Toro 74921, 74935 Operator's Manual

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Page 1

FormNo.3361-311RevD

ZMasterG3witha48in,52in, 60inor72inTURBOFORCE SideDischargeMower

ModelNo.74917—SerialNo.290000001andUp

ModelNo.74921—SerialNo.290000001andUp

ModelNo.74923—SerialNo.290000001andUp

ModelNo.74925—SerialNo.290000001andUp

ModelNo.74927—SerialNo.290000001andUp

ModelNo.74935—SerialNo.290000001andUp

ModelNo.74937—SerialNo.290000001andUp

ToregisteryourproductordownloadanOperator'sManualorPartsCatalogatnocharge,gotowww.Toro.com.OriginalInstructions(EN)

Page 2

Warning

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

ThissparkignitionsystemcomplieswithCanadian ICES-002

Becauseinsomeareastherearelocal,state,orfederal regulationsrequiringthatasparkarresterbeusedon theengineofthismachine,asparkarresterisavailable asanoption.Ifyourequireasparkarrestor,contact yourAuthorizedT oroDealer.

GenuineTorosparkarrestersareapprovedbytheUSDA ForestryService.

Important:ItisaviolationofCaliforniaPublic ResourceCodeSection4442touseoroperate theengineonanyforest-covered,brush-covered, orgrass-coveredlandwithoutasparkarrester mufermaintainedinworkingorder,ortheengine constricted,equipped,andmaintainedforthe preventionofre.Otherstatesorfederalareasmay havesimilarlaws.

Theenclosed

Engine Owner’ s Man ual

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

issupplied

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

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

Figure2

1.Safetyalertsymbol

Introduction

Readthisinformationcarefullytolearnhowtooperate andmaintainyourproductproperlyandtoavoidinjury andproductdamage.Youareresponsibleforoperating theproductproperlyandsafely .

YoumaycontactTorodirectlyatwww.Toro.comfor productandaccessoryinformation,helpndinga dealer,ortoregisteryourproduct.

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

Thismanualuses2otherwordstohighlightinformation. Importantcallsattentiontospecialmechanical informationandNoteemphasizesgeneralinformation worthyofspecialattention.

Contents

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

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

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

SlopeChart..........................................................6

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

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

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

Specications.....................................................12

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

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

Contactusatwww.T oro.com.

PrintedintheUSA.

AllRightsReserved

Page 3

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

BreakingInaNewMachine................................14

UsingtheRolloverProtectionSystem

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

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

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

OperatingtheMowerBladeControlSwitch

(PTO)............................................................16

OperatingtheThrottle.......................................17

OperatingtheChoke..........................................17

OperatingtheIgnitionSwitch.............................17

UsingtheFuelShut-OffValve............................18

StartingandStoppingtheEngine........................18

TheSafetyInterlockSystem................................19

DrivingForwardorBackward.............................20

StoppingtheMachine.........................................22

AdjustingtheHeightofCut................................22

AdjustingtheAnti-ScalpRollers.........................23

AdjustingtheFlowBafeCamLocks..................24

PositioningtheFlowBafe.................................24

PositioningtheSeat............................................25

UnlatchingtheSeat.............................................25

UsingtheDriveWheelReleaseValves.................25

UsingtheSideDischarge....................................26

TransportingMachines.......................................26

LoadingMachines..............................................27

OperatingTips...................................................28

Maintenance...............................................................29

RecommendedMaintenanceSchedule(s)................29

Lubrication.............................................................30

GreasingandLubrication...................................30

WheretoGreasetheMower...............................30

LubricateCasterWheelHubs.............................31

EngineMaintenance...............................................32

ServicingtheAirCleaner....................................32

ServicingtheEngineOil.....................................33

ServicingtheSparkPlug.....................................36

CheckSparkArrester(ifequipped)......................37

FuelSystemMaintenance.......................................38

ReplacingtheFuelFilter.....................................38

ServicingtheFuelTank......................................38

ElectricalSystemMaintenance................................39

ServicingtheBattery...........................................39

ServicingtheFuses.............................................41

DriveSystemMaintenance.....................................41

CheckingtheSeatBelt........................................41

CheckingtheRolloverProtectionSystem

(ROPS)Knobs...............................................41

AdjustingtheTracking........................................42

CheckingtheTirePressure.................................42

CheckingtheWheelHubSlottedNut..................43

AdjustingtheCasterPivotBearing......................43

UsingtheClutchShim........................................43

CoolingSystemMaintenance..................................45

CleaningtheEngineScreenandEngineOil

Cooler............................................................45

CleaningtheEngineCoolingFinsand

Shrouds..........................................................45

CheckandCleantheHydraulicUnit

Shrouds..........................................................46

BrakeMaintenance.................................................47

AdjustingtheParkingBrake................................47

BeltMaintenance....................................................48

InspectingtheBelts............................................48

ReplacingtheMowerBelt...................................48

ReplacingtheHydraulicPumpDrive

Belt................................................................49

ControlsSystemMaintenance.................................50

AdjustingtheControlHandlePosition................50

AdjustingtheMotionControlLinkage................50

AdjustingtheMotionControlDamper...............51

AdjustingtheMotionControlNeutralLock

Pivot..............................................................51

HydraulicSystemMaintenance...............................52

ServicingtheHydraulicSystem...........................52

MowerDeckMaintenance......................................54

LevelingtheMowerDeck...................................54

ServicingtheCuttingBlades...............................56

RemovingtheMowerDeck................................59

ReplacingtheGrassDeector.............................60

Cleaning.................................................................61

CleaningUndertheMower.................................61

WasteDisposal...................................................61

Storage.......................................................................61

CleaningandStorage..........................................61

Troubleshooting.........................................................63

Schematics.................................................................65

Page 4

Safety

•Useextracarewhenhandlinggasolineandother fuels.Theyareammableandvaporsareexplosive.

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

Thisproductiscapableofamputatinghandsand feetandthrowingobjects.Alwaysfollowallsafety instructionstoavoidseriousinjuryordeath.

Thisproductisdesignedforcuttingandrecyclinggrass or,whenequippedwithagrassbagger,forcatching cutgrass.Anyuseforpurposesotherthanthesecould provedangeroustouserandbystanders.

SafeOperatingPractices

ThefollowinginstructionsarefromANSIstandard B71.4-2004.

Training

–Useonlyanapprovedcontainer

–Neverrefuelordrainthemachineindoors.

–Neverremovegascaporaddfuelwithengine

running.Allowenginetocoolbeforerefueling. Donotsmoke.

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

Operation

•Neverrunanengineinanenclosedarea.

•Onlyoperateingoodlight,keepingawayfromholes andhiddenhazards.

•Besurealldrivesareinneutralandparkingbrakeis engagedbeforestartingengine.Starttheengineonly fromtheoperator’sposition.Useseatbeltswiththe rollbarintheraisedandlockedposition.

•Neverraisemowerwiththebladesrunning.

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

•Becomefamiliarwiththesafeoperationofthe equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.The ownerisresponsiblefortrainingtheusers.

•Neverletchildrenoruntrainedpeopleoperateor servicetheequipment.Localregulationsmayrestrict theageoftheoperator.

•Theowner/usercanpreventandisresponsiblefor accidentsorinjuriesoccurringtohimselforherself, otherpeopleorproperty.

Preparation

•Evaluatetheterraintodeterminewhataccessories andattachmentsareneededtoproperlyand safelyperformthejob.Onlyuseaccessoriesand attachmentsapprovedbythemanufacturer.

•Wearappropriateclothingincludinghardhat,safety glassesandhearingprotection.Longhair,loose clothingorjewelrymaygettangledinmovingparts.

•Inspecttheareawheretheequipmentistobeused andremoveallobjectssuchasrocks,toysandwire whichcanbethrownbythemachine.

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

•Neveroperatewiththedischargedeectorraised, removedoraltered,unlessusingagrasscatcher.

•Donotchangetheenginegovernorsettingor overspeedtheengine.

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

•Stopequipmentandinspectbladesafterstriking objectsorifanabnormalvibrationoccurs.Make necessaryrepairsbeforeresumingoperations.

•Keephandsandfeetawayfromthecuttingunits.

•Nevercarrypassengersandkeeppetsandbystanders away.

•Bealert,slowdownandusecautionwhenmaking turns.Lookbehindandtothesidebeforechanging directions.

•Slowdownandusecautionwhencrossingroadsand sidewalks.Stopbladesifnotmowing.

•Beawareofthemowerdischargedirectionanddo notpointitatanyone.

Page 5

•Donotoperatethemowerundertheinuenceof alcoholordrugs.

•Useextremecarewhenloadingorunloadingthe machineintoatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs, trees,orotherobjectsthatmayobscurevision.

SlopeOperation

•Donotmowslopesgreaterthan15degrees.

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

•Donotmowslopeswhengrassiswet.Slippery conditionsreducetractionandcouldcausesliding andlossofcontrol.

•Donotmakesuddenturnsorrapidspeedchanges.

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

•Reducespeedanduseextremecautiononslopes.

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

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

•Avoidsuddenstartswhenmowinguphillbecause themowermaytipbackwards.

•Beawarethatoperatingonwetgrass,acrosssteep slopes,ordownhillmaycausethemowertolose traction.Lossoftractiontothedrivewheelsmay resultinslidingandalossofbrakingandsteering.

•Alwaysavoidsuddenstartingorstoppingona slope.Iftireslosetraction,disengagethebladesand proceedslowlyofftheslope.

•Followthemanufacturer’srecommendationsfor wheelweightsorcounterweightstoimprovestability.

•Useextremecarewithgrasscatchersorother attachments.Thesecanchangethestabilityofthe machineandcauselossofcontrol.

•Checktheareatobemowedandneverfoldthe ROPSinareaswherethereareslopes,dropoffsor water.

•Lowertherollbaronlywhenabsolutelynecessary. Donotweartheseatbeltwiththerollbarfolded down.

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

Maintenanceandstorage

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

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

•Letenginecoolbeforestoringanddonotstorenear ame.

•Shutofffuelwhilestoringortransporting.Donot storefuelnearamesordrainindoors.

•Parkmachineonlevelground.Neverallowuntrained personneltoservicemachine.

•Usejackstandstosupportcomponentswhen required.

•Carefullyreleasepressurefromcomponentswith storedenergy.

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

•Usecarewhencheckingblades.Wraptheblade(s)or weargloves,andusecautionwhenservicingthem. Onlyreplacedamagedblades;neverstraightenor weldthem.

•Keephandsandfeetawayfrommovingparts.If possible,donotmakeadjustmentswiththeengine running.

UsingtheRolloverProtectionSystem (ROPS)

•Keeptherollbarintheraisedandlockedposition andusetheseatbeltwhenoperatingthemachine.

•Becertainthattheseatbeltcanbereleasedquickly intheeventofanemergency.

•Beawarethereisnorolloverprotectionwhenthe rollbarisdown.

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

•Keepallpartsingoodworkingconditionandall hardwaretightened.Replaceallwornordamaged decals.

•UseonlyToroapprovedattachments.Warrantymay bevoidedifusedwithunapprovedattachments.

Page 6

SlopeChart6SafetyandInstructional Decals

Page 7

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaof potentialdanger.Replaceanydecalthatisdamagedorlost.

68-8340

1-403005

98-5954

103-2076

54-9220

58-6520

1.Grease

105-7798

66-1340

Page 8

109-7232

109-7304

107-2102

107-2112

109-7929

109-9477

Page 9

110-2067

110-2068

1.ReadtheOperator’sManual.

114-4466

1.Main,25A

2.PTO,10A

114-9834

1.PowerT ake-off(PTO)4.Continuousvariable setting

2.Choke5.Slow

3.Fast

3.Charge,25A

4.Auxiliary,15A

115-7445

1.Greasepulleys

2.Maintenanceinterval—50

Page 10

116-0090

116-0166

116-0157

116-0165

116-0205

Manufacturer’sMark

1.Indicatesthebladeisidentiedasapartfromtheoriginal

machinemanufacturer.

109-7069

Page 11

ProductOverview

G008951

Usethesetimesforschedulingregularmaintenance (Figure5).

FuelGauge

Thefuelgaugeislocatedwiththehourmeterandthe barslightupwhentheignitionswitchison(Figure5).

Theindicatorlightappearswhenthefuellevelislow (approximatelyonegallonremaininginthefueltank).

SafetyInterlockIndicators

Therearesymbolsonthehourmeterandtheindicate withablacktrianglethattheinterlockcomponentisin thecorrectposition(Figure5).

