefromblade tohardsurface
2.PositionA
3.Rotatetheoppositeendsofthebladesforward.
4.Measurefromalevelsurfacetothecuttingedge
ofthebladesatthesamepositionasinstep2 above.
Note:Thedifferencebetweenthedimensions
obtainedinsteps2and4mustnotexceed3 mm(1/8inch).
Note:Ifthisdimensionexceeds3mm(1/8
inch),thebladeisbentandmustbereplaced.
g004536
Figure113
1.Sailareaoftheblade3.Curvedwasher
2.Blade4.Bladebolt
Rear-DischargeMachines
Important:Therightbladeonthismowerdeckis
g000975
counter-rotatingandusesaleft-threadedblade bolt.
Replaceabladeifithitsanobject,ifthebladeisout ofbalance,orifthebladeisbent.Toensureoptimum performanceandcontinuedsafetyconformanceof themachine,usegenuineTororeplacementblades. Replacementbladesmadebyothermanufacturers mayresultinnonconformancewithsafetystandards.
1.Holdthebladeendusingaragorthickly-padded glove.
2.Removetheleftandcenterbladebolt,curved washer,andbladefromthespindleshaft(Figure
114).
3.Removetherightbladebolt(leftthreadedbolt), curvedwasher,andbladefromthespindleshaft (Figure114).
Note:Notethetypeofbladeandwhereeach
bladeisinstalled.SeeFigure115forthecorrect position.
70
Figure114
LeftandCenterSpindleShown
1.Sailareaoftheblade3.Curvedwasher
2.Blade4.Bladebolt
SharpeningtheBlades
1.Usealetosharpenthecuttingedgeatboth endsoftheblade(Figure116).
Note:Maintaintheoriginalangle.
Note:Thebladeretainsitsbalanceifthesame
amountofmaterialisremovedfrombothcutting edges.
g000552
Figure116
1.Sharpenatoriginalangle.
g004536
2.Checkthebalanceofthebladebyputtingiton abladebalancer(Figure117).
Note:Ifthebladestaysinahorizontalposition,
thebladeisbalancedandcanbeused.
Figure115
Bladelocation
1.Frontofmowerdeck4.Counter-rotatingblade
2.Right-threadedbladebolts
3.Regularblades
5.Left-threadedbladebolt
Note:Ifthebladeisnotbalanced,lesome
metalofftheendofthesailareaonly(Figure
116).
g000553
Figure117
1.Blade2.Balancer
3.Repeatthisprocedureuntilthebladeis balanced.
InstallingtheBlades
Side-DischargeMachines
1.Installthebladeontothespindleshaft(Figure
113).
Important:Thecurvedpartoftheblade
g024248
mustpointupwardtowardtheinsideofthe mowertoensurepropercutting.
2.Installthecurvedwasherandbladebolt(Figure
113).
Note:Installthecurved-washerconetoward
thebolthead.
3.T orquethebladeboltto115to150N∙m(85to 110ft-lb).
71
Rear-DischargeMachines
Important:Therightbladeonthismowerdeckis
counter-rotatingandusesaleft-threadedblade bolt.UseFigure115forthecorrectplacementof themowerblades.
1.Installtheleftandcenterblades,curved washers,andbladeboltstothespindleshafts (Figure114andFigure115).
Important:Thecurvedpartoftheblade
mustpointupwardtowardtheinsideofthe mowertoensurepropercutting.
Note:Installthecurved-washerconetowards
thebolthead(Figure114).
2.Installtherightblade,curvedwasher,andblade bolt(left-threadedbolt)tothespindleshaft (Figure114andFigure115).
3.T orquethebladeboltto115to150N∙m(85to 110ft-lb).