BatteryIndicatorLight

Figure3

1.Height-of-cutdecklift pedal

2.Transportlock

3.Parkingbrakelever8.Fuelcap

4.Controls

5.Motioncontrollevers

6.Rollbar

7.Seatbelt

9.Mowerdeck

10.Casterwheel

Controls

Becomefamiliarwithallthecontrolsbeforeyoustartthe engineandoperatethemachine(Figure3andFigure4).

IftheignitionkeyisturnedtotheOnpositionforafew seconds,thebatteryvoltagewillbedisplayedinthearea wherethehoursarenormallydisplayed.

Thebatterylightturnsonwhentheignitionisturned onandwhenthechargeisbelowthecorrectoperating level(Figure5).

Figure5

1.Fuelgauge(bars)4.Safetyinterlocksymbols

2.Batterylight

3.Hourmeter

5.Lowfuelindicatorlight

Figure4

1.PTOSwitch4.Hourmeter/Safety

2.Choke

3.Throttlecontrol6.Fuses

5.Ignitionswitch

interlockdisplay/Fuel gauge

HourMeter

Thehourmeterrecordsthenumberofhourstheengine hasoperated.Itoperateswhentheengineisrunning.

ThrottleControl

ThethrottlecontrolisvariablebetweenFastandSlow.

Choke

Usethechoketostartacoldengine.Pullthechoke knobuptoengageit.

BladeControlSwitch(PTO)

Thebladecontrolswitch(PTO)isusedtoengagethe electricclutchanddrivethemowerblades.Pullthe

Page 12

switchuptoengagethebladesandrelease.Todisengage theblades,pushthebladecontrolswitch(PTO)down ormoveamotioncontrolleverintotheneutrallock position.

IgnitionSwitch

Thisswitchisusedtostartthemowerengineandhas threepositions:Start,RunandOff.

MotionControlLevers

Themotioncontrolleversareusedtodrivethemachine forward,reverse,andturneitherdirection.

Length:

RollBar-Up

RollBar-Down

RollBar-Up

RollBar-Down

Height:

48inchDeck52inchDeck

79.2inches(201.2 cm)

80.9inches(205.5 cm)

60inchDeck72inchDeck

83.1inches(211.1 cm)

84.8inches(215.4 cm)

79.2inches(201.2 cm)

80.9inches(205.5 cm)

86.1inches(218.7 cm)

87.8inches(223.0 cm)

NeutralLockPosition

Theneutrallockpositionisusedwiththesafetyinterlock systemtoengageandtodetermineneutralposition.

FuelShut-offValve

Closethefuelshut-offvalve(undertheseat)when transportingorstoringthemower.

Attachments/Accessories

AselectionofToroapprovedattachmentsand accessoriesareavailableforusewiththemachineto enhanceandexpanditscapabilities.Contactyour AuthorizedServiceDealerorDistributororgoto www.T oro.comforalistofallapprovedattachments andaccessories.

Specications

Note:Specicationsanddesignaresubjecttochange

withoutnotice.

RollBar-UpRollBar-Down

70.5inches(179.1cm)46.8inches(1 18.9cm)

Weight:

48inch Deck

23HP Kawasaki Units

27HP Kawasaki Units

29HP Kawasaki Units

34HP Kawasaki Units

1147lb (520kg)

NA1147lb

NANA1255lb

52inch Deck

NANANA

(520kg)

60inch Deck

NANA

(569kg)

72inch Deck

1350lb (612kg)

Width:

48inchDeck52inchDeck

WithoutDeck

DeectorUp54inches(137.2

DeectorDown63.55inches(161.4

WithoutDeck

DeectorUp61.73inches(156.8

DeectorDown75.67inches(192.2

45.7inches(116.1 cm)

cm)57.5

cm)

60inchDeck72inchDeck

53.0inches(134.6 cm)

cm)

45.7inches(116.1 cm)

57.5inches(146.0 cm)

67.63inches(171.8 cm)

59.1inches(150.1 cm)

73.61inches(187 cm)

87.55inches(222.4 cm)

Page 13

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

AddingFuel

Useunleadedregulargasolinesuitableforautomotive use(85pumpoctaneminimum).Leadedregular gasolinemaybeusedifunleadedregularisnotavailable.

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

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

•Fillthefueltankoutdoors,inanopenarea, whentheengineiscold.Wipeupany gasolinethatspills.

•Neverllthefueltankinsideanenclosed trailer.

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

•Neversmokewhenhandlinggasoline,and stayawayfromanopenameorwhere gasolinefumesmaybeignitedbyaspark.

•Storegasolineinanapprovedcontainerand keepitoutofthereachofchildren.Never buymorethana30-daysupplyofgasoline.

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

•Alwaysplacegasolinecontainersonthe groundawayfromyourvehiclebeforelling.

•Donotllgasolinecontainersinsidea vehicleoronatruckortrailerbedbecause interiorcarpetsorplastictruckbedliners mayinsulatethecontainerandslowtheloss ofanystaticcharge.

•Whenpractical,removegas-powered equipmentfromthetruckortrailerand refueltheequipmentwithitswheelsonthe ground.

•Ifthisisnotpossible,thenrefuelsuch equipmentonatruckortrailerfroma portablecontainer,ratherthanfroma gasolinedispensernozzle.

•Ifagasolinedispensernozzlemustbeused, keepthenozzleincontactwiththerimof thefueltankorcontaineropeningatall timesuntilfuelingiscomplete.

Gasolineisharmfulorfatalifswallowed. Long-termexposuretovaporscancauseserious injuryandillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgastankor conditioneropening.

•Keepgasawayfromeyesandskin.

•Donotoperatewithoutentireexhaust systeminplaceandinproperworking condition.

UsingStabilizer/Conditioner

Useafuelstabilizer/conditionerinthemachineto providethefollowingbenets:

•Keepsgasolinefreshduringstorageof90daysor less.Forlongerstorageitisrecommendedthatthe fueltankbedrained.

•Cleanstheenginewhileitruns

•Eliminatesgum-likevarnishbuildupinthefuel system,whichcauseshardstarting

Page 14

Important:Donotusefueladditivescontaining

G009189

G008942

methanolorethanol.

Addthecorrectamountofgasstabilizer/conditioner tothegas.

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

FillingtheFuelTank

Note:Donotllthefueltankcompletelyfull,thiswill

allowgasolinetoexpand.Allowa1/4to1/2inch(6 mmto13mm)spacebelowthebreathervalvelocated onthellerneck.

1.Shuttheengineoffandsettheparkingbrake.

2.Cleanaroundthefueltankcap.

CheckingtheEngineOilLevel

Beforeyoustarttheengineandusethemachine,check theoillevelintheenginecrankcase;refertoChecking theEngineOilLevel.

BreakingInaNewMachine

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

UsingtheRolloverProtection System(ROPS)

3.Fillthefueltank.Ensurethereisspacebelowthe breathervalveasshowninFigure6.

Toavoidinjuryordeathfromrollover:keepthe rollbarintheraisedlockedpositionanduse theseatbelt.

Ensurethattherearpartoftheseatissecured withtheseatlatch.

Thereisnorolloverprotectionwhentherollbar isinthedownposition.

•Lowertherollbaronlywhenabsolutely necessary.

•Donotweartheseatbeltwhentherollbaris inthedownposition.

•Driveslowlyandcarefully.

•Raisetherollbarassoonasclearance permits.

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

Figure6

Important:Lowertherollbaronlywhen

absolutelynecessary .

Important:Ensurethattherearpartoftheseatis securedwiththeseatlatch.

1.Tolowertherollbar,applyforwardpressuretothe upperpartoftherollbar.

2.Pullbothknobsoutandrotatethem90°sotheyare notengaged(Figure7).

Page 15

3.Lowertherollbartothedownposition(Figure7).

Operatingonwetgrassorsteepslopescan causeslidingandlossofcontrol.

Wheelsdroppingoveredgescancauserollovers, whichmayresultinseriousinjury,deathor drowning.

Thereisnorolloverprotectionwhentheroll barisdown.

Alwayskeeptherollbarintheraisedandlocked positionandusetheseatbelt.

Readandfollowtherolloverprotection instructionsandwarnings.

Toavoidlossofcontrolandpossibilityof rollover:

•Donotoperateneardrop-offsornearwater.

•Donotoperateonslopesgreaterthan 15degrees.

Figure7

1.ROPSknob

2.PullROPSknoboutand rotate90degrees

3.Rollbarintheupright position

4.Rollbarinthefolded position

4.Toraisetherollbar,raisetherollbartotheoperate position,rotatetheknobssotheymovepartially intothegrooves(Figure7).

5.Raisetherollbartothefulluprightpositionwhile pushingontheupperrollbarandthepinswillsnap intopositionwhentheholesalignwiththepins (Figure7).Pushontherollbarandensurethat bothpinsareengaged.

•Reducespeedanduseextremecautionon slopes.

•Avoidsuddenturnsorrapidspeedchanges.

Important:Alwaysusetheseatbeltwiththe rollbarintheraisedposition.

ThinkSafetyFirst

Pleasereadallsafetyinstructionsandsymbolsinthe safetysection.Knowingthisinformationcouldhelp youorbystandersavoidinjury.

Page 16

1.SafeZone-usethe

G009027

G008960

G008944

ZMasterhereonslopes lessthan15degreesor atareas.

2.DangerZone-useawalk behindmowerand/ora handtrimmeronslopes greaterthan15degrees, neardrop-offsandwater.

SettingtheParkingBrake

Parkingbrakemaynotholdmachineparked onaslopeandcouldcausepersonalinjuryor propertydamage.

Donotparkonslopesunlesswheelsare chockedorblocked

Figure8

3.Water

Figure10

Thismachineproducessoundlevelsinexcess of85dBAattheoperatorsearandcancause hearinglossthroughextendedperiodsof exposure.

Wearhearingprotectionwhenoperatingthis machine.

Theuseofprotectiveequipmentforeyes,ears,feetand headisrecommended.

Figure9

1.Wearsafetyglasses

2.Wearhearingprotection

ReleasingtheParkingBrake

Pushinthereleasebuttonbeforepushingdown.

Figure11

OperatingtheMowerBlade

OperatingtheParkingBrake

Alwayssettheparkingbrakewhenyoustopthe machineorleaveitunattended.

ControlSwitch(PTO)

Thebladecontrolswitch(PTO)startsandstopsthe mowerbladesandanypoweredattachments.

Page 17

EngagingtheBladeControlSwitch

G008945

G009174

G008946

G008959

(PTO)

Note:Engagingthebladecontrolswitch(PTO)with

thethrottlepositionathalforlesswillcauseexcessive weartothedrivebelts.

Figure12

DisengagingtheBladeControlSwitch (PTO)

2.Pulluponthechokeknobtoengagethechoke beforeusingtheignitionswitch(Figure15).

3.Pushdownonthechoketodisengagethechoke aftertheenginehasstarted(Figure15).

Figure15

1.On2.Off

Figure13

OperatingtheIgnitionSwitch

1.TurntheignitionkeytotheStartposition

OperatingtheThrottle

ThethrottlecontrolcanbemovedbetweenFastand Slowpositions(Figure14).

Alwaysusethefastpositionwhenturningonthe mowerdeckwiththebladecontrolswitch(PTO).

Figure14

(Figure16).Whentheenginesstarts,releasethekey .

Important:Donotengagestarterformore than5secondsatatime.Iftheenginefails tostartallowa15secondcool-downperiod betweenattempts.Failuretofollowthese instructionscanburnoutthestartermotor.

Note:Additionalstartingcyclesmayberequired whenstartingtheengineforthersttimeafterthe fuelsystemhasbeenwithoutfuelcompletely.

OperatingtheChoke

Usethechoketostartacoldengine.

1.Iftheengineiscold,usethechoketostartthe engine.

Page 18

START

RUN

STOP

G008947

Figure16

2.Turntheignitionkeytostoptostoptheengine.

UsingtheFuelShut-OffValve

Thefuelshut-offvalveislocatedundertheseat.

Closethefuelshut-offvalvefortransport,maintenance, andstorage.

Ensurethefuelshut-offvalveisopenwhenstarting theengine.

4.Movethebladecontrolswitch(PTO)totheOff position(Figure18).

5.MovethethrottlelevermidwaybetweentheSlow andFastpositions.

Figure17

1.On

2.Off

3.Hosegoingtotheengine

StartingandStoppingthe Engine

StartingtheEngine

1.RaisetheROPSupandlockintoplace,sitonthe seatandfastentheseatbelt.

2.Movethemotioncontrolstoneutrallocked position.

Figure18

6.TurntheignitionkeytotheStartposition (Figure16).Whentheenginesstarts,releasethekey .

Important:Donotengagestarterformore than5secondsatatime.Iftheenginefails tostartallowa15secondcool-downperiod betweenattempts.Failuretofollowthese instructionscanburnoutthestartermotor.

Note:Additionalstartingcyclesmayberequired whenstartingtheengineforthersttimeafterthe fuelsystemhasbeenwithoutfuelcompletely.

3.Settheparkingbrake;refertoSettingtheParking Brake.

Page 19

START

RUN

STOP

G008947

Figure19

1.Off3.Start

2.Run

StoppingtheEngine

Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethetractorwhileit isunattended.

Alwaysremovetheignitionkeyandsetthe parkingbrakewhenleavingthemachine unattended,evenifjustforafewminutes.

Lettheengineidleatslowthrottle(turtle)for60 secondsbeforeturningtheignitionswitchoff.

Figure20

Important:Makesurethatthefuelshutoffvalveis

closedbeforetransportingorstoringthemachine, asfuelleakagemayoccur.Settheparkingbrake beforetransporting.Makesuretoremovethekey asthefuelpumpmayrunandcausethebattery tolosecharge.

TheSafetyInterlockSystem

Ifsafetyinterlockswitchesaredisconnected ordamagedthemachinecouldoperate unexpectedlycausingpersonalinjury.

•Donottamperwiththeinterlockswitches.

•Checktheoperationoftheinterlock switchesdailyandreplaceanydamaged switchesbeforeoperatingthemachine.

Page 20

UnderstandingtheSafetyInterlock

G009181

System

Thesafetyinterlocksystemisdesignedtopreventthe enginefromstartingunless:

•Youaresittingontheseat.

•Theparkingbrakeisengaged.

•Thebladecontrolswitch(PTO)isdisengaged.

•Themotioncontrolleversareintheneutrallocked position

Thesafetyinterlocksystemalsoisdesignedtostopthe enginewhenthetractioncontrolsaremovedfromthe lockedpositionwiththeparkingbrakeengagedorif yourisefromtheseatwhenthePTOisengaged.

Thehourmeterhassymbolstonotifytheuserwhenthe interlockcomponentisinthecorrectposition.When thecomponentisinthecorrectposition,atrianglewill lightupinthecorrespondingsquare.

themotioncontrolleverstoneutrallockposition. Nowstarttheengine.Whiletheengineisrunning, releasetheparkingbrake,engagethebladecontrol switch(PTO)andriseslightlyfromtheseat;the engineshouldstop.

4.Sittingontheseat,engagetheparkingbrake,move thebladecontrolswitch(PTO)tooffandmove themotioncontrolleverstoneutrallockposition. Nowstarttheengine.Whiletheengineisrunning, centereithermotioncontrolandmove(forwardor reverse);theengineshouldstop.Repeatforother motioncontrol.

5.Sittingontheseat,disengagetheparkingbrake, movethebladecontrolswitch(PTO)tooffand movethemotioncontrolleverstoneutrallock position.Trystartingtheengine;theengineshould notcrank.

DrivingForwardorBackward

Thethrottlecontrolregulatestheenginespeedas measuredinrpm(revolutionsperminute).Place thethrottlecontrolinthefastpositionforbest performance.Alwaysoperateinthefullthrottle positionwhenmowing.

Figure21

1.Triangleslightupwhentheinterlockcomponentsareinthe correctposition

TestingtheSafetyInterlockSystem

ServiceInterval:Beforeeachuseordaily

Testthesafetyinterlocksystembeforeyouusethe machineeachtime.Ifthesafetysystemdoesnot operateasdescribedbelow,haveanAuthorizedService Dealerrepairthesafetysystemimmediately.

1.Sittingontheseat,engagetheparkingbrakeand movethebladecontrolswitch(PTO)toon.Try startingtheengine;theengineshouldnotcrank.

2.Sittingontheseat,engagetheparkingbrakeand movethebladecontrolswitch(PTO)tooff.Move eithermotioncontrollever(outofneutrallocked position).Trystartingtheengine;theengineshould notcrank.Repeatforothercontrollever.

3.Sittingontheseat,engagetheparkingbrake,move thebladecontrolswitch(PTO)tooffandmove

Machinecanspinveryrapidly.Operatormay losecontrolofmachineandcausepersonal injuryordamagetomachine.

•Usecautionwhenmakingturns.

•Slowthemachinedownbeforemaking sharpturns.

Page 21

UsingtheMotionControlLevers

G008952

G008953

Figure23

Figure22

1.Motioncontrol lever-neutrallockposition

2.Center,unlockedposition5.Frontofmachine

3.Forward

4.Backward

DrivingForward

Note:Theenginewillkillifthetractioncontrollevers

aremovedwiththeparkingbrakeengaged.

Tostop,pullthemotioncontrolleverstotheneutral position.

1.Releasetheparkingbrake;refertoReleasingthe ParkingBrakeinOperation.

2.Movetheleverstothecenter,unlockedposition.

3.Togoforward,slowlypushthemotioncontrol leversforward(Figure23).

DrivingBackward

1.Movetheleverstothecenter,unlockedposition.

2.Togobackward,slowlypullthemotioncontrol leversrearward(Figure24).

Figure24

Page 22

StoppingtheMachine

Tostopthemachine,movethetractioncontrollevers toneutralandmovetolockedposition,disengagethe powertakeoff(bladecontrolswitch(PTO),andturn theignitionkeytooff.

Settheparkingbrakewhenyouleavethemachine;refer toSettingtheParkingBrakeinOperation.Remember toremovethekeyfromtheignitionswitch.

Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethetractorwhileit isunattended.

Alwaysremovetheignitionkeyandsetthe parkingbrakewhenleavingthemachine unattended,evenifjustforafewminutes.

AdjustingtheHeightofCut

UsingtheTransportLock

Thetransportlockhastwopositionsandisusedwith thedeckliftpedal.Thereisalockpositionandaunlock positionforthetransportposition.Thetransportlock isusedwiththedeckliftpedal.RefertoFigure25

Figure25

TransportLockPositions

1.Transportlock3.Unlockposition—doesnot lockthemowerdeckinto transportposition

2.Lockposition—mower

deckwilllockintotransport position

AdjustingtheHeight-of-CutPin

Theheight-of-cutisadjustedfrom1to5-1/2inches (25to140mm)in1/4inch(6mm)incrementsby relocatingtheclevispinintodifferentholelocations.

1.Movethetransportlocktothelockposition.

2.Pushonthedeckliftpedalwithyourfootandraise themowerdecktothetransportposition(also the5-1/2inch(140mm)cuttingheightposition) (Figure26).

3.Toadjust,rotatethepin90degreesandremovethe pinfromtheheight-of-cutbracket(Figure26).

Page 23

4.Selectaholeintheheight-of-cutbracket correspondingtotheheight-of-cutdesiredand, insertthepin(Figure26).

5.Pushonthedecklift,pullbackonthetransport lock,andslowlylowerthemowerdeck.

Figure26

1.Deckliftpedal

2.Cutofheightpin

3.Transportlock

Figure27

1.Anti-scalproller4.FlangeNut

2.Spacer

3.Bushing

5.Bolt

AdjustingtheAnti-Scalp Rollers

Wheneveryouchangetheheight-of-cut,itis recommendedtoadjusttheheightoftheanti-scalp rollers.

1.Disengagethebladecontrolswitch(PTO),move themotioncontrolleverstotheneutrallocked positionandsettheparkingbrake.

2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.

Figure28

1.Anti-scalproller3.FlangeNut

2.Bushing4.Bolt

Figure29

1.Anti-scalproller4.FlangeNut

2.Spacer

3.Bushing

5.Bolt

Page 24

AdjustingtheFlowBafeCam

G008961

PositionA

Locks

Thisprocedureisapplicableonlytomachineswith theowbafelocks.Certainmodelswillhavenuts andboltsin-placeoftheowbafelocksandcanbe adjustedthesame.

Themowerdischargeowcanbeadjustedfordifferent typesofmowingconditions.Positionthecamlocks andbafetogivethebestqualityofcut.

1.Disengagethebladecontrolswitch(PTO),move themotioncontrolleverstotheneutrallocked positionandsettheparkingbrake.

2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Toadjustthecamlocks,swingtheleverupto loosenthecamlock(Figure30).

4.Adjustthebafeandcamlocksintheslotstothe desireddischargeow.

5.Swingtheleverbackovertotightenthebafeand camlocks(Figure30).

6.Ifthecamlocksdonotlockthebafeintoplace oritistootight,loosentheleverandthenrotate thecamlock.Adjustthecamlockuntilthedesired lockingpressureisachieved.

Thisisthefullrearposition.Thesuggesteduseforthis positionisafollows.

•Useforshort,lightgrassmowingconditions.

•Useindryconditions.

•Forsmallergrassclippings.

•Propelsgrassclippingsfartherawayfromthe mower.

Figure31

PositionB

Usethispositionwhenbagging.Alwaysalignitwith thebloweropening.

Figure30

1.Unlocklever

2.Rotatethecamlockto increaseordecrease lockingpressure

3.Positionthebafe

4.Locklever

PositioningtheFlowBafe

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

Note:Iftheenginepowerdrawsdownandthemower groundspeedisthesame,openupthebafe.

Figure32

PositionC

Thisisthefullopenposition.Thesuggestedusefor thispositionisasfollows.

•Useintall,densegrassmowingconditions.

•Useinwetconditions.

•Lowerstheenginepowerconsumption.

Page 25

•Allowsincreasedgroundspeedinheavyconditions.

G008962

•ThispositionissimilartothebenetsoftheToro SFSmower.

Figure33

PositioningtheSeat

UnlatchingtheSeat

Figure35

1.Seatlatch2.Seat

UsingtheDriveWheelRelease Valves

Handsmaybecomeentangledintherotating drivecomponentsbelowtheenginedeck,which couldresultinseriousinjury.

Theseatcanmoveforwardandbackward.Positionthe seatwhereyouhavethebestcontrolofthemachine andaremostcomfortable.

Toadjust,movetheleversidewaystounlockseat (Figure34).

Figure34

Stoptheengine,removethekey,andallowall movingpartstostopbeforeaccessingthedrive wheelreleasevalves.

Theengineandhydraulicdriveunitscan becomeveryhot.Touchingahotengineor hydraulicdriveunitscancausesevereburns.

Allowtheengineandhydraulicdriveunitsto coolcompletelybeforeaccessingthedrive wheelreleasevalves.

Thedrivewheelreleasevalvesarelocatedinthebackof eachhydraulicdriveunit,undertheseat.

Note:Makesurethereleasevalvesareinthefully horizontalpositionwhenoperatingthemachineor severedamagetothehydraulicsystemcanoccur.

1.DisengagethePTO(bladecontrolswitch)andturn theignitionkeytooff.Movetheleverstoneutral lockedpositionandapplyparkingbrake.Remove thekey .

2.Rotatethereleasevalveleversverticallytopushthe machine.Thisallowshydraulicoiltoby-passthe pumpenablingthewheelstoturn(Figure36).

3.Disengageparkingbrakebeforepushing.

Page 26

Figure36

1.Verticaltopushthe machine

2.Horizontaltorunthe machine

4.Rotatethereleasevalvelevershorizontallytorun themachine(Figure36).

UsingtheSideDischarge

Themowerhasahingedgrassdeectorthatdisperses clippingstothesideanddowntowardtheturf.

TransportingMachines

Useaheavy-dutytrailerortrucktotransportthe machine.Ensurethatthetrailerortruckhasall necessarybrakes,lighting,andmarkingasrequiredby law .Pleasecarefullyreadallthesafetyinstructions. Knowingthisinformationcouldhelpyou,yourfamily, petsorbystandersavoidinjury.

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

Donotdrivemachineonapublicstreetor roadway.

Totransportthemachine:

1.Ifusingatrailer,connectittothetowingvehicle andconnectthesafetychains.

2.Ifapplicable,connectthetrailerbrakes.

3.Loadthemachineontothetrailerortruck.

Withoutagrassdeector,dischargecover,or completegrasscatcherassemblymountedin place,youandothersareexposedtoblade contactandthrowndebris.Contactwith rotatingmowerblade(s)andthrowndebriswill causeinjuryordeath.

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

•Neverputyourhandsorfeetunderthe mower.

•Nevertrytoclearthedischargeareaor mowerbladesunlessyoumovethepower takeoff(bladecontrolswitch(PTO)tothe offposition,rotatetheignitionkeytooff andremovethekey.

•Makesurethegrassdeectorisinthedown position.

4.Stoptheengine,removethekey,setthebrake,and closethefuelvalve.

5.Usethemetaltiedownloopsonthemachineto securelyfastenthemachinetothetrailerortruck withstraps,chains,cable,orropes(Figure37).