RemovingtheMowerDeck

andremovethemowerbelt(Figure1 18or
Figure119).
Lockoutthespring-loadeddeckarmsbeforeservicing orremovingthemowerdeck.
WARNING
Deck-liftarmassemblieshavestoredenergy. Removingthedeckwithoutreleasingthe storedenergycancauseseriousinjuryor death.
Donotattempttodisassemblethedeckfrom thefrontframewithoutlockingoutthestored energy.
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch(PTO),andengagethe parkingbrake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Placetheheightadjustmentpininthe7.6cm(3 inch)cutting-heightlocation.
Note:Thislocksthedeck-liftarmsinthelowest
positionwhenthedeckisremovedandthe storedenergyinthedeckspringisreleased.
Figure118
Side-DischargeMachines
1.Clutchpulley5.Squareholeintheidler
2.Mowerbelt
3.Spring-loadedidlerpulley
4.Ratchet
armfortheratchet
6.Idlergreasetting
7.Beltguide
g009038
4.Removethebeltcovers.
5.Liftuptheoorpanandinsertaratchetinto thesquareholeinthedeckidler(Figure118or
Figure119).
6.Rotatethedeckidlerclockwise,liftuponthe belt-guidetab(rear-dischargemachinesonly),
72
Rear-DischargeMachines
Figure119
g010252
Figure120
1.Rightstabilizer
2.Deckstrut(rightsideshown)
3.Removetheshoulderboltandnut.
4.Removetheshoulderboltandnut.
8.Raisethedeckstrutsandsecuretheminthe raisedposition.
g024146
9.Slidethedeckouttotherightsideofthe machine.
1.Clutchpulley
2.Mowerbelt
3.Spring-loadedidlerpulley7.Squareholeintheidler
4.Ensurethatthebelt-guide tabhitsagainstthepivot hub.
5.Beltguide
6.Spring-loadedidlerpulley
armfortheratchet
8.Spring
7.Removeandretainthehardwareonbothsides
ofthedeckasshowninFigure120.
ReplacingtheGrass Deector
Side-DischargeMachinesOnly
WARNING
Anuncovereddischargeopeningcouldallow themachinetothrowobjectstowardyouor bystanders,resultinginseriousinjury.Also, contactwiththebladecouldoccur.
Neveroperatethemachineunlessyouinstall amulchplate,dischargedeector,orgrass collectionsystem.
1.Removethelocknut,bolt,spring,andspacer holdingthedeectortothepivotbrackets (Figure121).
2.Removethedamagedorworngrassdeector (Figure121).
73
Figure121
1.Bolt
2.Spacer6.Grassdeector
3.Locknut
4.Spring
5.Springinstalled
7.J-hookendofspring
Cleaning

CleaningundertheMower Deck

ServiceInterval:Beforeeachuseordaily
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch(PTO),andengagethe parkingbrake.
2.Shutofftheengine,removethekey ,andwait
g015594
forallmovingpartstostopbeforeleavingthe operatingposition.
3.RaisethemowerdecktotheTRANSPORT position.
CleaningtheSuspension
3.Placethespacerandthespringontograss deector.
4.Place1J-hookendofthespringbehindthe deckedge.
Note:Makesurethat1J-hookendofthe
springisinstalledbehindthedeckedgebefore installingtheboltasshowninFigure121.
5.Installtheboltandthenut.
6.Place1J-hookendofthespringaroundthe grassdeector(Figure121).
Important:Thegrassdeectormustbeable
torotate.Liftthedeectoruptothefullopen positionandensurethatitrotatesintothe fulldownposition.
System
MachineswithMyRide™ SuspensionSystemOnly
ServiceInterval:Beforeeachuseordaily
Usecompressedairtocleanthesuspensionsystem.
Note:Donotcleantheshockassemblieswith
pressurizedwater(Figure122).
g195820
Figure122

DisposingofWaste

Engineoil,batteries,hydraulicuid,andengine coolantarepollutantstotheenvironment.Disposeof theseaccordingtoyourstateandlocalregulations.
74
Storage

StorageSafety

•Shutofftheengine,removethekey,waitforall
movingpartstostop,andallowthemachineto coolbeforestoringit.
•Donotstorethemachineorfuelnearamesor
drainthefuelindoors.
•Removethekeyandstoreitinasafeplaceout
ofthereachofchildren.