Figure37

1.Tractionunittiedownloops

Page 27

LoadingMachines

Useextremecautionwhenloadingunitsontrailersor trucks.Onefullwidthrampthatiswideenoughto extendbeyondthereartiresisrecommendedinsteadof individualrampsforeachsideoftheunit(Figure38). Thelowerrearsectionofthetractorframeextends backbetweentherearwheelsandservesasastopfor tippingbackward.Havingafullwidthrampprovides asurfacefortheframememberstocontactifthe unitstartstotipbackward.Ifitisnotpossibletouse onefullwidthramp,useenoughindividualrampsto simulateafullwidthcontinuousramp.

Therampshouldbelongenoughsothattheangles donotexceed15degrees(Figure38).Asteeperangle maycausemowercomponentstogetcaughtastheunit movesfromramptotrailerortruck.Steeperangles mayalsocausetheunittotipbackward.Ifloadingon ornearaslope,positionthetrailerortrucksoitison thedownsideoftheslopeandtherampextendsupthe slope.Thiswillminimizetherampangle.Thetraileror truckshouldbeaslevelaspossible.

Important:DoNotattempttoturntheunitwhile ontheramp;youmaylosecontrolanddriveoff theside.

Avoidsuddenaccelerationwhendrivinguparampand suddendecelerationwhenbackingdownaramp.Both maneuverscancausetheunittotipbackward.

Loadingaunitontoatrailerortruckincreases thepossibilityofbackwardtip-overandcould causeseriousinjuryordeath.

•Useextremecautionwhenoperatingaunit onaramp.

•EnsuretheROPSisintheupposition whileusingtheseatbeltwhenloadingthe machine.EnsuretheROPSwillclearthe topofanenclosedtrailer.

•Useonlyasingle,fullwidthramp;DoNot useindividualrampsforeachsideofthe unit.

•Ifindividualrampsmustbeused,use enoughrampstocreateanunbrokenramp surfacewiderthantheunit.

•Donotexceeda15degreeanglebetween rampandgroundorbetweenrampand trailerortruck.

•Avoidsuddenaccelerationwhiledrivingunit uparamptoavoidtippingbackward.

•Avoidsuddendecelerationwhilebacking unitdownaramptoavoidtippingbackward.

Figure38

1.Trailer3.Notgreaterthan

2.Fullwidthramp4.Fullwidthramp—sideview

15degrees

Page 28

OperatingTips

FastThrottleSetting

Forbestmowingandmaximumaircirculation,operate theengineatthefastthrottleposition.Airisrequired tothoroughlycutgrassclippings,sodonotsetthe height-of-cutsolowastototallysurroundthemower byuncutgrass.Alwaystrytohaveonesideofthe mowerfreefromuncutgrass,whichallowsairtobe drawnintothemower.

CuttingaLawnfortheFirstTime

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

Cut1/3oftheGrassBlade

LongGrass

Ifthegrassiseverallowedtogrowslightlylongerthan normal,orifitcontainsahighdegreeofmoisture,raise thecuttingheighthigherthanusualandcutthegrassat thissetting.Thencutthegrassagainusingthelower, normalsetting.

WhenStopping

Ifthemachine’sforwardmotionmustbestoppedwhile mowing,aclumpofgrassclippingsmaydropontoyour lawn.Toavoidthis,moveontoapreviouslycutarea withthebladesengaged.

KeeptheUndersideoftheMower Clean

Cleanclippingsanddirtfromtheundersideofthe moweraftereachuse.Ifgrassanddirtbuildupinside themower,cuttingqualitywilleventuallybecome unsatisfactory.

Itisbesttocutonlyabout1/3ofthegrassblade. Cuttingmorethanthatisnotrecommendedunless grassissparse,oritislatefallwhengrassgrowsmore slowly.

MowingDirection

Alternatemowingdirectiontokeepthegrassstanding straight.Thisalsohelpsdisperseclippingswhich enhancesdecompositionandfertilization.

MowatCorrectIntervals

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

CuttingSpeed

BladeMaintenance

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

Toimprovecutquality ,useaslowergroundspeedin certainconditions.

AvoidCuttingTooLow

Ifthecuttingwidthofthemoweriswiderthanthe moweryoupreviouslyused,raisethecuttingheightto ensurethatuneventurfisnotcuttooshort.

Page 29

Maintenance

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst8hours

Aftertherst100hours

Beforeeachuseordaily

Every50hours

Every100hours

MaintenanceProcedure

•Changetheengineoil.

•Checkthewheelhubslottednuttorque.

•Checkthetorqueforwheellugnuts.

•Checktheparkbrakeadjustment.

•Checkthesafetysystem.

•Checktheengineoillevel.

•Checktheseatbelt.

•Checktherolloverprotectionsystem(ROPS)knobs.

•Cleantheenginescreenandtheoilcooler.

•Checkandcleanthehydraulicunitshrouds.

•Checkthemowerblades.

•Cleanthemowerdeck.

•Greasethemowerdeckspindlesandidlerarm.

•Checksparkarrester(ifequipped).

•Checkthetirepressure.

•Inspectthebeltsforcracksandwear.

•Checkthehydraulicoillevel.

•Lubricatethemowerdeckliftpivots.

•Changetheengineoil.(moreoftenindirtyordustyconditions)

•Check,cleanandregapthesparkplug.

•Checkandcleanenginecoolingnsandshrouds.

Every200hours

Every250hours

Every500hours

Monthly

Yearly

Yearlyorbeforestorage

•Lubricatethebrakehandlepivotwithlightoil.

•Changetheengineoillter.

•Replacetheprimaryairlter.

•Checkthesecondaryairlter.

•ChangethehydraulicltersandhydraulicoilwhenusingMobil1oil.

•Replacethesecondaryairlter .

•Replacethefuellter.(moreoftenindirtyordustyconditions).

•Checkthewheelhubslottednuttorque.

•Checkthetorqueforwheellugnuts.

•Adjustthecasterpivotbearing.

•Checktheparkbrakeadjustment.

•ChangethehydraulicltersandhydraulicoilwhenusingT oroPro-Seriesoil.

•Checkthebattery.

•Greasethepumpbeltidlerarm.

•Greasethefrontcasterpivots(moreoftenindirtyordustyconditions).

•Repackthefrontcasterwheelbearings(moreoftenindirtyordustyconditions).

•Lubricatethecasterwheelhubs

•Paintchippedsurfaces.

•Checkallmaintenanceprocedureslistedabovebeforestorage.

Important:Refertoyourengineoperator’smanualforadditionalmaintenanceprocedures.

Page 30

Ifyouleavethekeyintheignitionswitch,someonecouldaccidentlystarttheengineandseriously injureyouorotherbystanders.

Removethekeyfromtheignitionbeforeyoudoanymaintenance.

Lubrication

GreasingandLubrication

Greasemorefrequentlywhenoperatingconditionsare extremelydustyorsandy.

GreaseType:No.2generalpurposelithiumbaseor molybdenumbasegrease

HowtoGrease

1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

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

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

5.Wipeupanyexcessgrease.

WheretoAddLightOilorSpray Lubrication

ServiceInterval:Every100hours

Every200hours

•Brakehandlepivot.

•Deckliftpivots.

Figure39

WheretoGreasetheMower

ServiceInterval:Every50hours—Greasethemower

deckspindlesandidlerarm.

Yearly—Greasethepumpbeltidler arm.

Yearly—Greasethefrontcaster pivots(moreoftenindirtyordusty conditions).

Yearly—Repackthefrontcaster wheelbearings(moreoftenindirty ordustyconditions).

Important:Makesurecuttingunitspindlesare fullofgreaseweekly .

1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition, andsettheparkingbrake.

Page 31

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Greasethemowerdeckidlerpulleypivotuntilgrease comeoutthebottom(Figure40).

4.Greasethettingsonthesideofthe3spindle bearingsuntilgreasecomeoutthebottom (Figure40).

8.Pumpgreaseintothezerkuntilitoozesoutaround thetopbearing.

9.Removethegreasezerkinthehole.Installthehex pluganddustcap(Figure42).

Figure42

LubricateCasterWheelHubs

Figure40

5.Greasethedrivebeltidlerarm(Figure40).

Figure41

6.Removethedustcapandadjustthecasterpivots. Keepthedustcapoffuntilgreasingisdone.Referto AdjustingtheCasterPivotBearinginMaintenance.

7.Removethehexplug.Threadagreasezerkintothe hole.

ServiceInterval:Yearly

1.Stoptheengine,waitforallmovingpartstostop, andremovethekey.Engagetheparkingbrake.

Figure43

1.Sealguard2.Spacernutwithwrench ats

2.Removethecasterwheelfromthecasterforks.

3.Removethesealguardsfromthewheelhub.

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

5.Pryoutseals,andinspectbearingsforwearor damageandreplaceifnecessary.

6.Packthebearingswithageneral-purposegrease.

7.Insertonebearing,onenewsealintothewheel.

Page 32

Note:Thesealsmustbereplaced.

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

9.Inserttheassemblednutandaxleintothewheelon thesideofthewheelwiththenewsealandbearing.

10.Withtheopenendofthewheelfacingup,ll theareainsidethewheelaroundtheaxlefullof general-purposegrease.

11.Insertthesecondbearingandnewsealintothe wheel.

12.Applyathreadlockingadhesivetothe2ndspacer nutandthreadontotheaxlewiththewrenchats facingoutward.

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

14.Reinstallthesealguardsoverthewheelhuband insertwheelintocasterfork.Reinstallcasterbolt andtightennutfully.

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

EngineMaintenance

Contactwithhotsurfacesmaycausepersonal injury.

Keephands,feet,face,clothingandotherbody partsawaythemuferandotherhotsurfaces.

ServicingtheAirCleaner

ServiceInterval:Every250hours—Replacethe

primaryairlter.

Every250hours—Checkthe secondaryairlter.

Every500hours—Replacethe secondaryairlter.

Note:Servicetheaircleanermorefrequentlyif operatingconditionsareextremelydustyorsandy.

RemovingtheFilters

1.DisengagethePTO ,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Pushdowntoreleasetheretainingclampsontheair cleanerandpulltheaircleanercoveroffoftheair cleanerbody(Figure44).

4.Cleantheinsideoftheaircleanercoverwith compressedair.

5.Gentlyslidetheprimarylteroutoftheaircleaner body(Figure44).Avoidknockingthelterintothe sideofthebody .

6.Removethesecondarylteronlyifyouintendto replaceit.

Important:Neverattempttocleanthe secondarylter.Ifthesecondarylterisdirty, thentheprimarylterisdamagedandyou shouldreplacebothlters.

7.Inspecttheprimarylterfordamagebylookinginto thelterwhileshiningabrightlightontheoutside ofthelter.Holesinthelterwillappearasbright spots.Ifthelterisdamageddiscardit.

Page 33

ServicingtheEngineOil

Note:Therearedifferentoilcapacitiesforthe23hp,

27hp,29hp,and34hpengines.Ensurethecorrect capacityisused.

OilType:Detergentoil(APIserviceSG,SH,SJ,orSL)

OilCapacityfor23hpEngines:withalterchange,58

ounces(1.7L);withoutalterchange,51ounces(1.5L)

OilCapacityfor27and29hpEngines:withalter change,77ounces(2.3L);withoutalterchange,70 ounces(2.1L)

Figure44

1.Aircleanerclamps

2.Aircleanercover

3.Primaryairlter

4.Secondaryairlter

ServicingthePrimaryFilter

1.Donotcleanthepaperlter,replaceit(Figure44).

2.Inspecttheelementfortears,anoilylm,ordamage totherubberseal.

3.Replacethepaperelementifitisdamaged.

ServicingtheSecondaryFilter

Donotcleanthesecondarylter,replaceit.

Important:Neverattempttocleanthesecondary lter.Ifthesecondarylterisdirty,thenthe primarylterisdamagedandyoushouldreplace bothlters.

InstallingtheFilters

OilCapacityfor34hpEngines:withalterchange,64 ounces(1.9L);withoutalterchange,58ounces(1.7L)

Viscosity:Seethetablebelow .

Figure45

Note:Useofmulti-gradeoils(5W -20,10W -30,or

10W-40)willincreaseoilconsumption.Checktheoil levelmorefrequentlywhenusingthem.

Important:Topreventenginedamage,always operatetheenginewithbothairltersandcover installed.

1.Ifinstallingnewlters,checkeachlterforshipping damage.Donotuseadamagedlter.

2.Ifthesecondarylterisbeingreplaced,carefully slideitintothelterbody(Figure44).

3.Carefullyslidetheprimarylteroverthesecondary lter(Figure44).Ensurethatitisfullyseatedby pushingontheouterrimofthelterwhileinstalling it.

Important:Donotpressonthesoftinsidearea ofthelter.

4.Installtheaircleanercoverwiththebreathercap downandrotatesotheretainingclampslockthe coverinplace(Figure44).

CheckingtheEngineOilLevel

ServiceInterval:Beforeeachuseordaily

Note:Checktheoilwhentheengineiscold.

Contactwithhotsurfacesmaycausepersonal injury.

Keephands,feet,face,clothingandotherbody partsawayfromthemuferandotherhot surfaces.

Important:Donotoverllthecrankcasewithoil becausedamagetotheenginemayresult.Donot runenginewithoilbelowthelowmarkbecausethe enginemaybedamaged.

Page 34

1.DisengagethePTO ,movethemotioncontrollevers

G008804

G008792

G008804

G008793

totheneutrallockedpositionandsettheparking brake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position(Figure46).

ChangingtheEngineOil

ServiceInterval:Aftertherst8hours

Every100hours(moreoftenindirty ordustyconditions)

Note:Disposeoftheusedoilatarecyclingcenter.

1.Starttheengineandletitrunveminutes.This warmstheoilsoitdrainsbetter.

2.Parkthemachinesothattherearisslightlylower thanthefronttoensuretheoildrainscompletely.

3.DisengagethePTO ,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.

4.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position(Figure47).

Figure46

Figure47

Page 35

5.Slowlypourapproximately80%ofthespeciedoil

G008796

G008804

G008748

3/4

intothellertubeandslowlyaddtheadditionaloil tobringittotheFullmark(Figure48).

Figure48

6.Starttheengineanddrivetoaatarea.Checkthe oillevelagain.

ChangingtheEngineOilFilter

ServiceInterval:Every200hours

Note:Changetheengineoilltermorefrequently whenoperatingconditionsareextremelydustyorsandy.

1.Draintheoilfromtheengine;refertoChangingthe EngineOil.

2.Changetheengineoillter(Figure49).

Figure49

Note:Ensuretheoilltergaskettouchestheengine

andthenanextra3/4turniscompleted.

3.Fillthecrankcasewiththepropertypeofnewoil; refertoChangingtheOil.

Page 36

ServicingtheSparkPlug

G008803

ServiceInterval:Every100hours

Makesuretheairgapbetweenthecenterandside electrodesiscorrectbeforeinstallingthesparkplug. Useasparkplugwrenchforremovingandinstalling thesparkplug(s)andagappingtool/feelergaugeto checkandadjusttheairgap.Installanewsparkplug(s) ifnecessary.

Note:Therearedifferentsparkplugsforthe23hp, 27hp,29hp,and34hpengines.Ensurethecorrectspark plugisused.

Typefor23hp,27hp,and29hpEngines:NGK BPR4ESorequivalent

Typefor34hpEngines:NGK

BPR5ESorequivalent

AirGap:0.030inch(0.75mm)

RemovingtheSparkPlug

1.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

2.DisengagethePTO ,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.

3.Removethelefthandhydraulicunitshroudinthe orderlistedwithFigure50.Thisgivesyouaccess tothefrontsparkplug.

Figure50

1.Pullthistabouttothe sideinthedirectionofthe arrow

2.Pulltheshroudoffofthis frametabinthedirection ofthearrow

3.Pulltheshroudoffofthis frametabinthedirection ofthearrow

4.Shroud

4.Removethesparkplug.

Figure51

5.Installthelefthandhydraulicunitshroud(Figure50).

Page 37

CheckingtheSparkPlug

G008794

CheckSparkArrester(if

Important:Nevercleanthesparkplug(s).Always

replacethesparkplug(s)whenithas:ablack coating,wornelectrodes,anoilylm,orcracks.

Ifyouseelightbrownorgrayontheinsulator,the engineisoperatingproperly.Ablackcoatingonthe insulatorusuallymeanstheaircleanerisdirty.

Setthegapto0.030inches(0.76mm).

Figure52

InstallingtheSparkPlug

Tightenthesparkplug(s)to16ft.-lb(22N-m).

equipped)

ServiceInterval:Every50hours

Hotexhaustsystemcomponentsmayignite gasolinevaporsevenaftertheengineis stopped.Hotparticlesexhaustedduringengine operationmayigniteammablematerials. Firemayresultinpersonalinjuryorproperty damage.

DoNotrefuelorrunengineunlessspark arresterisinstalled.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Waitformufertocool.

3.Ifanybreaksinthescreenorweldsareobserved, replacethearrester.

4.Ifpluggingofthescreenisobserved,removethe arresterandshakelooseparticlesoutofthearrester andcleanscreenwithawirebrush(soakinsolventif necessary).Reinstallarresteronexhaustoutlet.

Figure53

Page 38

FuelSystem

G008963

12

Maintenance

Note:Itisimportanttoreinstallthefuellinehosesand securewithplastictiesthesameastheywereoriginally installedatthefactorytokeepthefuellineawayfrom componentsthatcouldcausefuellinedamage.

ReplacingtheFuelFilter

ServiceInterval:Every500hours/Yearly(whichever

comesrst)(moreoftenindirtyor dustyconditions).

Thefuellterislocatedneartheengineonthefront orrearsideoftheengine.

1.DisengagethePTO ,movethemotioncontrollevers totheneutrallockedposition,andsettheparking brake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Allowthemachinetocooldown.

4.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

5.Closethefuelshutoffvalveundertheseat (Figure54).

ServicingtheFuelTank

Donotattempttodrainthefueltank.Ensurethatan AuthorizedServiceDealerdrainsthefueltankand servicesanycomponentsofthefuelsystem.

Figure54

1.Fuellter

2.Hoseclamp

6.Squeezetheendsofthehoseclampstogetherand slidethemawayfromthelter(Figure54).

7.Removethelterfromthefuellines.

8.Installanewlterandmovethehoseclampsclose

9.Openthefuelshutoffvalve.

tothelter(Figure54).

3.Fuelline

Page 39

ElectricalSystem Maintenance

ServicingtheBattery

ServiceInterval:Monthly

Warning

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandleadcompounds,

chemicalsknowntotheStateofCalifornia

tocausecancerandreproductiveharm.

Washhandsafterhandling.

Batteryelectrolytecontainssulfuricacidwhich isadeadlypoisonandcausessevereburns.

Donotdrinkelectrolyteandavoidcontactwith skin,eyesorclothing.Wearsafetyglassesto shieldyoureyesandrubberglovestoprotect yourhands.

RemovingtheBattery

Incorrectbatterycableroutingcoulddamage themachineandcablescausingsparks.Sparks cancausethebatterygassestoexplode, resultinginpersonalinjury .

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

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

1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Firstdisconnectthenegativebatterycable(black) fromthenegative(-)(black)batteryterminal (Figure55).

4.Slidetheredterminalbootoffthepositive(red) batteryterminalandremovethepositive(+)(red) batterycable(Figure55).

5.Removethewingnutsecuringthebatteryclamp (Figure55).

6.Removetheclamp(Figure55).

Batteryterminalsormetaltoolscouldshort againstmetalmachinecomponentscausing sparks.Sparkscancausethebatterygassesto explode,resultinginpersonalinjury .

•Whenremovingorinstallingthebattery,do notallowthebatteryterminalstotouchany metalpartsofthemachine.

•Donotallowmetaltoolstoshortbetween thebatteryterminalsandmetalpartsofthe machine.

7.Removethebattery.

Page 40

G008804

G008964

1.Removethewingnutand clamp

2.Removethenegative batterycablebeforethe positive

Figure55

3.Removethepositive batterycable

4.Removebattery

ChargingtheBattery

Chargingthebatteryproducesgassesthatcan explode.

Neversmokenearthebatteryandkeepsparks andamesawayfrombattery.

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

1.Chargebatteryfor10to15minutesat25to30amps or30minutesat10amps.

2.Whenthebatteryisfullycharged,unplugthecharger fromtheelectricaloutlet,thendisconnectthe chargerleadsfromthebatteryposts(Figure56).

3.Installthebatteryinthemachineandconnectthe batterycables,refertoInstallingtheBattery.

Note:Donotrunthemachinewiththebattery disconnected,electricaldamagemayoccur.

InstallingtheBattery

1.Positionbatteryinthetraywiththeterminalposts oppositefromthehydraulictank(Figure55).

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

3.Theninstallthenegative(black)batterycableand groundwiretothenegative(-)batteryterminal.

4.Securethecableswith2bolts,2washers,and 2locknuts(Figure55).

5.Slidetheredterminalbootontothepositive(red) batterypost.

6.Installtheclampandsecureitwiththewingnut (Figure55).

1.PositiveBatteryPost

2.NegativeBatteryPost

Figure56

3.Red(+)ChargerLead

4.Black(-)ChargerLead

Page 41

ServicingtheFuses

DriveSystem

Theelectricalsystemisprotectedbyfuses.Itrequires nomaintenance,however,ifafuseblowscheckthe component/circuitforamalfunctionorshort.

1.Thefusesarelocatedonrighthandconsolenextto theseat(Figure57).

2.Toreplacethefuses,pulloutonthefusetoremove it.

3.Installanewfuse(Figure57).

Maintenance

CheckingtheSeatBelt

ServiceInterval:Beforeeachuseordaily

Visuallyinspectseatbeltforwear,cuts,andproper operationofretractorandbuckle.Replacebefore operatingifdamaged.

CheckingtheRollover ProtectionSystem(ROPS) Knobs

ServiceInterval:Beforeeachuseordaily

Checkthatboththemountinghardwareandtheknobs areingoodworkingcondition.Makesuretheknobs arefullyengagedwiththeROPSintheraisedposition. Theupperhoopoftherollbarmayneedtobepushed forwardorpulledrearwardtogetbothknobsfully engaged.

Figure57

1.Optionalaccesory-15amp

2.Charge-25amp5.Console

3.PTO-10amp

4.Main-25amp

Page 42

Figure59

Leftcontrollevershown

1.Controllever3.Stopplate

2.Bolt

Figure58

1.ROPSknob(locked position)

2.PullROPSknoboutand rotate90degreesto changerollbarposition

3.Rollbarintheupright position

4.Rollbarinthefolded position

AdjustingtheTracking

1.Disengagethebladecontrolswitch(PTO).

2.Drivetoanopenatarea,movethemotioncontrol leverstotheneutrallockedposition.

3.Movethethrottlemidwaybetweenfastandslow.

4.Movebothmotioncontrolleversallthewayforward untiltheybothhitthestopsintheT-slot.

5.Checkwhichwaythemachinetracks.

6.Ifittrackstotheright,loosentheboltsandadjust theleftstopplaterearwardontheleftT-slotuntil themachinetracksstraight(Figure59).

7.Ifittrackstotheleft,loosentheboltsandadjustthe rightstopplaterearwardontherightT-slotuntilthe machinetracksstraight(Figure59).

8.Tightenthestopplate(Figure59).

CheckingtheTirePressure

ServiceInterval:Every50hours/Monthly(whichever

comesrst)

Maintaintheairpressureinthereartiresat13psi(90 kPa).Uneventirepressurecancauseunevencut.Check thetireswhentheyarecoldtogetthemostaccurate pressurereading.

Note:Thefronttiresaresemi-pneumatictiresanddo notrequireairpressuremaintenance.

Page 43

Figure60

Note:Donotuseanti-seizeonthewheelhub.

AdjustingtheCasterPivot Bearing

ServiceInterval:Every500hours/Yearly(whichever

comesrst)

1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

CheckingtheWheelHub SlottedNut

ServiceInterval:Aftertherst100hours

Every500hours

1.Removethecotterpin.

2.Torquetheslottednutto200ft-lb(271N-m).

3.Checkthedistancefromthebottomoftheslotin thenuttotheinsideedgeofthehole.Twothreads (0.1inch)orlessshouldbeshowing.

3.Removethedustcapfromcasterandtightenlock nut(Figure62).

4.Tightenthelocknutuntilthespringwashersareat andthenbackoffa1/4turntoproperlysetthe pre-loadonthebearings(Figure62).

Important:Makesurethespringwashersare installedcorrectlyasshowninFigure62.

5.Installthedustcap(Figure62).

Figure61

1.0.1inchmax2.Nomorethantwothreads (0.1inchmax)shouldbe showinghere.

4.Ifmorethantwothreads(0.1inch)areshowing, removethenutandinstallawasherbetweenthehub andthenut.

5.Torquetheslottednutto200ft-lb(271N-m).

6.Thentightenthenutuntilthenextsetofslotsline upwiththecrossholeintheshaft.Donotloosen thenuttoaligntheslot.Ifrequired,tightentothe nextsetofslots.