CleaningandStorage

1.Disengagetheblade-controlswitch(PTO),and engagetheparkingbrake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Removegrassclippings,dirt,andgrimefromthe externalpartsoftheentiremachine,especially theengineandhydraulicsystem.Cleandirtand chafffromtheoutsideoftheenginecylinder headnsandblowerhousing.
Important:Y oucanwashthemachinewith
milddetergentandwater.Donotpressure washthemachine.Avoidexcessiveuse ofwater,especiallynearthecontrolpanel, engine,hydraulicpumps,andmotors.
4.Checktheparkingbrakeoperation;referto
EngagingtheParkingBrake(page25).
5.Servicetheaircleaner;refertoServicingtheAir
Cleaner(page42).
6.Greasethemachine;refertoLubrication(page
38).
7.Changethecrankcaseoil;refertoChangingthe
EngineOil(page44).
8.Checkthetirepressure;refertoCheckingthe
TirePressure(page53).
9.Changethehydrauliclters;refertoReplacing
theHydraulicFluidandFilters(page66).
13.Preparethemachineforstoragewhennon-use occursover30days.Preparethemachinefor storageasfollows:
A.Addapetroleum-based
stabilizer/conditionertofuelinthe tank.Followmixinginstructionsfrom thestabilizermanufacturer.Donotuse analcohol-basedstabilizer(ethanolor methanol).
Note:Afuelstabilizer/conditionerismost
effectivewhenmixedwithfreshfueland usedatalltimes.
B.Runtheenginetodistributeconditionedfuel
throughthefuelsystemfor5minutes.
C.Shutofftheengine,allowittocool,and
drainthefueltank.
D.Starttheengineandrunituntilitstops.
E.Disposeoffuelproperly.Recyclethefuel
accordingtolocalcodes.
Important:Donotstorefuelcontaining
stabilizer/conditionerlongerthan thedurationrecommendedbythe fuel-stabilizermanufacturer.
14.Removeandchecktheconditionofthespark plug(s);refertoServicingtheSparkPlug(page
45).Withthesparkplug(s)removedfromthe
engine,pour30ml(2tablespoons)ofengine oilintothesparkplughole.Usethestarterto cranktheengineanddistributetheoilinsidethe cylinder.Installthesparkplug(s).Donotinstall thewireonthesparkplug(s).
15.Checkandtightenallbolts,nuts,andscrews. Repairorreplaceanypartthatisdamaged.
16.Paintallscratchedorbaremetalsurfaces.Paint isavailablefromyourAuthorizedServiceDealer.
17.Storethemachineinaclean,drygarageor storagearea.Removethekeyfromtheswitch andkeepitoutofreachofchildrenorother unauthorizedusers.Coverthemachineto protectitandkeepitclean.
10.Chargethebattery;refertoChargingtheBattery
(page49).
11.Scrapeanyheavybuildupofgrassanddirt fromtheundersideofthemower,thenwashthe mowerwithagardenhose.
Note:Runthemachinewiththeblade-control
switch(PTO)engagedandtheengineathigh idlefor2to5minutesafterwashing.
12.Checktheconditionoftheblades;referto
ServicingtheCuttingBlades(page69).
75
Troubleshooting
Problem
Themalfunction-indicatorlight(MIL) comeson.
Thestarterdoesnotcrank.
PossibleCauseCorrectiveAction
1.Theengineistoohot.
2.Thereisoldfuelinthefueltank.2.Usenewfuel.
3.Thefuel-shutoffvalveisnotopen completely.
4.Theaircleanerisdirty.4.Makesurethattheaircleanerand
5.Thebatteryisnotcharged.
6.Incorrectfuelltersarebeingusedor thefuelltersaredirty.
7.Theconnectionstothesensors electronic-controlunit(ECU)andfuel injectorsarenotsecuredproperly .
8.Thereislowvoltagefromthebattery.
9.Afuseisblown.9.Checkandreplaceanyblownfuses.
1.Theblade-controlswitchisengaged.1.Disengagetheblade-controlswitch.
2.Theparkingbrakeisdisengaged.2.Engagetheparkingbrake.
3.Themotion-controlleversarenotin theNEUTRAL-LOCKposition.
4.Y ouarenotsittingintheoperator’s seat.