7.Installthecotterpin.Useanewcotterpinifneeded.

Figure62

1.SpringWashers3.DustCap

2.LockNut

UsingtheClutchShim

Somelatermodelyearunitshavebeenbuiltwith clutchesthatcontainabrakeshim.Whentheclutch brakehasworntothepointwheretheclutchnolonger engagesconsistently,theshimcanberemovedtoextend theclutchlife.

Page 44

Figure63

1.Armature5.Brakespacer

2.Fieldshell6.Re-gapshim

3.Rotor7.Brakepole

4.Brakemountingbolt

Note:DoNotremovethebrakepolefromthe eldshell/armature.Thebrakepolehasworn tomatchthearmatureandneedstocontinueto matchaftertheshimisremovedtoensureproper braketorque.

Figure65

1.Brakemountingbolt

RemovingtheClutchShim

1.Stoptheengine,waitforallmovingpartstostop, andremovethekey.Engagetheparkingbrake. Allowthemachinetocoolcompletelybeforestarting theseinstructions.

2.Usinganaircompressor,blowoutanydebrisfrom underthebrakepoleandaroundthebrakespacers.

Figure64

3.Checktheconditionofthewireharnessleads, connectors,andterminals.Cleanorrepairas necessary.

B.Usingneedlenosepliers,orbyhand,takehold

ofthetabandremovetheshim(DoNotdiscard theshimuntilproperclutchfunctionhasbeen conrmed).

Figure66

1.Shim

C.Usingapneumaticline,blowoutanydebris

fromunderthebrakepoleandaroundthebrake spacers.

D.Re-torqueeachbolt(M6x1)to10ft-lb(13N-m)

+/-0.5ft-lb(0.7N-m).

4.Verifythat12Vispresentattheclutchconnector whenthePTOswitchisengaged.

5.Measurethegapbetweentherotorandarmature. Ifthegapisgreaterthan.04inch(1mm),proceed withthefollowingsteps:

A.Loosenbothbrakemountingboltsone-halfto

onefullturnasshownbelow .

E.Usinga0.010inchthickfeelergauge,verifythat

agapispresentbetweentherotorandarmature faceonbothsidesofthebrakepoleasshown. (Duetothewaytherotorandarmaturefaces wear(peaksandvalleys)itissometimesdifcult tomeasurethetruegap.)

Page 45

CoolingSystem

G008804

Maintenance

CleaningtheEngineScreen andEngineOilCooler

ServiceInterval:Beforeeachuseordaily

Figure67

1.Feelergauge

Figure68

1.Feelergauge

•Ifthegapislessthan0.010inch,thenreinstall theshimandreferencetheTroubleshooting section.

•Ifthegapissufcient,proceedtothesafety checkinstep6.

Removeanybuild-upofgrass,dirtorotherdebrisfrom theoilcooler(Figure69).

Figure69

Beforeeachuseremoveanybuild-upofgrass,dirtor otherdebrisfromtheenginescreen.Thiswillhelp insureadequatecoolingandcorrectenginespeedand willreducethepossibilityofoverheatingandmechanical damagetotheengine(Figure70).

F.Performthefollowingsafetycheck:

a.Sitontheseatandstarttheengine.

b.MakesurethebladesDoNotengagewiththe

PTOswitch“off”andtheclutchdisengaged.

Iftheclutchdoesnotdisengage,reinstallthe shimandreferencetheTroubleshooting section.

c.EngageanddisengagethePTOswitch

tenconsecutivetimestoensuretheclutch isfunctioningproperly.Iftheclutch doesnotengageproperly,referencethe Troubleshootingsection.

CleaningtheEngineCooling FinsandShrouds

ServiceInterval:Every100hours/Yearly(whichever

comesrst)

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Removetheairintakescreen,recoilstarterandfan housing(Figure70).

4.Cleanthedebrisandgrassfromtheengineparts.

5.Installairintakescreen,recoilstarterandfanhousing (Figure70).

Page 46

Figure70

1.Engineguard4.Fanhousing

2.Engineairintakescreen

3.Bolt

5.Screw

CheckandCleantheHydraulic UnitShrouds

ServiceInterval:Beforeeachuseordaily

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Raisetheseat.

4.Cleanthedebrisandgrassfromthehydraulicunit shrouds(Figure71).

5.Lowertheseat.

Figure71

1.Hydraulicunitshrouds

Page 47

BrakeMaintenance

standardnut.DoNotallowthecabletoturnwhen thenutsaretightened.

AdjustingtheParkingBrake

ServiceInterval:Aftertherst100hours

Every500hours

Mechanicalorhydraulicjacksmayfailto supportmachineandcauseaseriousinjury .

•Usejackstandwhensupportingmachine.

•Donotusehydraulicjacks.

Checktomakesurethebrakeisadjustedproperly.

1.Drivethemachineontoalevelsurface.

2.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

3.Stoptheengine,waitforallthemovingpartstostop, andremovethekey.

4.Raisethebackofthemachineupandsupportthe machinewithjackstands.

15.Closethedrivewheelreleasevalve.RefertoUsing theDriveWheelValvesinOperation.

16.Repeatontheoppositesideofthemachine.

17.Installthereartiresandtorquethelugnutsto90-95 ft-lb(122-129N-m).

18.Removejackstands.

5.Removethereartiresfromthemachine.

6.Removeanydebrisfromthebrakearea.

7.Openthedrivewheelreleasevalves.RefertoUsing theDriveWheelValvesinOperation.

8.Disengagetheparkingbrake.

9.Usinghandsandngersonly,pushthecaliperlever armtoengagethebrakepadsontherotoruntilthe leverstops(Figure72).

Notetheorderofthestandardnutandlocknut.

10.Whileholdingtheleveratthestoppedposition,use theotherhandorngerstopullthecablethreaded endtightthroughtheswivel.Spinthestandardnut againsttheswivel(Figure72).

11.Trytoturnthewheelhubinbothdirectionsrelative tothecaliper.Thereshouldbeslightmovement betweenthem;somefriction/resistanceisacceptable.

12.Ifthereisnomovementbetweenthehubrotorand thecaliperthenbackoffthestandardnutoneturn fromtheswivelandrepeatstep11

13.Ifthehubrotormovesveryfreelyrelativetothe caliper,thentightenthestandardnutoneturn againsttheswivelandrepeatstep11

Figure72

LeftHandBrakeShown

1.Cableanchor

2.Threadedrod7.Pullcablethreadedrod

3.Pushleverthisdirection8.Holdthreadedrodhere

4.Caliperleverarm9.Swivel(pivothead)

5.Standardnut(shown againstswivel)

6.Locknut

thisdirection

14.Oncestep11isachieved,holdthethreadedrod endwithatoolandtightenthelocknutagainstthe

Page 48

BeltMaintenance

G009036

InspectingtheBelts

ServiceInterval:Every50hours

Checkthebeltsforsquealingwhenthebeltisrotating, bladesslippingwhencuttinggrass,frayedbeltedges, burnmarksandcracksaresignsofawornmowerbelt. Replacethemowerbeltifanyoftheseconditionsare evident.

ReplacingtheMowerBelt

Squealingwhenthebeltisrotating,bladesslippingwhen cuttinggrass,frayedbeltedges,burnmarksandcracks aresignsofawornmowerbelt.Replacethemowerbelt ifanyoftheseconditionsareevident.

1.DisengagethePTO ,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Lowerthemowertothe3inch(76mm)heightofcut.

4.Removethebeltcovers(Figure73).

Figure73

1.Pushtabdown2.Removebeltcover

5.Usearatchetinthesquareholeintheidlerarmto removetensionontheidlerspring(Figure74).

6.Removethebeltfromthemowerdeckpulleys.

7.Removethebeltguideonthespringloadedidler armshowninFigure74.

Figure74

1.Clutchpulley5.Squareholeintheidler

2.Mowerbelt6.Idlergreasezerk

3.Springloadedidlerpulley

4.Ratchet

10.Installthebeltguideontheidlerarmshownin Figure74.

11.Usingtheratchetinthesquarehole,installtheidler spring(Figure74).

Makesurethespringendsareseatedintheanchor grooves.

12.Installthebeltcovers(Figure75).

armfortheratchet

7.Beltguide

8.Removetheexistingbelt.

9.Installthenewbeltaroundthemowerpulleysand theclutchpulleyundertheengine(Figure74).

Page 49

Figure75

1.Positionthebeltcover3.Ensurethetabisunder themetalcatch

2.Slidebeltcoverunderthe

sidecatches

ReplacingtheHydraulicPump DriveBelt

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Removemowerbelt.RefertoReplacingtheMower BeltinMaintenance.

4.Raisethemachineandsupportitwithjackstands (Figure76).

Figure76

1.Idlerpulley

2.Clutchpulley6.Squareholeinidlerarm

3.Pumpdrivebelt7.Idlerspring

4.Righthandhydraulicpump pulley

5.Lefthandhydraulicpump pulley

5.Usearatchetinthesquareholeintheidlerarmto removetheidlerspring(Figure76).

6.Unhooktheidlerspringfromtheframe(Figure76).

7.Removethebeltfromthehydraulicunitdrivepulleys andtheenginepulley

8.Installthenewbeltaroundenginepulleyandthe twodrivepulleys.

9.Usingaratchetinthesquareholeintheidlerarm, installtheidlerspringtotheframe(Figure76).

10.Installthemowerbelt.RefertoReplacingthe MowerBelt.

Page 50

ControlsSystem Maintenance

AdjustingtheControlHandle Position

Therearetwoheightpositionsforthecontrollevers; highandlow.Removetheboltstoadjusttheheightfor theoperator.

1.DisengagethePTO ,movethemotioncontrollevers totheneutrallockedposition,andsettheparking brake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Loosentheboltsandangenutsinstalledinthe levers(Figure77).

Figure78

4.Aligntheleversfronttorearpositionbybringthe leverstogethertotheneutralpositionandslide themuntiltheyarealigned,thentightenthebolts (Figure78).

Figure77

1.Bolt

2.Handle4.Nut

3.Controllever

AdjustingtheMotionControl Linkage

Locatedoneithersideofthefueltank,belowtheseatare thepumpcontrollinkages.Rotatingthepumplinkage witha1/2inchwrenchallowsnetuningadjustments sothatthemachinedoesnotmoveinneutral.Any adjustmentsshouldbemadeforneutralpositioningonly.

Enginemustberunninganddrivewheelsmust beturningsomotioncontroladjustmentcanbe performed.Contactwithmovingpartsorhot surfacesmaycausepersonalinjury .

Keepngers,hands,andclothingclearof rotatingcomponentsandhotsurfaces.

1.Priortostartingtheengine,pushthedeckliftpedal andremovetheheightofcutpin.Lowerdeckto theground.

2.Raisetherearofmachineupandsupportwithjack stands(orequivalentsupport)justhighenoughto allowdrivewheelstoturnfreely.

3.Removetheelectricalconnectionfromtheseat safetyswitch,locatedunderthebottomcushionof theseat.Theswitchisapartoftheseatassembly.

4.Temporarilyinstallajumperwireacrossthe terminalsintheconnectorofthemainwiring harness.

Page 51

5.Startengine.Brakemustbeengagedandmotion controlleversouttostartengine.Operatordoes nothavetobeintheseatbecauseofthejumper wirebeingused.Runengineatfullthrottleand

releasebrake.

6.Runtheunitatleast5minuteswiththedrivelevers atfullforwardspeedtobringhydraulicoilupto operatingtemperature.

Note:Themotioncontrolleverneedstobein neutralwhilemakinganynecessaryadjustments.

7.Bringthemotioncontrolleversintotheneutral position.Adjustpumpcontrolrodlengthsby rotatingthedoublenutsontherodintheappropriate directionuntilthewheelsslightlycreepinreverse (Figure79).Movethemotioncontrolleverstothe reversepositionandwhileapplyingslightpressureto theleverallowthereverseindicatorspringstobring theleversbacktoneutral.Thewheelsmuststop turningorslightlycreepinreverse.

AdjustingtheMotionControl Damper

Thetopdampermountingboltcanbeadjustedto obtainamoredesiredmotioncontrolleverresistance. SeeFigure80formountingoptions.

Figure80

RHMotionControlShown

Figure79

1.Doublenuts

8.Shutoffunit.Removejumperwirefromwire harnessandplugconnectorintoseatswitch.

1.Torquethelocknutto200in-lb(16.7ft-lb).Boltmust protrudepastendoflocknutaftertorque.