5.Thebatteryisdead.
6.Theelectricalconnectionsare corrodedorloose.
7.Afuseisblown.7.Replacethefuse.
8.Arelayorswitchisdamaged.
1.Shutofftheengineandletitcool.
3.Openthefuel-shutoffvalve.
precleanerareclean.Replaceif necessary.
5.Chargeorreplacethebattery.
6.ContactanAuthorizedServiceDealer.
7.ContactanAuthorizedServiceDealer.
8.Ensurethatyouareusingagood12V batteryandthatitisfullycharged.
3.Movethemotion-controllevers outwardtotheNEUTRAL-LOCKposition.
4.Sitontheoperator’sseat.
5.Chargethebattery.
6.Checktheelectricalconnectionsfor goodcontact.
8.ContactanAuthorizedServiceDealer.
Theenginedoesnotstart,startshard,or failstokeeprunning.
1.Thefueltankisempty.1.Fillthefueltank.
2.Thefuel-shutoffvalveisclosed.2.Openthefuel-shutoffvalve.
3.Theoillevelinthecrankcaseislow.3.Addoiltothecrankcase.
4.Thethrottleisnotinthecorrect position.
5.Thereisdirtinthefuellter.5.Replacethefuellter.
6.Dirt,water,orstalefuelisinfuel system.
7.Theaircleanerisdirty.
8.Theseatswitchisnotfunctioning properly.
9.Theelectricalconnectionsare corroded,loose,ordamaged.
10.Therelayorswitchiswornor damaged.
11.Thesparkplugisfouledorimproperly gapped.
12.Thespark-plugwireisnotconnected.
4.Besurethatthethrottlecontrolis midwaybetweentheslowandfast positions.
6.ContactanAuthorizedServiceDealer.
7.Cleanorreplacetheair-cleaner element.
8.Checktheseat-switchindicator. Replacetheseatifnecessary .
9.Checktheelectricalconnections forgoodcontact.Cleanthe connectorterminalsthoroughlywith electrical-contactcleaner,apply dielectricgrease,andmakethe appropriateconnections.
10.ContactanAuthorizedServiceDealer.
11.Adjustorreplacethesparkplug.
12.Checkthespark-plugwireconnection.
76
Problem
PossibleCauseCorrectiveAction
Theenginelosespower.
Theengineoverheats.
Themachinepullstotheleftorright(with leversfullyforward)
Themachinedoesnotdrive.
1.Theengineloadisexcessive.1.Reducethegroundspeed.
2.Theaircleanerisdirty.
3.Theoillevelinthecrankcaseislow.3.Addoiltothecrankcase.
4.Thecoolingnsandtheairpassages abovetheengineareplugged.
5.Theventholeinthefuelcapisplugged.5.Cleanorreplacethefuelcap.
6.Thereisdirtinthefuellter.6.Replacethefuellter.
7.Thereisdirt,water,orstalefuelinthe fuelsystem.
1.Theengineloadisexcessive.1.Reducethegroundspeed.
2.Theoillevelinthecrankcaseislow.2.Addoiltothecrankcase.
3.Thecoolingnsandairpassages undertheengine-blowerhousingare plugged.
4.Theaircleanerisdirty.
5.Dirt,water,orstalefuelisinthefuel system.
1.Thetrackingneedsadjustment1.Adjustthetracking.
2.Thetirepressureinthedrivetiresis notcorrect.
1.Thebypassvalvesarenotclosedtight.1.Tightenthebypassvalves.
2.Thepumpbeltisworn,loose,or broken.
3.Thepumpbeltisoffapulley.3.Changethebelt.
4.Theidlerspringisbrokenormissing.4.Replacethespring.
5.Thehydraulicuidlevelislowortoo hot.
2.Cleantheair-cleanerelement.
4.Removetheobstructionfromthe coolingnsandtheairpassages.
7.ContactanAuthorizedServiceDealer.
3.Removetheobstructionfromthe coolingnsandairpassages.
4.Cleanorreplacetheair-cleaner element.
5.ContactanAuthorizedServiceDealer
2.Adjustthetirepressureinthedrive tires.
2.Changethebelt.
5.Addhydraulicuidtothereservoirsor letitcooldown.
Themachinevibratesabnormally .
Thecuttingheightisuneven.
1.Thecuttingblade(s)is/arebentor unbalanced.
2.Theblademountingboltisloose.2.Tightentheblademountingbolt.
3.Theenginemountingboltsareloose.3.Tightentheenginemountingbolts.