2.Leastresistance(softestfeel)

3.Damper

4.Mediumresistance(mediumfeel)

5.Mostresistance(rmestfeel)

AdjustingtheMotionControl NeutralLockPivot

Theangednutcanbeadjustedtoobtainamoredesired motioncontrolleverresistancewhenmovingittothe neutrallockposition.SeeFigure81foradjustment options.

1.Loosenthejamnut.

2.Tightenorloosentheangednuttothedesiredfeel.

Formoreresistance,tightentheangednut.

Forlessresistance,loosentheangednut

3.Tightenjamnut.

9.Removethejackstands.

10.Raisethedeckandre-installtheheightofcutpin.

11.Checkthatthemachinedoesnotcreepinneutral withtheparkbrakesdisengaged.

Page 52

HydraulicSystem Maintenance

ServicingtheHydraulic System

Figure81

1.Flangednut2.Jamnut

115W-50.

HYPR-OIL

HydraulicOilType:Toro hydraulicoilorMobil

Important:Useoilspeciedorequivalent.Other uidscouldcausesystemdamage.

EachHydraulicSystemOilCapacity:52ounces(1.5

l)persidewithlterchange

™

500

CheckingtheHydraulicOil

ServiceInterval:Every50hours—Checkthehydraulic

oillevel.

1.Positionthemachineonalevelsurface.

2.DisengagethePTO ,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.

3.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

4.Allowtheenginetoandhydraulicsystemtocoolfor tenminutes.

5.Raisetheseatup.

6.Cleantheareaaroundthedipsticksofhydraulic systemreservoirs(Figure82).

7.Removeonedipstickfromthehydraulicreservoir (Figure82).

8.Wipethedipstickoffandthreadthedipstickinto thereservoir.

9.Removethedipstickandlookatthemetalend (Figure82).Thelevelneedstobewithinknurled section.Ifoillevelislow ,slowlypouronlyenough oilintothehydraulicreservoirtoraisethelevelto theknurledsection.

Important:Donotoverllthehydraulicunits withoilasdamagemayoccur.Donotrunthe machinewithoilbelowtheknurledsection becausedamagemayoccur.

10.Installthedipstick.

Page 53

ReplacingtheHydraulicFiltersand HydraulicOil

ServiceInterval:Every250hours

Every500hours

Toreplacethehydraulicoil,theltersneedtobe removed.Replacebothatthesametime.Refertothe oilspecicationsunderServicingtheHydraulicSystem forthecorrectoil.

1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Raisethemachineandsupportitwithjackstands (Figure83).

Figure82

Topview(underseat)

1.Oilneedstobewithin knurledsection

2.Dipsticklocations

Hydraulicoilescapingunderpressurecan penetrateskinandcauseinjury .

•Ifhydraulicoilisinjectedintotheskinit mustbesurgicallyremovedwithinafew hoursbyadoctorfamiliarwiththistypeof injury.Gangrenemayresultifthisisnot done.

•Keepbodyandhandsawayfrompinhole leaksornozzlesthatejecthighpressure hydraulicoil.

•Usecardboardorpapertondhydraulic leaks.

Figure83

1.Jackstands

4.Removeboththemowerbeltandthepumpdrive belt.Thiswillpreventoilgettingonthebelts.Refer toBeltsintheMaintenanceSection.

5.Placeadrainpanunderthelter,removetheold lterandwipethesurfaceclean(Figure84).

•Safelyrelieveallpressureinthehydraulic systembeforeperforminganyworkonthe hydraulicsystem.

•Makesureallhydraulicoilhosesandlines areingoodconditionandallhydraulic connectionsandttingsaretightbefore applyingpressuretohydraulicsystem.

Page 54

G008968

MowerDeck Maintenance

LevelingtheMowerDeck

SettingUptheMachine

Note:Ensurethemowerdeckisleveledbefore

matchingtheheight-of-cut(HOC).

1.Positionmoweronaatsurface.

2.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

3.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

Figure84

BottomViewofMachine

1.Filterlocations

2.Hydrauliclter

4.Checktirepressureofthedrivetires.Ifneeded, adjustto13psi(90kPa)

5.Positionthemowertothe3inch(76mm) height-of-cutposition.

6.Applyathincoatofhydraulicoiltotherubber gasketonthereplacementlter(Figure84).

7.Installthereplacementhydrauliclter.

8.Installthepumpdrivebeltandthemowerbelt.

9.Removethejackstandsandlowerthemachine (Figure83).

10.Addoiltothehydraulicreservoirandcheckforany leaks.

11.Cleanupanyspilledoil.

12.Starttheengineandletitrunforabouttwominutes topurgeairfromthesystem.Stoptheengineand checkforleaks.

13.Checktheoillevelwhiletheoiliscold.

14.Ifrequired,addoiltothehydraulicreservoir.Do notoverll.

DeckLeveling

1.Positionthemoweronaatsurface.

2.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

3.Checkthetirepressureinthedrivetires.Proper inationpressurefortiresis13psi(90kPa).Adjust ifnecessary.

4.Positionthetransportlockinthelatchingposition.

5.Pushthedeckliftpedalallthewayforwardandthe deckwilllatchatthe51/2inch(14cm)transport position(Figure85).

Figure85

1.Deckliftpedal

2.Heightofcutpin

3.Transportlock

Page 55

6.Inserttheheightadjustmentpinintothe3inch(7.6 cm)cuttingheightlocation.

7.Releasethetransportlockandallowthedeckto lowertothecuttingheight.

8.Raisethedischargechute.

9.Onbothsidesofthedeck,measurefromthelevel surfacetothefronttipoftheblade(PostionA). Themeasurementshouldread3inches(7.6mm) (Figure86).

Figure87

1.Adjustmentnut3.Reardeckadjustment

2.JamNut4.Frontdeckadjustment

Figure86

1.3inches(7.6cm)atAis correct

2.31/4inches(8.3cm)atB iscorrect

3.Measureherefromthe bladetiptohardsurface

4.MeasureatAandBon bothsides

10.Fine-tunetheadjustmentnutonthefrontdecklift assemblybyturningit(Figure87).

Toincreasetheheight,turntheadjustmentnut clockwise;todecrease,turncounterclockwise.

11.Ifthefrontdecklinksdonothaveenough adjustmenttoachieveaccuratecutheight,the singlepointadjustmentcanbeutilizedtogainmore adjustment.

12.Toadjustthesinglepointsystem,loosenthetwo boltsatthebottomoftheheightofcutplate.Refer toFigure88.

Figure88

1.Boltsatthebottomoftheheight-of-cutplate

Page 56

13.Ifthedeckistoolow ,tightenthesinglepoint adjustmentboltbyrotatingitclockwise.Ifthedeck istoohigh,loosenthesinglepointadjustmentbolt byrotatingitcounterclockwise(Figure89).

Note:Loosenortightenthesinglepointadjustment boltenoughtomovetheheight-of-cutplate mountingboltsatleast1/3thelengthoftheavailable travelintheirslots.Thiswillregainsomeupand downadjustmentoneachofthefourdecklinks.

ServicingtheCuttingBlades

Maintainsharpbladesthroughoutthecuttingseason becausesharpbladescutcleanlywithouttearingor shreddingthegrassblades.Tearingandshreddingturns grassbrownattheedges,whichslowsgrowthand increasesthechanceofdisease.

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

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

•Inspectthebladeperiodicallyforwearor damage.

Figure89

1.Singlepointadjustmentbolt

14.Tightenthetwoboltsatthebottomoftheheightof cutplate(Figure88).T orqueto27-33ft-lb(37-45 N-m).

Note:Inmostconditions,thebackbladetipshould beadjusted1/4inch(6.4mm)higherthanthefront.

15.Onbothsidesofthedeck,measurefromthelevel surfacetothebacktipoftheblade(PostionB).The measurementshouldread31/4inches(8.3cm) (Figure86).

16.Fine-tunetheadjustmentnutonthefrontdecklift assemblybyturningit(Figure87).

Toincreasetheheight,turntheadjustmentnut clockwise;todecrease,turncounterclockwise.

17.Measureuntilallfoursidesarethecorrectheight. Tightenallthejamnutsonthedeckliftarm assemblies.

•Replaceawornordamagedblade.

BeforeInspectingorServicingthe Blades

Parkthemachineonalevelsurface,disengagetheblade controlswitch(PTO),andsettheparkingbrake.Turn theignitionkeytoOff.Removethekey.

InspectingtheBlades

ServiceInterval:Beforeeachuseordaily

1.Inspectthecuttingedges(Figure90).Iftheedges arenotsharporhavenicks,removeandsharpenthe blades.RefertoSharpeningtheBlades.

2.Inspecttheblades,especiallythecurvedarea (Figure90).Ifyounoticeanydamage,wear,oraslot forminginthisarea(Figure90),immediatelyinstalla newblade.

18.Lowerdischargechute.

Page 57

Abladethatisbentordamagedcouldbreak apartandcouldseriouslyinjureorkillyouor bystanders.

•Alwaysreplacebentordamagedbladewith anewblade.

Figure90

1.CuttingEdge3.Wear/slotForming

2.CurvedArea4.Crack

CheckingforBentBlades

1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Rotatethebladesuntiltheendsfaceforwardand backward(Figure91).Measurefromalevelsurface tothecuttingedge,positionA,oftheblades (Figure91).Notethisdimension.

•Neverleorcreatesharpnotchesinthe edgesorsurfacesofblade.

RemovingtheBlades

Bladesmustbereplacedifasolidobjectishit,ifthe bladeisoutofbalanceorisbent.T oensureoptimum performanceandcontinuedsafetyconformanceof themachine,usegenuineTororeplacementblades. Replacementbladesmadebyothermanufacturersmay resultinnon-conformancewithsafetystandards.

1.Holdthebladeendusingaragorthickly-padded glove.

2.Removethebladebolt,curvedwasher,andblade fromthespindleshaft(Figure92).

Figure91

1.Measureherefromblade tohardsurface

2.PositionA

4.Rotatetheoppositeendsofthebladesforward.

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

Figure92

1.SailAreaofBlade3.Curvedwasher

2.Blade4.BladeBolt

Page 58

SharpeningtheBlades

Whensharpeningblade,piecesofbladecould bethrownandcauseseriousinjury .

InstallingtheBlades

1.Installthebladeontothespindleshaft(Figure95).

Important:Thecurvedpartoftheblademust bepointingupwardtowardtheinsideofthe mowertoensurepropercutting.

Wearpropereyeprotectionwhensharpening blade.

1.Usealetosharpenthecuttingedgeatbothends oftheblade(Figure93).Maintaintheoriginalangle. Thebladeretainsitsbalanceifthesameamountof materialisremovedfrombothcuttingedges.

Figure93

1.Sharpenatoriginalangle

2.Checkthebalanceofthebladebyputtingitona bladebalancer(Figure94).Ifthebladestaysina horizontalposition,thebladeisbalancedandcanbe used.Ifthebladeisnotbalanced,lesomemetaloff theendofthesailareaonly(Figure95).Repeatthis procedureuntilthebladeisbalanced.

2.Installthespringdiskandbladebolt.Thespring diskconemustbeinstalledtowardthebolthead (Figure95).Torquethebladeboltto85-110ft-lb (115-150N-m).

Figure95

1.SailAreaofBlade

2.Blade

3.SpringDisk

4.BladeBolt

5.ConeT owardsBoltHead

Figure94

1.Blade2.Balancer

Page 59

RemovingtheMowerDeck

Beforeservicingorremovingthemowerdeck,the springloadeddeckarmsmustbelockedout.

Deckliftarmassemblieshavestoredenergy. Removingthedeckwithoutreleasingthe storedenergycancauseseriousinjuryordeath.

DoNotattempttodisassemblethedeckfrom thefrontframewithoutlockingoutthestored energy.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Removetheheightadjustmentpinandlowerthe decktotheground.

3.Placetheheightadjustmentpininthe3inch(7.6cm) cuttingheightlocation.Thislocksthedeckliftarms inthelowestpositionwhenthedeckisremovedand thestoredenergyinthedeckspringisreleased.

4.Removethebeltcovers.

5.Liftuptheoorpanandinsertaratchetintothe squareholeinthedeckidler(Figure96).

6.Rotatethedeckidlerclockwiseandremovethe mowerbelt(Figure96).

Figure96

1.Clutchpulley5.Squareholeintheidler

2.Mowerbelt6.Idlergreasezerk

3.Springloadedidlerpulley

4.Ratchet

armfortheratchet

7.Beltguide

7.Removeandretainthehardwareonbothsidesofthe deckasshowninFigure97.

Page 60

Figure97

1.Rightstabilizer

2.Deckstrut(rightsideshown)

3.Removethereardeckliftattachmentshoulderboltandnut.

4.Removethefrontdeckliftattachmentshoulderboltandnut.