4.Theenginepulley ,idlerpulley,orblade pulleyisloose.
5.Theenginepulleyisdamaged.
6.Thebladespindleisbent.
7.Themotormountislooseorworn.
1.Theblade(s)isnotsharp.1.Sharpentheblade(s).
2.Acuttingblade(s)is/arebent.2.Installanewcuttingblade(s).
3.Themowerisnotlevel.
4.Ananti-scalproller(ifapplicable)isnot setcorrectly .
5.
Theundersideofthemowerdeckis dirty.
Thetirepressureisincorrect.
6.
7.Abladespindleisbent.
1.Installnewcuttingblade(s).
4.Tightentheappropriatepulley.
5.ContactanAuthorizedServiceDealer.
6.ContactanAuthorizedServiceDealer.
7.ContactanAuthorizedServiceDealer.
3.Levelthemowerfromside-to-sideand front-to-rear.
4.Adjusttheanti-scalpwheelheight.
5.
Cleantheundersideofthemower deck.
Adjustthetirepressure.
6.
7.ContactanAuthorizedServiceDealer.
77
Problem
PossibleCauseCorrectiveAction
Thebladesdonotrotate.
Theclutchdoesnotengage.
1.Themowerdeckbeltisdamaged, worn,loose,orbroken.
2.Themowerdeckbeltisoffthepulley.
3.Thepumpdrivebeltisworn,loose,or broken.
4.Theidlerspringisbrokenormissing.4.Replacethespring.
1.Thefuseisblown.1.Replacethefuse.Checkthecoil
2.Thereislowvoltagesupplyatthe clutch.
3.Thecoilisdamaged.3.Replacetheclutch.
4.Thereisinadequatecurrentsupply.4.Repairorreplacetheclutchlead
5.Therotor/armatureairgapistoolarge.
1.Installanewdeckbelt.
2.Installthemowerbeltonthedeck pulleyandchecktheidlerpulley,idler arm,andspringforcorrectposition andfunction.
3.Checkthebelttensionorinstallanew belt.
resistance,batterycharge,charging system,andwiringconnections,and replacecomponentsifnecessary.
2.Checkthecoilresistance,battery charge,chargingsystem,andwiring connectionsandreplacepartsif necessary.
wireorelectricalsystem.Cleanthe connectorcontacts.
5.Removetheshimorreplacetheclutch.
78
Schematics
FUEL
NC
NC
CONNECTOR CAP
RED
RED RED
RED
F02 15A
ACC'Y
START RELAY
K01
30
85 86
87
BLUE
F01 20A
MAIN
SP01
RED/GREEN
SP02
BLUE/YELLOW
BLUE
BLUE/BLACK
SP03
RED/GREEN
RED/GREEN
RED/GREEN
SP05
BLACK
BLACK
W010 GXL16BU/RD
RED/WHITE
BLACK
VIOLET/WHITE
SP04
SW03
BRAKE Switch
P10
2
P10
1
SW04
SEAT Switch
P02
2
P02
1
RED/WHITE
RED/WHITE
RED/WHITE
RED/WHITE
GREEN/YELLOW
GREEN/YELLOW
ORANGE
ORANGE/RED
BLACK
GREEN
YELLOW
BLACK
RED/WHITE
RED/GREEN
BLACK
P14
CHECK FAULT
A
B
BLACK
J01
STARTER POST BATTERY POST
1
J02
ENGINE GND BATTERY GND
1
CLUTCH
L01
P06
A
P06
B
VIOLET/RED
SW09
FUEL SENDER
P13
B
OUT
C
PWR
P13
A
GND
GRAY/BROWN GRAY/BROWNGRAY/BROWN
YELLOW/BLUE
J03
1
J04
1
BLACK
RED/WHITE
MOD01
HOUR METER
P11
2
GND
3
SW PWR4B+7OPC
11
START SIGNAL16KEY S17NEUTRAL19PARK BRAKE13PTO ON15PTO MOMEN
P11
12
OIL PRESS
14
CHECK FAULT
20
OIL TEMP
10
CAN H
1
GND-S/D
5
EFI ENG MIL
6
PTO OUT
8
FUEL SOL
9
CAN L
18
FUEL LEVEL
RED/WHITE
SW10
B
S
A
I
OFF
RUN
START
IGNITION SWITCH
P08
D
P08
ACB
ACC'Y
PT01
CAP
ACC PWR
GND
ACC SIGNAL
P12
A
B
C
GRAY/VIOLET
YELLOW/WHITE
YELLOW/BLACK
GRAY/WHITE
GRAY/ORANGE
OIL PRESSURE
DC
REG
FUSE
ALT
ENG
GND
IGNITION
MODULES
FLYWHEEL
30A
OIL PRESS
NC
PWR-RUN
GND-S/D
OIL TEMP
ENGINE
ENG01
FUEL SOLENOID
OIL TEMPERATURE
STARTNCNC
P05
A
B
C
D
E
F
G
H
P15
A
B
BLACK
SERVICE PORT
PT02
CAP
P03
1
GND2PWR - FUSED
3
PWR - SW
4
CAN-L5CAN-H6NC
SW07
LH NEUTRAL Switch
P01
1
P01
2
SW08
RH NEUTRAL Switch
P09
1
P09
2
PWR DIST MODULE
P04
1
3
456
7
P04
8
9
10
11
12
2
PTO Switch
SW12
V+
GND
OUT
KNOB EXTENDED = HIGH
KNOB DEPRESSED = OPEN
P07
B
P07
A
C
GREEN/BROWN
ElectricalSchematic(Rev .A)
79
g224051
CaliforniaProposition65WarningInformation

Whatisthiswarning?

Youmayseeaproductforsalethathasawarninglabellikethefollowing:
WARNING:CancerandReproductiveHarm—www.p65Warnings.ca.gov.

WhatisProp65?

Prop65appliestoanycompanyoperatinginCalifornia,sellingproductsinCalifornia,ormanufacturingproductsthatmaybesoldinorbroughtinto California.ItmandatesthattheGovernorofCaliforniamaintainandpublishalistofchemicalsknowntocausecancer,birthdefects,and/orother reproductiveharm.Thelist,whichisupdatedannually,includeshundredsofchemicalsfoundinmanyeverydayitems.ThepurposeofProp65isto informthepublicaboutexposuretothesechemicals.
Prop65doesnotbanthesaleofproductscontainingthesechemicalsbutinsteadrequireswarningsonanyproduct,productpackaging,orliteraturewith theproduct.Moreover,aProp65warningdoesnotmeanthataproductisinviolationofanyproductsafetystandardsorrequirements.Infact,the CaliforniagovernmenthasclariedthataProp65warning“isnotthesameasaregulatorydecisionthataproductis‘safe’or‘unsafe.’”Manyofthese chemicalshavebeenusedineverydayproductsforyearswithoutdocumentedharm.Formoreinformation,gotohttps://oag.ca.gov/prop65/faqs-view-all
AProp65warningmeansthatacompanyhaseither(1)evaluatedtheexposureandhasconcludedthatitexceedsthe“nosignicantrisklevel”;or(2) haschosentoprovideawarningbasedonitsunderstandingaboutthepresenceofalistedchemicalwithoutattemptingtoevaluatetheexposure.

Doesthislawapplyeverywhere?

Prop65warningsarerequiredunderCalifornialawonly.ThesewarningsareseenthroughoutCaliforniainawiderangeofsettings,includingbutnot limitedtorestaurants,grocerystores,hotels,schools,andhospitals,andonawidevarietyofproducts.Additionally ,someonlineandmailorder retailersprovideProp65warningsontheirwebsitesorincatalogs.
.

HowdotheCaliforniawarningscomparetofederallimits?

Prop65standardsareoftenmorestringentthanfederalandinternationalstandards.TherearevarioussubstancesthatrequireaProp65warning atlevelsthatarefarlowerthanfederalactionlimits.Forexample,theProp65standardforwarningsforleadis0.5μg/day,whichiswellbelow thefederalandinternationalstandards.

Whydon’tallsimilarproductscarrythewarning?

•ProductssoldinCaliforniarequireProp65labellingwhilesimilarproductssoldelsewheredonot.
•AcompanyinvolvedinaProp65lawsuitreachingasettlementmayberequiredtouseProp65warningsforitsproducts,butothercompanies
makingsimilarproductsmayhavenosuchrequirement.
•TheenforcementofProp65isinconsistent.
•CompaniesmayelectnottoprovidewarningsbecausetheyconcludethattheyarenotrequiredtodosounderProp65;alackofwarningsfora
productdoesnotmeanthattheproductisfreeoflistedchemicalsatsimilarlevels.

WhydoesToroincludethiswarning?

Torohaschosentoprovideconsumerswithasmuchinformationaspossiblesothattheycanmakeinformeddecisionsabouttheproductstheybuyand use.T oroprovideswarningsincertaincasesbasedonitsknowledgeofthepresenceofoneormorelistedchemicalswithoutevaluatingthelevelof exposure,asnotallthelistedchemicalsprovideexposurelimitrequirements.WhiletheexposurefromToroproductsmaybenegligibleorwellwithinthe “nosignicantrisk”range,outofanabundanceofcaution,TorohaselectedtoprovidetheProp65warnings.Moreover ,ifTorodoesnotprovidethese warnings,itcouldbesuedbytheStateofCaliforniaorbyprivatepartiesseekingtoenforceProp65andsubjecttosubstantialpenalties.
RevA
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