8.Raisethedeckstrutsandsecurethemintheup position.Slidethedeckouttotherightsideofthe machine.

Note:MakesuretheLendofthespringisinstalled behindthedeckedgebeforeinstallingtheboltas showninFigure98.

3.Installtheboltandnut.PlacetheJhookendofthe springaroundthegrassdeector(Figure98).

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

Figure98

1.Bolt

2.Spacer6.GrassDeector

3.Locknut

4.Spring8.Jhookendofspring

5.Springinstalled

7.Lendofspring,place

behinddeckedgebefore installingbolt

ReplacingtheGrassDeector

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

•Neveroperatethelawnmowerunlessyou installacoverplate,amulchplate,oragrass chuteandcatcher.

•Makesurethegrassdeectorisinthedown position.

1.Removethelocknut,bolt,springandspacerholding thedeectortothepivotbrackets(Figure98). Removethedamagedorworngrassdeector.

2.Placethespacerandspringontograssdeector. PlacetheLendofspringbehinddeckedge.

Page 61

Cleaning

Storage

CleaningUndertheMower

ServiceInterval:Beforeeachuseordaily

1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Raisethemowertothetransportposition.

WasteDisposal

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

CleaningandStorage

1.Disengagethepowertakeoff(bladecontrolswitch (PTO),settheparkingbrake,andturntheignition keytoOff.Removethekey.

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

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

3.Checkthebrake;refertoServicingtheBrakeinthe MaintenanceSection.

4.Servicetheaircleaner;refertoServicingtheAir CleanerintheMaintenanceSection.

5.Greasethemachine;refertoGreasingand LubricationintheMaintenanceSection.

6.Changethecrankcaseoil;refertoServicingthe EngineOilintheMaintenanceSection.

7.Checkthetirepressure;refertoCheckingtheTire PressureintheMaintenanceSection.

8.Changethehydrauliclters;refertoServicingthe HydraulicSystemintheMaintenanceSection.

9.Chargethebattery;refertoServicingtheBatteryin theMaintenanceSection.

10.Scrapeanyheavybuildupofgrassanddirtfromthe undersideofthemower,thenwashthemowerwith agardenhose.

Note:Runthemachinewiththebladecontrol switch(PTO)engagedandtheengineathighidle for2to5minutesafterwashing.

11.Checktheconditionoftheblades;refertoServicing theCuttingBladesintheMaintenanceSection.

12.Preparethemachineforstoragewhennon-use occursover30days.Preparethemachineforstorage asfollows:

A.Addapetroleumbasedstabilizer/conditioner

tofuelinthetank.Followmixinginstructions fromthestabilizermanufacturer.Donotusean alcoholbasedstabilizer(ethanolormethanol).

Note:Afuelstabilizer/conditionerismost effectivewhenmixedwithfreshfuelandused atalltimes.

Page 62

B.Runtheenginetodistributeconditionedfuel

throughthefuelsystem(5minutes).

C.Stoptheengine,allowittocool,anddrainthe

fueltank;refertoServicingtheFuelTankinthe MaintenanceSection.

D.Restarttheengineandrunituntilitstops.

E.Disposeoffuelproperly.Recycleasperlocal

codes.

Important:Donotstore stabilizer/conditionedfuelover90days.

13.Checkandtightenallbolts,nuts,andscrews.Repair orreplaceanypartthatisdamaged.

14.Paintallscratchedorbaremetalsurfaces.Paintis availablefromyourAuthorizedServiceDealer.

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

Page 63

Troubleshooting

Problem

Starterdoesnotcrank

Enginewillnotstart,startshard,orfails tokeeprunning

PossibleCauseCorrectiveAction

1.Bladecontrolswitch(PTO)isengaged.1.Movebladecontrolswitch(PTO)to

2.Parkingbrakeisnoton.

3.Driveleversarenotinneutrallock position.

4.Operatorisnotseated.4.Sitontheseat.

5.Batteryisdead.

6.Electricalconnectionsarecorrodedor loose.

7.Fuseisblown.

8.Relayorswitchisdefective.8.ContactanAuthorizedServiceDealer .

1.Fueltankisempty.

2.Fuelshutoffvalveisclosed.2.Openthefuelshutoffvalve.

3.Oillevelinthecrankcaseislow .

4.Thethrottleandchokearenotinthe correctposition.

5.Dirtinfuellter .5.Replacethefuellter.

6.Dirt,water,orstalefuelisinthefuel system.

7.Aircleanerisdirty.

8.Seatswitchisnotfunctioningproperly.8.Checktheseatswitchindicator.

9.Electricalconnectionsarecorroded, looseorfaulty.

10.Relayorswitchisdefective.10.ContactanAuthorizedServiceDealer.

11.Faultysparkplug.

12.Sparkplugwireisnotconnected.12.Checkthesparkplugwireconnection.

disengaged.

2.Settheparkingbrake.

3.Ensurethedriveleversareinthe neutrallockposition.

5.Chargethebattery .

6.Checktheelectricalconnectionsfor goodcontact.

7.Replacefuse.

1.Fillthefueltank.

3.Addoiltothecrankcase.

4.Besurethethrottlecontrolismidway betweenthe“SLOW”and“FAST” positions,andthechokeisinthe“ON” positionforacoldengineorthe“OFF” positionforawarmengine.

6.ContactanAuthorizedServiceDealer.

7.Cleanorreplacetheaircleaner element.

Replaceseatifneeded.

9.Checktheelectricalconnections forgoodcontact.Cleanconnector terminalsthoroughlywithelectrical contactcleaner,applydielectricgrease andreconnect.

11.Clean,adjustorreplacesparkplug.

Enginelosespower.

Engineoverheats.

Mowerpullsleftorright(withleversfully forward)

1.Engineloadisexcessive.1.Reducethegroundspeed.

2.Aircleanerisdirty.

3.Oillevelinthecrankcaseislow .

4.Coolingnsandairpassagesabove theengineareplugged.

5.Ventholeinthefuelcapisplugged.5.Cleanorreplacethefuelcap.

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

7.Dirt,water,orstalefuelisinthefuel system.

1.Engineloadisexcessive.1.Reducethegroundspeed.

2.Oillevelinthecrankcaseislow .

3.Coolingnsandairpassagesabove theengineareplugged.

1.Trackingneedsadjustment1.Adjustthetracking.

2.Tirepressureindrivetiresnotcorrect.2.Adjusttirepressureinthedrivetires.

2.Cleantheaircleanerelement.

3.Addoiltothecrankcase.

4.Removetheobstructionfromthe coolingnsandairpassages.

7.ContactanAuthorizedServiceDealer.

2.Addoiltothecrankcase.

3.Removetheobstructionfromthe coolingnsandairpassages.

Page 64

Problem

PossibleCauseCorrectiveAction

Machinedoesnotdrive.

Abnormalvibration.

Unevencuttingheight.

1.Bypassvalvesisnotclosedtight.1.Tightenthebypassvalves.

2.Pumpbeltisworn,looseorbroken.

3.Pumpbeltisoffapulley.3.Changethebelt.

4.Brokenormissingidlerspring.4.Replacethespring.

5.Hydraulicoillevelislowortoohot.5.Addhydraulicoiltoreservoirsorletit

1.Cuttingblade(s)is/arebentor unbalanced.

2.Blademountingboltisloose.2.Tightentheblademountingbolt.

3.Enginemountingboltsareloose.3.Tightentheenginemountingbolts.

4.Looseenginepulley,idlerpulley,or bladepulley.

5.Enginepulleyisdamaged.

6.Bladespindleisbent.

7.Motormountislooseorworn.

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

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

3.Mowerdeckisnotlevel.

4.Undersideofmowerisdirty .4.Cleantheundersideofthemower.

5.Tirepressureisnotcorrect.5.Adjustthetirepressure.

6.Bladespindlebent.

2.Changethebelt.

cooldown.

1.Installnewcuttingblade(s).

4.Tightentheappropriatepulley.

5.ContactanAuthorizedServiceDealer.

6.ContactanAuthorizedServiceDealer.

7.ContactanAuthorizedServiceDealer.

3.Levelmowerdeckfromside-to-side andfront-to-rear.

6.ContactanAuthorizedServiceDealer.

Bladesdonotrotate.

Clutchwillnotengage.

1.Mowerdeckbeltisworn,looseor broken.

2.Mowerdeckbeltisoffpulley.

3.Pumpdrivebeltisworn,looseor broken.

4.Brokenormissingidlerspring.4.Replacethespring.

1.Fuseisblown.

2.Lowvoltagesupplyattheclutch.

3.Damagedcoil.3.Replaceclutch.

4.Inadequatecurrentsupply.4.Repairorreplaceclutchleadwireor

5.Rotor/armatureairgapistoolarge.

1.Installnewdeckbelt.

2.Installmowerdeckpulleyandcheck theidlerpulley,idlerarmandspringfor correctpositionandfunction.

3.Checkthebelttensionorinstallnew belt.

1.Replacefuse.Checkcoilresistance, batterycharge,chargingsystem,and wiringconnectionsandreplaceif necessary.

2.Checkcoilresistance,battery charge,chargingsystem,andwiring connectionsandreplaceifnecessary .

electricalsystem.Cleanconnector contacts.

5.Removeshimorreplaceclutch.

Page 65

Schematics

WireDiagram(Rev.A)

Page 66

Notes:

Page 67

Notes:

Page 68

The Toro Total Coverage Guarantee

A Limited Warranty (see warranty periods below)

Landscape

Contractor

Equipment (LCE)

The Toro Company and its afﬁliate, Toro Warranty Company, pursuant to an

Conditions and Products Covered

agreement between them, jointly promise to repair the listed Toro Products if defective in materials or workmanship.

The following warranty time periods apply from the date of purchase by the original owner:

Product Warranty Period

Mid-Size Walk-Behind Mowers 2 years** GrandStand

•

Z Master

•

Z Master® G3 Mowers

•

Batteries (for above units)

Mowers Engine Frame

Z300, Z400, Z500 Mowers Engine Frames

Engine Frame

5 years or 1,200 hours* 2 years** Lifetime (original owner only)***

4 years or 1,200 hours* 2 years** Lifetime (original owner only)***

5 years or 1,200 hours* 2 years** Lifetime (original owner only)***

1 year

Attachments (for above units) 1 year

*Whichever occurs ﬁ rst. **Some engines used on Toro LCE Products are warranted by the engine manufacturer. ***Lifetime Frame Warranty - If the main frame, consisting of the parts welded together to form the tractor structure that other components such as the engine are secured to, cracks or breaks in normal use, it will be repaired or replaced under warranty at no cost for parts and labor. Frame failure due to misuse or abuse and failure or repair required due to rust or corrosion are not covered.

This warranty includes the cost of parts and labor, but you must pay transportation costs.

Instructions for Obtaining Warranty Service

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

1. Contact any Authorized Toro Service Dealer to arrange service at their dealership. To locate a dealer convenient to you, refer to the Yellow Pages of your telephone directory (look under “Lawn Mowers”) or access our web site at www.Toro.com. You may also call the numbers listed in item #3 to use the 24-hour Toro Dealer locator system.

2. Bring the product and your proof of purchase (sales receipt) to the Service Dealer. The dealer will diagnose the problem and determine if it is covered under warranty.

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

LCB Customer Service Department Toro Warranty Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196 888-865-5676 (U.S. Customers) 888-865-5691 (Canada customers)

You must maintain your Toro Product by following the maintenance

Owner Responsibilities

procedures described in the Operator’s Manual. Such routine maintenance, whether performed by a dealer or by you, is at your expense.

Items and Conditions Not Covered

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

Cost of regular maintenance service or parts, such as ﬁ lters, fuel,

• lubricants, tune-up parts, blade sharpening, brake and clutch adjustments. Any product or part which has been altered or misused or required

• replacement or repair due to normal wear, accidents, or lack of proper maintenance. Repairs necessary due to improper fuel, contaminants in the fuel system,

• or failure to properly prepare the fuel system prior to any period of nonuse over three months.

Pickup and delivery charges.

•

General Conditions

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

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

All implied warranties of merchantability (that the product is ﬁt for ordinary use) and ﬁtness for use (that the product is ﬁt for a particular purpose) are limited to the duration of the express warranty.

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

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

Customers who have purchased Toro products outside the United States or Canada should contact their Toro Distributor (Dealer) to obtain guarantee

Countries Other than the United States or Canada

policies for your country, province, or state. If for any reason you are dissatisﬁ ed with your Distributor’s service or have difﬁ culty obtaining guarantee information, contact the Toro importer. If all other remedies fail, you may contact us at Toro Warranty Company.

Part Number 374-0037 Rev. H